METHOD AND SYSTEM FOR TESTING SAFETY AUTOMATION LOGIC OF A MANUFACTURING CELL
First Claim
1. A method for testing the performance of automation logic used in a manufacturing cell, the method comprising:
- connecting a first automation component to a host machine through an input/output (I/O) card;
transmitting a predetermined test scenario from a test scenario generator module (TSGM) to the host machine;
generating a set of input control signals using the host machine in response to the test scenario, wherein the input control signals are adapted to control a function of the component based on the test scenario;
recording the behavior of the first automation component as input control signals and a corresponding set of output control signals in a memory location, as a set of recorded test signals;
disconnecting the first automation component from the I/O card;
connecting the I/O card to an automation controller through an I/O block;
automatically transmitting the test scenario and the recorded test signals to the automation controller through the I/O card and the I/O block for playback on the automation controller, thereby emulating an operation of the first automation component; and
testing the performance of the automation logic using the recorded test signals.
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Accused Products
Abstract
A method for testing the safety automation logic used in a manufacturing cell includes recording control signals of a safety-related component such as an E-Stop, light curtain, gate lock, or a safety mat using a host machine, and then disconnecting the component from the host machine. The recorded test signals are transmitted to an automation controller in accordance with a test scenario from a test scenario generator module (TSGM) to emulate operation of the component. The automation logic may be certified using the playback of the recorded test signals. A system for testing the safety automation logic includes the controller, host machine, and TSGM. The host machine records the control signals and plays back the test signals on the controller to emulate operation of the component. The automation control logic may be certified using the test signals, e.g., by comparing these to the test specification or standard.
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Citations
18 Claims
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1. A method for testing the performance of automation logic used in a manufacturing cell, the method comprising:
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connecting a first automation component to a host machine through an input/output (I/O) card; transmitting a predetermined test scenario from a test scenario generator module (TSGM) to the host machine; generating a set of input control signals using the host machine in response to the test scenario, wherein the input control signals are adapted to control a function of the component based on the test scenario; recording the behavior of the first automation component as input control signals and a corresponding set of output control signals in a memory location, as a set of recorded test signals; disconnecting the first automation component from the I/O card; connecting the I/O card to an automation controller through an I/O block; automatically transmitting the test scenario and the recorded test signals to the automation controller through the I/O card and the I/O block for playback on the automation controller, thereby emulating an operation of the first automation component; and testing the performance of the automation logic using the recorded test signals. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A method for testing the performance of safety-related automation logic used in a manufacturing cell, the method comprising:
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connecting a safety-related component to a host machine through an input/output (I/O) card; recording a set of input control signals into, and a corresponding set of feedback or output control signals out of, the component using the host machine, wherein the recorded signals collectively define a set of recorded test signals; disconnecting the safety-related component from the I/O card; connecting an automation controller to the host machine through the I/O device and an I/O block; generating a predetermined test scenario using a test scenario generator module (TSGM); and transmitting the recorded test signals from the host machine to the automation controller in response to the predetermined test scenario to thereby test the performance of safety-related automation logic using the recorded test signals. - View Dependent Claims (10, 11, 12, 13, 14)
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15. A system for testing safety automation logic used in a manufacturing cell, the system comprising:
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an automation controller for controlling the execution of the safety automation logic; a host machine connected to the automation controller via an input/output (I/O) card and an I/O block; and a testing scenario generator module (TSGM) in communication with the host machine, and adapted for generating a predetermined test scenario; wherein the host machine is operable for recording a set of input control signals and a corresponding output control signals from a safety-related component as a set of recorded test signals, and for automatically transmitting the recorded test signals and the predetermined test scenario to the automation controller to thereby test the safety automation logic. - View Dependent Claims (16, 17, 18)
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Specification