DE102008048985A1 - Automation system's test e.g. bus test, performing method for e.g. organization task, involves comparing testing result with reference result deviated from specification data, and implementing or importing data in testing program - Google Patents

Abstract

The invention relates to a method for testing an automation system 2 in which a system 7 to be controlled by the automation system 2 is simulated, wherein a test device 1 with a test program for simulating the system 7 is used, and by the simulation a test result of the automation system 2 is obtained, and wherein the test result is compared with a target result derived from the specification data, for which comparison the test apparatus 1 is used with the test program, wherein the specification data has been implemented or imported into the test program, and on a test apparatus 1 for testing a Automation system 2 with different terminal strips and / or interfaces, the tester 1 has a memory 1.1 with a Püfprogramm and various test adapter 1.6 and / or interfaces 1.5 for connection to the automation system 2, wherein a comparator 1.2 for comparison the test results with the specification data of the automation system 2 is provided.

Description

The The invention relates to a method for testing a Automation system at the one by the automation system to be controlled system and / or sub-functions of the automation system be simulated using a tester with a Test program for simulation of the system and / or subfunctions of the automation system is used, and by the simulation Test results of the automation system can be obtained and on a tester for testing a Automation system with various terminal strips and / or Interfaces, the tester has a memory with a test program and various test adapters and / or interfaces for connection to the automation system having.

at The automation system can be a system that consists of one or more of the following components: sensors, Actuators, signal transmission (including terminals, distributors and signal matching, separation, conversion and amplification for wired transmission or including amplifiers, Converter, access points for wireless signal transmission), Logic system (hardwired or freely programmable), embedded Systems, Visualization System, Operator Observation Components, Logging components (writers, electronic logs, Erstwertmeldesysteme), long-term data archiving, computer systems for general organizational tasks (eg warehousing, Quality assurance, laboratory data acquisition, plant maintenance, Cost accounting, production planning, financial accounting, etc.) and / or Alarm systems.

In the process engineering and energy technology production In some cases there are considerable risks for people and the environment and devices. In pharmaceutical production and food production there are risks for the patient or consumer. Around the economic and quality production and to ensure the safety of such equipment or of the products produced, be u. a. Automation systems, such as process control systems (PLS), Programmable logic controllers (PLC) or special safety-related Controllers (SSPS), Operator Observation Devices, Logging Components, Long-Term Data Archiving Systems, Alerting systems and computer systems for general organizational tasks (eg warehousing, quality assurance, Laboratory data acquisition, plant maintenance, cost accounting, production planning, Financial accounting etc.) u. a. used. With the help of such automation systems become protective functions and also all other production steps reliably executed.

Plant designers, -Installers and operators will become even more in the future to meet the requirements of traceable, documented Must take exams. The effort The result is conceivable high.

A essential condition for reliability of these systems is that the automation systems work according to specification. This is the case with all currently available automation systems Solutions extensive and time-consuming tests manually perform and document. Partially require Laws or the standards or a so-called verification, Validation or qualification of the automation system, d. H. the proof of specification conformity.

Under automatic verification / validation / qualification becomes the comparison of test results or test result and target results or the desired result, ie the expected result. The Target result is preferably determined by the test program or the tester from specification or specifications derived.

automation systems are tested today in particular at a factory acceptance as follows. Those to be controlled by the via the automation system System to be expected field signals by means of switches, rotary potentiometer, Luminaires and analogue displays simulated. Bus communication is through corresponding bus simulation simulated. Operator actions of the operator are simulated by the examiner. This is done on a basis the existing specification data for the automation system. The test results obtained therefrom are paper and ballpoint or electronically documented.

There is already a method for releasing the function of a control automatic control from the DE / EP 0 283 382 T1 known. A plant for implementing this industrial process includes functional elements such as actuators with associated probes, the control automatic control being connected to an automatic simulation system which is programmed to simulate the function of the functional elements of the plant in order to realize the industrial process ,

Under Use of a simulation automatic thus become different process sequences a system simulated and the behavior of the control automatic control or the automation system as part of a simulation of the Tested system without these connected to an existing system would have to be.

Of the Invention is based on the object, a tester for automation systems in such a way and to arrange, that routine work in the qualification or establishment of the Automation system to be processed automatically.

Solved the object is achieved by a method according to claim 1 or a tester according to claim 18th

According to the invention the test results with one from the specification data to be derived from the target result, and for this Compare the tester with the test program is used, and the specification data in the test program implemented or imported. In the specification data these are in particular specification data of the automation system. You can also use specification data from the plant become.

The Tester automates the processing of the test, in particular the simulation of the system or sub-functions of the automation system, the recording of the data of the automation system in the simulation, ie the test result, the comparison of this test result with an expected from the specification data and expected Target result and preferably the storage or verification of this Comparison result in the implementation phase (eg in module tests, Integration tests), during the factory acceptance test (Factory Acceptance Test), commissioning check (Site Acceptance Test) and cyclically repeating during the operating phase Tests or changes to the process, plant or the automation system.

The Specification data primarily describe the structure and the Function of the automation system or of the computer system, in particular the input / output assignment list, the limit list, the logic description, the circuit diagrams, the operating picture sketches, the description of operation and observation or visualization devices and / or systems, the data recording or logging, the specifications and specifications for the general computer systems and / or alerting. The specification data partly also describe the structure and function of the system and the process that goes beyond the automation system to be controlled.

With Help of specification data provided to the tester specified externally, supports the tester the operator in the creation of test cases, which then be processed as Prüfsteuerrezept. The test control recipes After, the tester communicates with the automation system. The resulting test result is from the tester determined, compared with the specification and if necessary the examiner displayed for review. The tester created automatically a comprehensive documentation of the finished test control recipe, the test result and / or the comparison result.

According to the invention a comparator unit for comparing the test results provided with the specification data of the automation system.

Advantageous this may also be the case if the input-output test, the bus test, the logic test, the operator observation test, the protocol check, the long-term archiving check and / or the limit test as well as the module tests, integration tests, Regression onstests automated both by the tester or manually by the operator under direction or instruction the tester can be performed. The above test can also be done by the operator be carried out alone, with the respectively obtained Tax audit recipe is recorded.

Further It may be advantageous if a basic test recipe by Operator is created, the test program the corresponding Basic test recipe calls, whereby the selection of the basic test recipe over predefinable rules or manually and the test program based on the combination of the basic test recipe with the specification data created a Prüfsteuerrezept.

The Test program fits with the creation of the test control recipe based on the selection of the basic test recipe so to speak its program properties to the specification data. The basic testing recipes are selected automatically (via rules) or manually and linked to specification data to inspection control recipes made and then "driven off" by the test program.

The relationship between the basic test recipe and the test control recipe will be explained with reference to the following simplified example. The operator selects the basic test recipe "Check individual analog input" to test the conventional (4-20 mA) analog input "FI4711". Prüfgrundrezept specification data Prüfsteuerrezept Check individual analog input Measuring point name: FI4711 Designation: Flow measurement Check FI4711 1) Simulate 4 mA at input (via I / O test adapter) Name of terminals: X1: 41.1 Simulate 4 mA at X1: 41.1 (via communication channel "I / O test adapter" card 8, channel 3) 2) Read the variable from the automation system Name of the input variable in the automation system: FI4711I Read FI4711I.PV (via communication channel OPC) 3) Compare whether the value of the variable corresponds to the lower end of the range. Create protocol Lower end of measuring range: 0 L / h Is FI4711I.PV = 0 L / h? If yes: protocol = OK otherwise protocol = NOK 4) Simulate 20 mA at input (via I / O test adapter) Name of terminals: X1: 41.1 Simulate 20 mA at X1: 41.1 (via communication channel "I / O test adapter" card 8, channel 3) 5) Read the variable from the automation system Name of the input variable in the automation system: FI4711I Read FI4711I.PV (via communication channel "OPC") 6) Compare whether the value of the variable corresponds to the upper end of the measuring range. Lower end of measuring range: 200 L / h Is FI4711I.PV = 200 L / h? If yes: protocol = OK otherwise protocol = NOK

On Basis of the specification would be from the basic test recipe "Check single analog input "for a specific analog input eg the test control recipe "Check FI4711 "developed. Because the specification by the test program can be queried, the tester can over the test program the specific test control recipe create and process. During the processing of the exemplary sketched test control recipe, it would come to communication with the automation system via two communication channels (OPC and EA signal adapter).

Advantageous It may also be, if by means of the test program either automatically or with reference to the operator a basic test recipe is selected, the test program the specification data retrieves the specification data with the basic test recipe linked and used to create the test control recipe, via the terminal block or interface with the automation system Signals of the test control recipe is applied and the received signals and / or data or the test result the same or at least one other interface of the automation system or read by the operator.

there It may be advantageously provided that the test recipes and / or test reports hierarchically one above the other be nested.

The test recipes can be structured hierarchically as shown in the following table. For example: At the bottom level 1 is the test recipe "Check analog input" (as in the example above). In the next level 2 is the test recipe "Check all analog inputs of an analog input card". Finally, level 3 is followed by the logic system check. level Prüfgrundrezept Prüfsteuerrezept 3 I / O testing logic system I / O check logic system ITR1.1 2 I / O check I / O card type AI Terminal strip ITR1.1.X1 1 I / O check "Check analog input" Channel 3, signal F4711I.PV

Eg: The operator calls the basic test recipe (level L3) for a logic system ITR1.1 of the automation system. This makes the basic test recipe the test control recipe "I / O Check Logic System ITR1.1 ". All hierarchically subordinate basic check recipes L2 & L1 are automatically instantiated by the hierarchically superior recipe.

From Of particular importance for the present invention be, if the interfaces and the terminal strips identification means and an examination of the mapping between the interfaces and the terminal strips by the test program.

in the Connection with the training according to the invention and arrangement, it may be advantageous if as a means of identification RFID's are used. The connection of the interfaces of the test device (bus or I / O signals) to the corresponding terminals of the automation system is detected via RFID system, d. H. through the approach of the test adapter to the terminals of the automation system it is determined which terminal of the automation system with connected to which test adapter of the tester is. This can prevent test wiring errors.

Advantageous It may also be when the signal exchange between the test adapter and / or the interface and a terminal strip is wireless. This simplifies the test setup.

Furthermore It may be advantageous if for test communication separate terminal strips, interfaces, adapters of the automation system used for the communication of the automation system not to be used with the system. This can be guaranteed be that tests z. T. also during the ongoing operations, or examinations in parallel to each other (eg I / O check and logic check).

Further It may be advantageous if the communication between the tester and the automation system via multiple communication channels or several test adapters and terminal strips simultaneously he follows. The communication channels transmit digital Bus, conventional electrical, acoustic and optical signals and files. The transmission is via the test program controlled.

there It may be beneficial if the operator passes the exam of the automation system and the communication with the automation system can perform manually. Manual testing means that the operator the signals at the terminal strips and / or interfaces or adapters set themselves. This is for rare or irregular testing procedures the most efficient Procedure, since an automation or creation of a test program or test recipe is not always worthwhile.

After all It can be beneficial if testing actions are carried out by the operator to be recorded and recorded in a test control recipe will be integrated. There are test actions, which must be done by the operator. However, the acts should be part of the verification, Validation and / or verification process, d. H. a test program In addition to the signal exchange with the logic system, an operator request can also be made (Instructions with or without feedback to the test system) output.

The Manual testing takes place where no specification exists is or from the specification no test instruction for the preparation of a test control recipe is derivable or the test instruction is on paper. Such performed Tests (without test recipe) can be recorded become. From this, a manual test control recipe can be derived, which can be repeated at any time.

Advantageous It can also be this if that manually and / or automatically created Prüfsteuerrezept and / or the thus obtained Test results recorded by a recorder become. The recorder records the set by the operator Signal pattern on. From the recorded signal pattern sequence arises then a new, so far created manually test control recipe, as explained by the following example.

Of the User tests an XX logic device with two digital inputs I1 and I2 and an output O1 by using it without the use of test prescriptions directly at the test communicator the signals I1 and I2 first to "0" and determines at the output: O1 = 0. Then it sets the signal I1 = 1 and the signal I2 to "0" and determines at the output O1 = 0. After that he puts I1 = 1 and I2 = 1 and determines at the output O1 = 1. The recorder saves the User-defined signal patterns and results. From the Sequence of the signal patterns creates a new test control recipe, which now anytime again, even for other logic devices can be traveled. Will the test control recipe stored in this way applied to an AND device, it would have the same result produce, as in the example.

This Test control recipe can thus be repeated in the same way or be retrieved from the recorder, without creating the same based on a basic test recipe.

The Recorder function allows random (previously undefined) Tests that are nevertheless always understood can.

• a) ein altes Automatisierungssystem oder eine Nachbildung des alten Automatisierungssystems an das Prüfgerät angeschlossen und ein Prüfprogramm absolviert wird;
• b) der Prüfablauf, das Prüfergebnis und/oder das Vergleichsergebnis aufgezeichnet werden;
• c) der aufgezeichnete Prüfablauf auf einem anderen, neuen und/oder modifizierten Automatisierungssystem durchgeführt wird;
• d) die beiden Prüfungsergebnisse und/oder Vergleichsergebnisse verglichen werden.

It may also be advantageous if, when changing from an old automation system to a new or modified automation system or for the purpose of checking an existing automation system for changes in the process, in the system or in the automation system, a migration test is completed

• a) an old automation system or a replica of the old automation system connected to the tester and a test program is completed;
• b) the test procedure, the test result and / or the comparison result are recorded;
• c) the recorded test procedure is carried out on another, new and / or modified automation system;
• d) the two examination results and / or comparison results are compared.

system migrations are characterized by the fact that the function of existing systems to be modeled on new systems. The "specification" yields arising from the function of the old system, d. H. the new system should work the same as the old system.

A similar Procedure is used for recurring tests. A recurring exam is usually meant for the same test program the same (or a similar) Bring the test result.

A similar Procedure is performed for change check. amendments usually refer only to certain parts of the system and should be non-reactive to other system parts. D. H. system parts not affected by the change must be after a change work the same as before.

From Advantage may be when using the tester exams on the automation system and in particular a logic system of the automation system while the automation system and possibly the system is in operation, wherein a decoupling between the plant and the automation system Field signals to be exchanged takes place. The field signals are for the time of exams or other activities simulated in the automation system. The for the exam the automation system necessary signals are over separate test communication channels to the automation system passed on or acquired from there. The during the Decoupling present field signals thus have to the test or the test signals and / or on the automation system no influence and vice versa have the test signals or the test does not affect the field signals, where the decoupling of the corresponding signals preferably by a Operating switch is made.

In order to certain functions can be tested without the am Automation system to influence hanging plant peripherals or to be influenced by it, it is possible to decouple the field signals (I / O, bus). Becomes outputs simulated in this case, d. H. the value of before decoupling output is maintained after decoupling.

moreover It may be beneficial if, when a deviation occurs between the test result and the target result ticket management is completed. If deviations (errors) are detected, then these deviations are treated as in Ticket Management in IT, d. H. an error log is generated and the workflow is over Error analysis, troubleshooting, test repetition controlled. If If an error is detected, an error log is generated.

Besides It may be beneficial if for at least one test result a tax audit report at least one report with the result of the comparison being included in the report and that is an evaluation of the automatically determined comparison result is performed by the operator or automatically and that the report is in the form of at least one document and / or one File is documented.

For example, a rating may be in the form of "negative", "positive", "positive (or negative) with annotation" or "indefinite". Positive means that the test result corresponds to the target result derived from the specification. Negative means that the test result does not correspond to the target result. "Positive or negative with annotation" means that the test result corresponds to the target result (resp. not compliant) and additional findings on the test result or framework conditions or the like were obtained and should be documented. Indefinite means that the evaluation of the result could not yet be carried out or has not come to a clear conclusion.

In terms of of the tester, it may be advantageous if a part of the memory, another memory and / or a recorder for manual and / or automatic test procedures, Test recipes, test results and / or comparison results is provided. These data are thus storable and at any time available.

For this It may be beneficial if multiple communication interfaces are provided, which are preferably designed as a test adapter are. Further advantages and details of the invention are in the Claims and explained in the description and shown in the figures. It shows:

1 Overall system overview;

2 Functional overview of testing device;

3 Signal flow / Extent;

4 Signal flow module test I / O check;

5 Signal flow integration test for "computer system for general organizational tasks";

6 Signal flow "decoupling" during tests while the system is running;

7 Hierarchy of recipes and reports.

According to 1 is determined by the specifications or specification data, both the automation system 2 as well as the tester 1 serve as input, the automation system 2 checked and then created a documentation of the test.

Using the specification data provided to the tester 1 from a specification unit 1.3 specified from the outside, or in the tester 1 implemented, supports the tester 1 the operator in the creation of test cases, which then to the DUT, the automation system 2 via interfaces 1.5 or test adapter 1.6 of the tester 1 or interfaces 3.1 of the automation system 2 or the operator is communicated. Subsequently, the resulting test result from the tester 1 determined, presented to the operator for assessment, as well as a comprehensive documentation of the performed test automatically in the documentation unit 1.4 generated. The valuation can also be made automatically based on the comparison result.

• 1) Die Prüf-Rezept Planung umfasst die Erstellung von Prüfgrundrezepten. Dies kann durch Prüf-Aufzeichnung, vorzugsweise durch einen Rekorder, der in der operativen Prüfumgebung durchgeführten Prüfungen oder durch Spezifikation im Prüfrezept Editor stattfinden.
• 2) Die Prüf-Bericht Planung umfasst die Erstellung von Prüfbericht Dokumentationsvorlagen (Prüfgrundbericht) mit dem Prüfbericht Editor.
• 3) Die Prüfdurchführung. Sie umfasst a) die Kommunikation zum Bediener zum Zwecke der Prüfausführung (Prüfsteuer Cockpit), die Zuordnung von Prüf grundrezepten zu Prüfobjekten, den Start/Stop von Prüfsteuerprozeduren und/oder die Festlegung des Prüfumfangs. Ferner die Prüf-Dokumentation (Prüfbericht Cockpit), die Planung und die Definition von durchzuführenden Prüfungen, insbesondere die Übernahme von Prüfgrundberichten in Prüfberichte, die Bewertung von Prüfungen, die Kontrolle und die Übersicht über durchgeführte Prüfungen und das Ticketmanagement; b) die Kommunikation mit dem Automatisierungssystem und die Erfassung der Prüfergebnisse Test Daten (Test Kommunikator). Im Falle der E/A-Prüfung über den OPC-Adapter (oder den Bus-Adapter oder File-Adapter) und den E/A-Adapter; c) die Ausführung der Prüfsteuerrezepte durch das Prüfprogramm; e) die Evaluierung der Prüfergebnisse, den Vergleich mit den erwarteten Soll-Ergebnissen durch den Komparator, also die Herstellung eines Vergleichsergebnisses und die Erzeugung eines vorläufigen Prüfberichts; f) die Übernahme der Spezifikationsdaten, den automatisierten Vergleich der Spezifikationsdaten gegenüber dem letzten Stand der Spezifikationsdaten, die sog. Delta Analyse und die Ableitung des Prüf-Umfangs, die sog. Risiko Analyse.

According to 2 The tester function can be divided into three sub-areas, the test recipe planning, the test report planning and the test execution.

• 1) The test-recipe planning includes the creation of test master recipes. This can be done by test recording, preferably by a recorder, the tests performed in the operative test environment, or by specification in the test recipe editor.
• 2) The test report planning includes the creation of test report documentation templates (basic test report) with the test report editor.
• 3) The test procedure. It comprises a) the communication to the operator for the purpose of test execution (test cockpit), the assignment of test recipes to test objects, the start / stop of test control procedures and / or the determination of the scope of testing. Furthermore, the test documentation (test report cockpit), the planning and the definition of tests to be performed, in particular the acceptance of test report reports in test reports, the evaluation of tests, the control and overview of tests carried out and the ticket management; b) the communication with the automation system and the recording of test results test data (test communicator). In the case of I / O testing via the OPC adapter (or the bus adapter or file adapter) and the I / O adapter; c) the execution of the test control recipes by the test program; e) the evaluation of the test results, the comparison with the expected target results by the comparator, ie the production of a comparison result and the production of a preliminary test report; f) the acceptance of the specification data, the automated comparison of the specification data compared to the latest version of the specification data, the so-called delta analysis and the derivation of the scope of the test, the so-called risk analysis.

1) Test recipe planning

Prüfgrundrezepte such as module, integration tests, I / O test, limit test, protocol test, Bus test, visualization test, etc. are in the test recipe Editor generated. Basic test recipes are subject to change control. Variants such. B. customer-specific or application-specific (Burner control, F & G, ESD)) are managed.

Of the Check Recipe Editor runs independently of current testing operation and can be on any machine be installed.

Similar A keyboard recorder is used by the recorder operator activities recorded in the test communicator and can be used at any time be "driven off" again.

In The basic test recipe library contains the basic test recipes and version-controlled system, customer and application-specific variants from. The basic testing recipe library may or may not be on the same computer hardware as the test execution functions lie.

2) test report planning

through of the test report editor become basic test reports for modules, integration tests, FATs, SATs, I / O tests, limit tests, Protocol tests, bus tests, migration tests etc. created.

A hierarchical composition can be made. For example if a FAT is an I / O test, an I / O test is conventional I / O's, bus I / O's etc. System, customer (logo) and application specific Vairantes can be defined.

In The basic test report library contains the basic test reports and version-controlled system, customer and application-specific variants from. The review base report library may or may not be on the same computer hardware as the test execution Functions are.

3) Test procedure

A test object or an automation system 2 and / or a part of an automation system 2 is assigned a basic test recipe or vice versa. The test master recipe is assigned to the project-specific specification data such as system topology, automation system, (I / O cards, etc.), I / O assignment, limit value setting, logic specifications, etc. This creates a test control recipe. Possibly. A system-, customer-, or application-specific (sub) variant of the basic test recipe can still be selected.

The Test control recipe is about the test control Cockpit controlled (start, stop, hand, automatic etc.).

The Test control recipe or preliminary test result is assigned to a test report. This can be done both before as well as done after the execution.

The Operating prompts are according to the test recipe sent to the examiner and answered by this. The Results / answers are recorded as test results and if necessary displayed in the test report.

Consists the test control recipe from multiple levels, can these are individually hand-operated and operated. Lowest Level is the process image (current status of the input and output signals and the test communication)

The inspection cockpit displays the system status such as system errors, such as B. Communication error to the automation system ( 2 ), check-report cockpit and the like.

The (electronic) test report is the "test protocol" for the automation system to be tested. The start and end of an inspection are defined in the inspection report cockpit. The status of the test work is monitored via the test report cockpit. The printout of the entire test report or extracts thereof as well as the selection of the desired documentation design is made from the test report cockpit. An overview of all tests currently in progress is displayed.

One Audit report can have multiple levels. Allocation and management of these levels takes place in the test report cockpit instead of.

One new test report is created. The test report a basic test report is assigned (or vice versa).

Of the Basic test report is in at least one or more System, customer or application specific (sub) variants of the test report. The selection of the variant will made from the test report cockpit. The review the check by the operator is made. The status the checks are displayed, such as "in Work "," completed "," too Rate ", and the like. Archived test reports and raw inspection data can be displayed.

deviations Test errors, repairs, repeated tests in the test report cockpit if necessary using the ticket management managed.

Further A specification import and delta & risk analysis is provided. specification data are selected and intended for import.

amendments in the specification are recognized. Scope of change and Depth are analyzed, the risks associated with it (eg repercussions on non-changed parts) evaluated and as a basis for retests used.

The test communicator is the coordination point for the necessary communication to the automation system. He takes the signals from the adapters 3.1 . 3.2 , Video adapters, file adapters, bus adapters, other adapters etc. and visualizes them on a common user interface 2.2 , The test control recipes access the signals of the test communicator.

The test communicator shows the communication status to the individual adapters or interfaces 3.1 . 3.2 , Video adapters, file adapters, bus adapters, other adapters etc.

Next Signal communication is also the file transfer and possibly the readout of files as well as the transfer of sound and images through the test Communicator carried out or coordinated.

The I / O adapter 3.1 allows the feeding (simulation) and the measurement of conventional electrical signals in the automation system such as 4-20 mA, 0-24 Volt etc .. The signal image, which is currently connected to the automation system 2 delivered or from the automation system 2 is visualized and can be influenced / adjusted by the operator.

The OPC adapter 3.2 enables bidirectional communication with the automation system 2 such as B. the logic system 2.1 , the visualization system 2.9 , the PLS, etc.) via the OPC standard family. The signal image which is currently delivered to the system to be tested or measured by the system to be tested is visualized and can be adjusted by the operator.

The audio adapter enables reading (listening) communication with the automation system 2 , Such as B. the logic system 2.1 , the visualization system 2.9 , the PLS 2.8 the general computer system 2.0 , etc. The audio adapter can be connected via microphone systems as well as directly to the sound cards of the automation system.

The video adapter enables reading communication with the automation system 2 such as B. the visualization system 2.9 , the process control system (PLS) 2.8 , the general computer system 2.0 etc. The video adapter can be used both via camera systems and directly to the graphics cards of the automation system 2 be connected.

Of the User Simulator simulates keyboard and mouse operation.

The Modbus / Profibus adapter enables bidirectional communication with the automation system 2 such as B. the visualization system 2.9 , the PLS 2.8 , etc., and provides visualization with operating option of the communication image.

The File Adapter enables communication with the automation system 2 such as B. the logic system, the visualization system 2.9 , the logging system 2.6 , the process control system 2.8 , the general computer system 2.0 Etc.)

The comparator 1.2 evaluates whether the measured data / signals or the test results correspond to the expected data / signals or the target result. The need for a further manual examination or evaluation of this comparison result may be required. The evaluation will be carried out in the test report. It then decides whether a review is needed and how its scope is defined.

Other technology specific adapters (eg for Ethernet, for Bus systems, for special software technologies) are also intended.

3 shows that, depending on the desired scope of testing, the I / O adapter 3.1 of the tester 1 either directly to the I / O modules 2.3 of the automation system 2 (eg logic system 2.1 ) can be connected. This would typically be the case at a factory acceptance test. Alternatively, the I / O adapter 3.1 also in the field z. B. to the on-site distributor or on Rangierverteiler 2.4 or directly to actuators, sensors 2.5 be connected. For large-scale installations, the wireless I / O adapter 3.1 are used, typically in the commissioning test (SAT).

For module test I / O for a logic system 2.1 according to 4 Logic system input signals are tested by the I / O adapter 3.1 a signal "a" to the logic system 2.1 is sent. If the check is carried out automatically, this can be done in the logic system 2.1 incoming signal via BUS or OPC adapter 3.2 "B" read again and in the tester 1 be evaluated.

I / O test for a logic system 2.1 Logic system output signals are checked by the signal "c" from the logic system 2.1 via the I / O adapter 3.1 to the tester 1 Posted. If the check is carried out automatically, this can be done by the logic system 2.1 outgoing signal "d" via the BUS or OPC adapter 3.2 in the tester 1 read out again and in the tester 1 be evaluated.

The protocol system 2.6 can be checked by simulating events specified in the specification as events to be logged and the tester 1 checks whether the events were logged in accordance with the specification.

In principle, the signal flow can be tested for any number of similar subsystems of the automation system 2 , z. B. a logic system 2.1 , a logic system 2.11 , or a logic system 2.1x but also subsystems of different types take place.

The long-term archive system 2.7 can be checked by simulating signals specified in the specification as (trend) signals to be archived and the tester 1 Checks whether the waveform has been recorded (archived) in accordance with specifications.

The process control system 2.8 can be tested by simulating operator actions, displays, control & regulation algorithms and alarms specified in the specification, and the test equipment 1 Checks if the behavior of the process control system 2.8 is in accordance with specifications.

Sensors and actuators 2.5 can be tested (input, output or bus) signals specified in the specification for the communication, simulated and measured and the tester 1 checks if the behavior of the sensor / actuator 2.5 is in accordance with specifications.

Operation / Display 2.2 can be tested by simulating and measuring operator actions, displays and alarms specified in the specification and by verifying the behavior of the operator control system 2.2 is in accordance with specifications. This includes the operator himself, the operator simulator, the video adapter, file adapter and other adapters.

5 describes the signal flow integration test for a "computer system for general organisato tasks ".

Under a computer system 2.0 For general organizational tasks, for example, systems for warehousing, quality assurance, laboratory data acquisition, asset maintenance, cost accounting, production planning, financial accounting, etc. understood. This example assumes that the logic system connects to this general computer system 2.0 and that the integration of the two systems should be checked by means of the tester.

The signal flow in the integration test can be simulated by operator input 4 , Signal "a" or by the operator himself 4 stimulated and via the OPC or I / O or bus adapter 3.2 as signal "b", "c" read back and in the tester 1 be evaluated automatically.

Conversely, signals "d", "e" via OPC or I / O or bus adapter 3.2 in the logic system 2.1 stimulated and for automatic evaluation "f" via the video adapter 5 be read back and automatically evaluated.

The signal flow "a" initiated by the operator 4 or operator simulation 4 and return flow "f" via the video adapter 5 or by observation and manual input of the operator is feasible.

In principle, tests can also be performed without a direct interface (adapter) between the tester 1 and logic system 2.1 be performed. In this case, the manual test user interface serves as the auditor for the appropriate operation of the computer system 2.0 calls for general organizational tasks and observes corresponding reactions of the system and test results in the tester 1 (manually) enters.

6 shows the representation of the signal flow for the purpose of testing the automation system 2 while the system is running.

Tests can also be carried out in such a way that the system to be tested, such as For example, the logic system 2.1 from the plant 7 is decoupled. A test mode switcher decouples the input signals 6.1 as well as the field output signals 6.2 activated. The tester 1 can then simulate input signals "a" and read out test results "b", while the signals effective in the system 6.1 constantly kept "c" during the test.

According to 7 is provided a hierarchy for tax check recipes, as well as for the resulting reports.

The flexibility of the test program adaptation is achieved, small, in particular reusable parts are defined as Prüfgrundrezepte. In order to carry out a concrete test economically, quickly and clearly, the test control recipe is composed by combining and hierarchizing test master recipes. The reports are made according to 7 in a corresponding manner arranged hierarchically.

Concerning the other procedures for carrying out the method according to the invention and / or for constructing the test device according to the invention, in addition to the methods described in US Pat 1 to 7 illustrated flowcharts and the teaching contained therein to those skilled in the art.

1

tester

1.1

Storage, recorder

1.2

comparator, comparator

1.3

specification device

1.4

documentation unit

1.5

Interface, terminal block

1.6

Test Fixtures

1.7

Tracers, RFID

2

automation system

2.1

logic system

2.11

logic system 2

2.1x

logic system x

2.2

Operation / Display

2.3

I / O module

2.4

marshalling

2.5

actuator, sensor

2.6

log system

2.7

Long-term archive system Storage

2.8

process Control System

2.9

visualization system

2.0

Computer system generally

3.1

Interface, Terminal block, I / O adapter

3.2

OPC, Bus adapters and / or other adapters

4

Operator, user

5

Video Connector

6.1

Field signals input

6.2

Field signals output

7

investment

a

signal

b

signal

c

signal

d

signal

e

signal

f

signal

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - DE 0283382 T1 [0008]

Claims (20)

Method for testing an automation system ( 2 ) in which one by the automation system ( 2 ) to be controlled ( 7 ) is simulated, whereby a test device ( 1 ) with a test program for simulating the system ( 1 ) and by the simulation a test result of the automation system ( 2 ), characterized in that the test result is compared with a desired result to be derived from the specification data, whereby for this comparison the test apparatus ( 1 ) is used with the test program, where the specification data has been implemented or imported into the test program. A method according to claim 1, characterized in that the EA test, the bus test, the logic test, the operator observation test, the protocol test, the long-term archiving test, the module test, the integration test, the regression test and / or the Limit value test by the test device ( 1 ) automated or by the operator manually or by the operator manually and with guidance by the tester ( 1 ) be performed. Method according to claim 1 or 2, characterized, that - a test master recipe by the operator is created; - the test program the corresponding Basic test recipe calls, whereby the selection of the basic test recipe over predefinable rules or done manually; - the Test program based on the combination of the basic test recipe creates a test control recipe with the specification data. Method according to one of the preceding claims, characterized in that a) a basic test recipe is selected either automatically or with reference to the operator by means of the test program; b) the test program retrieves the specification data, links the specification data to the basic test recipe and from this creates the test control recipe; c) the automation system is supplied with signals of the test control recipe via the terminal strip or interface; d) the received signals and / or data as a test result on the same or at least one other interface of the automation system ( 2 ) or read by the operator. Method according to claim 4, characterized in that that the basic test, test control recipes and / or the Test reports nested hierarchically become. Method according to one of the preceding claims, characterized in that the interfaces ( 1.5 ), the terminal strips ( 1.5 ) and / or the test adapter ( 1.6 ) Identification means ( 1.7 ) and a check of the assignment between the interfaces and the terminal strips is carried out by the test program. Method according to one of the preceding claims, characterized in that as a means of identification ( 1.7 ) RFID's are used. Method according to one of the preceding claims, characterized in that the signal exchange between the test adapter ( 1.6 ) and / or the interface ( 1.5 ) and / or a terminal block ( 3.1 ) and / or an adapter ( 3.1 . 3.2 ) and / or automation system 2 wirelessly. Method according to one of the preceding claims, characterized in that for the test communication separate terminal strips ( 3.1 ), Interfaces and / or adapters ( 3.2 ) of the automation system ( 2 ) used for the communication of the automation system ( 2 ) with the plant ( 7 ) Not used. Method according to one of the preceding claims, characterized in that the communication between the test device ( 1 ) and the automation system ( 2 ) via multiple communication channels or multiple test adapters ( 1.5 . 1.6 ) and terminal strips ( 3.1 . 3.2 ) takes place simultaneously. Method according to one of the preceding claims, characterized in that the operator checks the automation system ( 2 ) and the communication with the automation system ( 2 ) manually. Method according to one of the preceding claims, characterized in that testing actions by the operator, into a test control recipe to get integrated. Method according to one of the preceding claims, characterized in that the manually and / or automatically created Test control recipe and / or the test results obtained with it be recorded by a recorder. Method according to one of the preceding claims, characterized in that when changing from an old automation system ( 2 ) to a new or modified automation system ( 2 ) or for the purpose of checking an existing automation system ( 2 ) after changes in the process, in the annex ( 7 ) or in the automation system ( 2 ) a migration test is completed, wherein a) an old automation system ( 2 ) or a replica of the old automation system ( 2 ) to the tester ( 1 ) and a test program is completed; b) the test procedure, the test result and / or the comparison result are recorded; c) the recorded test procedure on another, new and / or modified automation system ( 2 ) is carried out; d) the two examination results and / or comparison results are compared Method according to one of the preceding claims, characterized in that with the testing device ( 1 ) Tests on the automation system ( 2 ) and in particular a logic system ( 2.1 ) of the automation system ( 2 ) while the automation system ( 2 ) and, if applicable, the annex ( 7 ) is in operation, with a decoupling between the plant ( 7 ) and the automation system ( 2 ) field signals to be exchanged. Method according to one of the preceding claims, characterized in that when a deviation occurs between the test result and the target result ticket management is completed. Method according to one of the preceding claims, characterized in that for at least one test result a tax audit report at least one report with the result of the comparison being included in the report and that is an evaluation of the automatically determined comparison result is performed by the operator or automatically and that the report is in the form of at least one document and / or one File is documented. Tester ( 1 ) for testing an automation system ( 2 ) with various terminal strips and / or interfaces ( 1.5 ) and / or adapters ( 1.6 ), whereby the testing device ( 1 ) a memory ( 1.1 ) with a test program and various terminal strips, test adapters ( 1.6 ) and / or interfaces ( 1.5 ) for connection to the automation system ( 2 ), characterized in that a comparator unit ( 1.2 ) for comparing the test results with the specification data of the automation system ( 2 ) is provided. Apparatus according to claim 18, characterized in that a part of the memory, another memory and / or a recorder ( 1.1 ) is provided for manual and / or automatic test sequences, test recipes, test results and / or comparison results. Apparatus according to claim 18 or 19, characterized in that a plurality of communication interfaces ( 1.5 ) are provided, which are preferably designed as a test adapter.