Control Function Block Testing with Automated Scenario Coverage
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Solution Overview
Problem
Current control function block testing procedures in industrial plants are time-consuming and often fail to represent all possible scenarios, leading to unknown behavior that can harm productivity and safety.
Innovation Solution
An automated system and method for testing control function blocks using a testing block to execute test cases, compare actual outputs with expected values, and gather information on the control function block's performance, reducing human error and capturing all 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 testing system performs self-testing by automatically generating test cases, executing them on the control function block, and comparing actual outputs with expected outputs. The system serves itself by using its own resources (testing block, test case library, comparison logic) to complete the entire testing process without external manual intervention, thereby reducing both time and resource requirements while maintaining simplicity.
2Ease of operation
If manual testing is performed by engineers, then flexibility in testing approach is maintained, but the testing may be deficient in representing all possible scenarios
Solution Approach 1:
The system incorporates feedback mechanisms where the testing block automatically compares actual outputs from the control function block with expected outputs stored in the test case library. This feedback loop ensures that all predefined test scenarios are systematically executed and evaluated, guaranteeing complete scenario coverage while maintaining operational flexibility through the structured test case framework.
Solution Approach 2:
The system performs preliminary actions by pre-defining a comprehensive library of test cases that cover all possible scenarios before actual testing begins. These pre-prepared test cases include all edge cases, normal operations, and error conditions, ensuring that when testing executes, complete scenario coverage is automatically achieved without requiring manual judgment during the testing process.
3Productivity
If automated testing is implemented, then testing speed and completeness improve, but system complexity increases
Solution Approach 1:
The testing system is segmented into distinct functional modules: a testing block for executing test cases, a test case library for storing test definitions and expected outputs, and a comparison mechanism for validating results. This segmentation allows each component to perform its specific function efficiently, improving overall testing productivity while managing complexity through modular design where each segment is independently manageable.
Data Source
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.