Automated Testing Tool for Industrial Control Systems
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Solution Overview
Problem
Current testing methods for software applications and industrial control systems are labor-intensive, costly, and prone to inefficiencies and errors, particularly in Operational Technology (OT) environments, where manual testing and limited automation lead to incomplete test coverage and increased risks of latent defects.
Innovation Solution
The introduction of the Flowchart-Driven Automated Testing Tool (FDATT) and OT Automated Testing Technologies, which utilize flowchart-based designs to automate test generation and execution, and integrate simulation hardware and software to automate testing across a wide range of I/O points, respectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual testing methods are used, then testing flexibility and adaptability are maintained, but testing efficiency and productivity are reduced
Solution Approach 1:
The system enables self-service through automated test case generation where the testing tool automatically creates test cases from requirement documents without extensive manual intervention. The automated execution engine also runs tests and generates reports autonomously, significantly improving productivity while maintaining high automation levels
Solution Approach 2:
The patent replaces manual mechanical testing processes with an automated software-based testing system. The testing tool uses computational algorithms to generate, execute, and analyze test cases, substituting human operators with an automated system that achieves higher efficiency and consistency
2Reliability
If comprehensive test coverage is achieved through manual testing, then testing thoroughness is improved, but testing time and cost increase
Solution Approach 1:
The system performs preliminary actions by automatically generating test cases before actual execution. Test cases are pre-created from requirement documents, and the system pre-configures test environments and data setups, allowing for comprehensive test coverage to be achieved efficiently without time penalties
Solution Approach 2:
The automated testing system enables continuous test execution without interruption. Multiple test cases can run in parallel, and the system continuously monitors and reports results, maintaining continuous useful action that achieves comprehensive coverage faster than sequential manual testing
3Productivity
If automated testing is implemented, then testing efficiency is improved, but system complexity increases
Solution Approach 1:
The testing tool is designed as a universal platform that handles multiple functions: requirement analysis, test case generation, test execution, result analysis, and report generation. This multi-functionality consolidates what would otherwise be separate complex systems into a single integrated tool, improving efficiency without proportionally increasing complexity
Solution Approach 2:
The system introduces an intermediary testing tool that acts as a mediator between requirements documents and test execution. This intermediate layer automatically translates requirements into test cases and coordinates execution, simplifying the overall system architecture by providing a standardized interface between different components
4Measurement precision
If manual testing is used for OT systems, then hardware compatibility is maintained, but testing accuracy and precision are reduced
Solution Approach 1:
The patent replaces manual mechanical testing with automated software-based testing that precisely controls test parameters. The automated system accurately measures and verifies hardware responses, achieving higher precision while maintaining hardware compatibility through protocol-based communication
Solution Approach 2:
The system implements feedback mechanisms where automated testing tools continuously monitor hardware responses, compare actual results against expected values, and adjust test parameters in real-time. This feedback loop ensures high accuracy in measuring hardware performance while maintaining automation
Data Source
AI summary
An automated testing system for industrial control systems, including multiple embodiments. The Flowchart-Driven Automated Testing Tool (FDATT) enables users to create and execute test cases via a graphical interface integrated with control systems for efficient automation. The Spreadsheet Testing approach combines in-memory database unit tests with spreadsheet-like assertions for verifying calculations and updates on Data Transfer Objects (DTOs), promoting clarity and independent calculations. The OT Automated Testing Technologies utilizes SIMCase (a/k/a SIMCube) hardware, SIMSuite software, and the Breakout Board™ for scalable testing of PLCs without modifying native code, supporting functions like Flex Matrix and Tag Ring Out for I/O signal verification. Finally, the Test Data Import and Verification Tool imports input and expected output bit files for PLC logic testing through industrial communication protocols, ensuring accurate logic verification and error detection.