Closed-Loop I/O Point Testing for Remote Factory Acceptance Tests
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Solution Overview
Problem
Current Factory Acceptance Test (FAT) processes for industrial automation systems are inefficient and require extensive manual intervention, lacking automated solutions for comprehensive I/O testing across various signal types, which prolongs the testing duration and increases the need for specialized expertise.
Innovation Solution
A testing system comprising a testing server, user computing device, and a Bluetooth-enabled meter, with software agents that automate I/O testing by generating and applying test signals, measuring outputs, and providing web-based instructions and feedback, allowing remote and efficient testing of I/O points with minimal operator expertise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual FAT testing procedures are used for I/O testing, then comprehensive testing coverage can be achieved, but the testing duration is prolonged and requires extensive specialized expertise
Solution Approach 1:
The system enables automated self-testing of I/O points through software agents that autonomously generate test signals, acquire measurements, and document results without requiring continuous human intervention or specialized operator expertise throughout the testing process
Solution Approach 2:
Manual mechanical testing procedures are replaced with an automated software-based system that uses computer-executable instructions, web interfaces, and electronic communication to perform I/O testing, eliminating the need for manual operation while maintaining comprehensive testing coverage
2Measurement precision
If manual FAT testing procedures are used for I/O testing, then comprehensive testing coverage can be achieved, but extensive specialized expertise is required
Solution Approach 1:
The system enables automated self-testing of I/O points through software agents that autonomously generate test signals, acquire measurements, and document results without requiring continuous human intervention or specialized operator expertise throughout the testing process
Solution Approach 2:
A web-based user interface acts as an intermediary between the operator and the complex testing system, presenting simplified instructions and receiving results without requiring the operator to understand the underlying technical complexities of I/O testing procedures
3Productivity
If automated testing system is implemented, then testing efficiency is improved and time is reduced, but system complexity increases
Solution Approach 1:
The automated testing system is divided into independent software agents (control system agent, HMI agent, other agents) that can be selectively deployed and executed, allowing the system to scale in complexity only as needed for specific testing requirements rather than requiring full system complexity for all tests
Solution Approach 2:
The software agents are designed to handle multiple types of I/O points and testing scenarios through a unified architecture, reducing overall system complexity by using a single versatile platform rather than multiple specialized systems for different testing functions
Data Source
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AI summary
System and methods for testing input/output (I/O) points in an automation system. A control system software agent in the automation system is configured to send and receive test setpoints for the automation system. A testing server specifies the test setpoints to the automation system for a plurality of I/O points to be tested and generates a web user interface presenting instructions for conducting testing of the I/O points using the specified test setpoints. A user computing device associated with the I/O points to be tested receives the web user interface and displays the instructions, communicates the instructions to a smart meter for applying input signals to the I/O points to be tested and/or measuring output signals from the I/O points to be tested in accordance with the instructions, and communicates results of the testing to the testing server for generating documentation.