Method and system for testing safety automation logic of a manufacturing cell

A method for testing the performance of safety-related automation logic used in a manufacturing cell, the method comprising:

• connecting a safety-related component to a host machine through an input/output (I/O) card;
• transmitting a set of input control signals to the connected safety-related component via the I/O card;
• recording the set of input control signals into, and a corresponding set of feedback or output control signals out of, the connected safety-related 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.

A system for testing safety automation logic used in a manufacturing cell, the system comprising:

• 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 generating a set of input control signals and transmitting the generated set of input control signals to a safety-related component via the I/O card, recording the set of input control signals and a corresponding output control signals from the connected 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 when the safety-related component is disconnected from the I/O card.