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© Institute Industrial IT - Fraunhofer IOSB 1
UCAAT 2013, 23rd October, Paris
Test Automation in Industrial Automation
Barath Kumar
inIT – Institute of Industrial Information Technologies, Lemgo, Germany
Shiraz Gilani
Fraunhofer IOSB-INA , Anwendungszentrum Industrial Automation
Lemgo, Germany
© Institute Industrial IT - Fraunhofer IOSB 2
Why test automation is required in
Industrial automation
Due to problems in conventional manual testing:
• Cost intensive
• Requires high effort
• Unproductive (time consuming)
• Often inadequate (error prone)
• Low coverage
© Institute Industrial IT - Fraunhofer IOSB 3
Objective
To test :
• new control software of Programmable logic controllers (PLC)s
• modified PLC logic
• migrating Systems
© Institute Industrial IT - Fraunhofer IOSB 4
Test setup
PLC
PLC
PLCI/O
I/O
Plant
Profinet
ProfiBus
PLC
PLC
Profinet
I/O
I/O
Unit under
Test
Manufactoring Automation setup
© Institute Industrial IT - Fraunhofer IOSB 5
PLC
PLC
PLCI/O
I/O
Plant
Profinet
ProfiBus
PLC
Profinet
I/O
I/OInput
Output
Test setup
Manufactoring Automation setup
© Institute Industrial IT - Fraunhofer IOSB 6
PLC
PLC
PLCI/O
I/O
Plant
Unit Under Test (UUT)
PLC
I/O
Signals
Environment
Profinet
ProfiBus
Programmed using
conventional PLC
languages e.g. IEC
61131, C, etc.
Test setup – Hardware in the the loop
© Institute Industrial IT - Fraunhofer IOSB 8
Industrial automation environment
gateway
PLCs
fieldbus IO device Production
modules
Process behavior Network behavior
Conveyor
belt
Hybrid
module
(Robot)
© Institute Industrial IT - Fraunhofer IOSB 11
• Hybrid system nature
• Non-deterministic
• Timed nature (real-time systems)
Industrial automation complexities
© Institute Industrial IT - Fraunhofer IOSB 12
Pilot project: test focus
To identify:
• Logical Errors
• e.g. if a funnel is blocked , does the PLC stop the conveyor belt?
• Timing Errors
• e.g. if a funnel is blocked, does the PLC stop the conveyor in the pre-defined duration?
• Plant Errors
• e.g. if a sensor is broken can the PLC still handle the plant appropriately
© Institute Industrial IT - Fraunhofer IOSB 13
Pilot project framework
Model
(Commercial tool)
Industrial
Automation
Adapter
(Our software)
Test Suite
Test
Execution
Engine
(Our Software)
Test Generation
(Commercial tool)
FieldbusPLC
© Institute Industrial IT - Fraunhofer IOSB 21
Logical errors - results
Module ID Inserted Errors Detected Errors
1 24 16
2 24 14
3 42 27
4 88 53
5 36 22
6 122 108
7 48 34
© Institute Industrial IT - Fraunhofer IOSB 22
Timing errors - results
Module ID Error Log
Correctly detected errors : 287
1 to 7 Undetected errors :
36
False detection : 51
© Institute Industrial IT - Fraunhofer IOSB 23
Plant errors - results
Module ID Inserted Errors Detected Errors
1 10 4
2 11 4
3 14 6
4 3 0
5 10 4
6 46 17
7 11 5