System and method for automatically testing a program for safety-related automation systems

• US 8,539,448 B2
• Filed: 09/27/2011
• Issued: 09/17/2013
• Est. Priority Date: 03/27/2009
• Status: Active Grant

• Current Assignee: ABB AG (ABB Limited)
• Original Assignee: ABB AG (ABB Limited)
• Inventors: Drath, Rainer, Veryha, Yauheni, Neuprtl, Heinrich, Hrnicke, Mario, Gramberg, Oliver
• Primary Examiner(s): Khatri, Anil
• Application Number:
  US13/246,338
• Publication Number:
  US 20120036499A1
• Time in Patent Office: 721 Days
• Field of Search: 717124-130
• US Class Current: 717/124
• CPC Class Codes: G05B 19/056 Programming the PLC
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A method and system are provided for automatically testing a program for automation systems (e.g., programmable logic controllers) with regard to maintaining programming guidelines for program design for automation systems. A copy of at least part of a safety-related program is obtained from a development system for automation systems as a copy to be tested. The program copy to be tested is loaded into a test device for testing programs. The test device has access to programming guidelines for program testing. The test device automatically performs the program test with regard to maintaining programming guidelines, and outputs the test result.

Claims

1. A method for automatically testing a program for a safety-related automation system having at least one safety-related programmable logic controller for compliance with programming guidelines pertaining to designing programs for the safety-related programmable logic controller, a non-safety related programmable logic controller which communicates with the safety-related programmable logic controller, and safety related input/output devices and non-safety input/output devices which are connected to the controllers, the method comprising:

obtaining at least part of a safety-related program from a development system for automation systems, the safety-related program being stored in a programming environment for creating a safety-related program in the development system;

loading the obtained safety-related program into a test device for testing safety-related programs, the test device having access to guidelines for designing programs for safety-related programmable logic controllers;

automatically testing, by a processor of the testing device, the loaded safety-related program in the test device for compliance with the programming guidelines for designing programs for safety-related programmable logic controllers; and

outputting results of the testing from the test device;

wherein the programming guidelines are in machine-readable form and are interpreted by the processor of the test device during execution of the test of the safety-related program.

2. The method as claimed in claim 1, comprising:

revising the safety-related program loaded in the test device when the safety-related program is identified as being erroneous during the test; and

testing the revised safety-related program again in the test device until one of (i) there are no errors, and (ii) a remaining deviation from the programming guidelines is identified as being non-critical.

3. The method as claimed in claim 2, wherein the programming guidelines are in machine-readable form and are interpreted by the processor of the test device during execution of the test of the safety-related program.

4. The method as claimed in claim 2, wherein the obtaining of the safety-related program comprises directly locating the safety-related program in the development system and automatically loading the located safety-related program using the test device.

5. The method as claimed in claim 2, wherein the obtaining of the safety-related program comprises directly accessing the safety-related program in the development system using the test device, and

wherein the testing of the safety-related program comprises testing the safety-related program inside the development system using the test device.

6. The method as claimed in claim 1, wherein the obtaining of the safety-related program comprises directly locating the safety-related program in the development system and automatically loading the located safety-related program using the test device.

7. The method as claimed in claim 1, wherein the obtaining of the safety-related program comprises directly accessing the safety-related program in the development system using the test device, and

wherein the testing of the safety-related program comprises testing the safety-related program inside the development system using the test device.

8. The method as claimed in claim 1, wherein the obtaining of the safety-related program comprises exporting a copy of the safety-related program to the test device.

9. A system for automatically testing a program for a safety-related automation system having at least one safety-related programmable logic controller for compliance with programming guidelines pertaining to designing programs for the safety-related programmable logic controller, a non-safety related programmable logic controller which communicates with the safety-related programmable logic controller, and safety-related input/output devices and non-safety input/output devices which are connected to the controllers, the system comprising:

a development computer configured to interact with a safety-related automation system,

wherein the development computer includes a development system having a programming environment for creating a safety-related program, and a test device including a processor configured to load and test the safety-related program, and

wherein the processor of the test device is configured to automatically test the safety-related program for compliance with programming guidelines for designing programs for safety-related programmable logic controllers, and to output a result the test;

wherein the programming guidelines are in machine-readable form and configured to be interpreted by the processor of the test device during execution of the test of the safety-related program.

10. The system as claimed in claim 9, wherein the processor of the test device is configured to revise a copy of the safety-related program identified as being erroneous on the basis of the programming guidelines during the test, and to again test the revised copy of the safety-related program until one of (i) there are no errors, and (ii) a remaining deviation from the programming guidelines is identified as being non-critical.

11. The system as claimed in claim 10, wherein the processor of the test device, in loading the safety-related program, is configured to directly locate the safety-related program to be tested in the development system and automatically load the program.

12. The system as claimed in claim 11, wherein the programming guidelines are at least one of guidelines, rules and specifications for designing programs for programmable logic controllers.

13. The system as claimed in claim 10, wherein the processor of the test device, in loading the safety-related program, is configured to directly access the safety-related program to be tested in the development system and test the safety program.

14. The system as claimed in claim 13, wherein the programming guidelines are at least one of guidelines, rules and specifications for designing programs for programmable logic controllers.

15. The system as claimed in claim 10, wherein the programming guidelines are at least one of guidelines, rules and specifications for designing programs for programmable logic controllers.

16. The system as claimed in claim 10, wherein the development system is a pre-certified component.

17. The system as claimed in claim 9, wherein the processor of the test device, in loading the safety-related program, is configured to directly locate the safety-related program to be tested in the development system and automatically load the program.

18. The system as claimed in claim 9, wherein the processor of the test device, in loading the safety-related program, is configured to directly access the safety-related program to be tested in the development system and test the safety program.