Combined I/O Channel Validation for Concurrent Signal Pattern Testing
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Solution Overview
Problem
Existing industrial control systems require serialized and laborious manual testing of combined I/O channels, which is prone to human errors and can only be conducted after physical connections are established, making it inefficient and inaccurate.
Innovation Solution
A method and system for testing configuration and operation of configurable I/O devices that record and analyze signal transmissions across primary and secondary channels within combined I/O channels, allowing for concurrent testing without physical connections, using a processor and communication library to generate and compare signal patterns against predefined values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual testing of combined I/O channels is performed after physical connections are established, then testing can be conducted with actual field devices, but the process is laborious, time-consuming, and prone to human errors
Solution Approach 1:
The system performs configuration validation and operational testing of combined I/O channels before physical connections to field devices are established. The processor simulates signal transmissions and validates channel configurations in advance, eliminating the need for time-consuming manual testing after installation while maintaining high accuracy through automated validation protocols.
Solution Approach 2:
The system creates virtual representations of I/O channels and field devices, allowing testing to be performed on these digital copies rather than requiring physical connections to actual field devices. This copying approach enables accurate testing of signal transmissions and channel configurations without the time constraints and human errors associated with manual physical testing.
2Measurement precision
If serialized manual testing is used for each I/O channel, then individual channel configurations can be verified, but the overall testing process becomes inefficient and cannot be performed concurrently
Solution Approach 1:
The system merges multiple I/O channel testing operations into a single concurrent execution framework. The processor simultaneously initiates and validates signal transmissions across multiple primary and secondary channels within combined I/O groups, maintaining precise configuration validation for each channel while achieving high productivity through parallel processing of what would traditionally require serialized manual testing.
3Reliability
If physical connections to field devices are required before testing, then actual operational conditions can be tested, but the setup process is delayed and cannot be validated in advance
Solution Approach 1:
The system performs preliminary validation of I/O channel configurations and operational parameters before physical connections to field devices are established. The processor simulates various operational conditions and signal transmissions, validating the configuration logic and channel combinations in advance, thereby eliminating setup delays while ensuring operational reliability through thorough pre-validation.
4Adaptability or versatility
If multiple I/O channels are combined into a single combined I/O channel, then device footprint is reduced and cost efficiency improves, but testing complexity increases and cannot be performed using conventional methods
Solution Approach 1:
The system segments the testing process into distinct components: primary channel signal initiation, secondary channel signal coordination, and combined channel validation. By dividing the complex testing task into these manageable segments, the system can concurrently test multiple channels while maintaining precise control over each individual channel's configuration and signal behavior, thereby managing testing complexity despite the increased versatility of combined I/O channels.
Data Source
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AI summary
The present invention provides methods, systems and computer program products for detecting a configuration error or operating error corresponding to an input/output (I/O) device. The I/O device comprises a plurality of I/O points configured to establish a combined I/O channel between said I/O device and a field device, said combined I/O channel comprising a primary I/O channel and at least one secondary I/O channel. A validation device requests the I/O device to send signal patterns on the primary and secondary channels and then records the transmitted signals to compare them to predefined signal pattern stored in a repository, in order to detect an error either in configuration or operation.