Control Function Block Testing with Automated Output Comparison
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Solution Overview
Problem
Current control function block testing procedures in industrial control systems are time-consuming and often fail to represent all possible scenarios, leading to unknown behavior during plant implementation, which can be harmful to productivity and safety.
Innovation Solution
An automated control function block testing system that includes a control function block and a testing block, which executes test cases, compares actual outputs with expected values, and gathers information on the function block's performance, reducing human error and capturing all possible scenarios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual testing procedures are used for control function blocks, then testing can be performed with simple equipment, but the testing process becomes time-consuming and resource-intensive
Solution Approach 1:
The patent replaces manual mechanical testing processes with an automated computer-based testing system. The control function block is automatically tested by a computer that executes test cases, compares actual outputs with expected outputs, and generates test reports, eliminating the need for manual engineer intervention in the testing execution process.
Solution Approach 2:
The testing system performs self-testing where the control function block automatically executes test cases with various input values and compares its own outputs against expected results. The system autonomously identifies errors and generates test documentation without requiring external manual analysis for each test case.
2Quantity of substance
If manual testing procedures are used for control function blocks, then testing resources can be minimized, but the testing coverage becomes insufficient and may miss critical scenarios
Solution Approach 1:
The testing process is segmented into distinct automated components: test case definition, automatic execution with multiple input values, output comparison against expected results, error identification, and report generation. This segmentation allows comprehensive coverage of all possible scenarios while maintaining efficient resource utilization through automated parallel processing.
Solution Approach 2:
The system automatically varies input parameters and test conditions to cover all possible scenarios that control function blocks may encounter during plant implementation. By systematically changing test parameters and executing multiple test cases with different input values, the system achieves complete testing coverage without proportionally increasing resource requirements.
3Reliability
If comprehensive testing scenarios are implemented, then reliability of control function blocks improves, but testing complexity increases
Solution Approach 1:
The patent replaces complex manual testing procedures with automated computer-based execution. The computer automatically manages the complexity of comprehensive test scenarios by systematically executing test cases, comparing outputs, and generating reports, thereby achieving high reliability testing without requiring complex manual coordination.
4Productivity
If automated testing is implemented, then testing speed and coverage improve, but system complexity increases
Solution Approach 1:
The automated testing system is designed as a universal platform that can test any control function block type through standardized test cases and output comparisons. The same automated infrastructure handles diverse testing scenarios, achieving high productivity across different control functions without proportionally increasing system complexity.
Data Source
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AI summary
An automated control function block testing system and method configured for testing a control function block are described herein. The control function block comprises a control function block type that corresponds to a function of the control function block used for controlling a process within an industrial plant. The control function block executes one or more processes (or test cases during testing) based on the control function block type. The testing block is configured to obtain a test value based on the control function block type, and transmit the test value to the control function block for executing the test case therewith. The control function block executes the test case with the test value to generate an actual output to transmit to the testing block. The testing block compares the actual output to an expected value to gather information regarding the control function block.