As the Industrial Internet of Things is taking hold, we are seeing more and more desktop/software electronics being used to build smart devices, machines, and equipment for manufacturing OEMs. These devices are the “things” in IIoT and form a connected ecosystem and are at the core of the digital thread.

Desktop/software product development, therefore, holds an important place in the adoption of IIoT. Here selecting a reliable platform is crucial in deciding the overall time to market and overall cost of production and quality. Test automation services and simulations are being widely used in conjunction to produce reliable and stable desktop/software devices.

Simulation refers to the process where a sample device model is simulated to perform under practical conditions, uncover the unknown design interactions, and gain a better perspective of possible glitches. It helps the test automation to streamline the defect identification and fixing process.

An automated testing process includes simulation and testing together to improve the overall efficiency of the desktop/software device. In the current technological epoch, smart test automation is a “smarter” option to create reliable desktop/software devices from the ground up.

Smart Test Automation- a Revolution for Desktop/Software Applications

Industrial automation is at the core of Industrie 4.0. The inclusion of smart devices into the automated industrial network has made many manual work processes easier and more accurate. With the emergence of software-driven desktop/software systems, the industrial automation sector is witnessing a tectonic shift towards a better implementation of IIoT.

As the dependence on these devices increases, desktop/software device testing should not be an afterthought while implementing the big picture. That said, carrying out multiple tests in an IIoT environment where the number of desktop/software systems is increasing can be challenging. To improve the overall accuracy, bespoke smart test automation for desktop/software devices is required.

Smart test automation is the platform wherein the desktop/software devices are tested to understand their design interactions and discover possible glitches in the device operation. This is very important as it ensures that the product does what is expected out of it. This innovative approach has with time, proven to show spectacular results wherein the desktop/software applications work more effectively, thereby improving the overall efficiency of the IIoT systems.

How does Test Automation help to build sound Desktop/Software Devices?

Desktop/software application testing is often misunderstood as software testing. However, both are quite different. Desktop/software product testing involves validation and verification of both hardware and firmware testing. The end goal is to create a desktop/software device that meets the user requirements. Automated desktop/software device testing works well for this purpose, as it involves a lot of iterations, and tests the firmware and hardware requirements. Below are some of the advantages of automated testing, which makes it a class apart from manual testing:

Improved productivity

One cannot deny that manual testing means a highly stressed QA team and higher risks of human errors. Having an automated testing system in place takes the stress off from the QA team to a great extent, as it allows a seamless feedback cycle and better communication between various departments. Also, it facilitates easy maintenance of the automated tests logs. These reasons culminate in a reduced product-to-market time with a highly productive team. A happy workforce and a smooth testing system form the backbone of a quality end product.

Reduced Business Costs

Multiple errors, multiple tests, reruns, all these may seem trivial, but with times they cumulate to increase the business costs. Automated test algorithms help to reduce the business costs, as they are designed to detect failures or glitches in the design in the earlier stages of the desktop/software product development. This means you will require lesser product test reruns as compared to manual testing.

Improved Accuracy

This is one of the major advantages you can leverage from a smart test automation setup. It eliminates human error, especially in a complex network. Even though the chances of computer-driven errors persist, the rate of errors is reduced to a great extent. It leads to accuracy that is sure to meet the customer demands and keep them happy.

Assurance of Stability

Automates testing helps you to validate the stability of your product at the earliest phase of product development before its release. The manual stability tests often take a lot of time and can be hampered by human errors. Automated testing helps you curate a format to get automated updates of the status of the product through the relevant database.

Smart Test Automation- Challenges and Tips

With a complex smart testing process, automation comes with greater challenges. However, most of them can be resolved if you have the expertise and knowledge to implement the right strategies to get the best out of the smart test automation setup.

Some of the challenges are:

Lack of skilled professionals to handle technology-driven testing algorithms.

Not everyone has the skills to perform automated tests to the fullest. You either hire a skilled professional or train your employees to adapt to the automated testing culture.

Lack of proper planning between the teams

One crucial aspect that decides the success of automated testing is good teamwork. Your teams need to work collaboratively to ensure stability in the tests. You can try out the modular approach to achieve this, where tests are built locally over a real device or browser. The teams can then run them regularly and map out the results and coordinate in a better way.

Dynamic nature of automated tests

This is quite common, as companies are yet to inculcate agility in their processes. It is required for the successful implementation of these tests. One way to overcome this is to start with baby steps and then scale your testing process later as the situation demands.

Conclusion

Undoubtedly, smart test automation is the future of desktop/software devices. For efficient implementation of automated test systems, we at Utthunga provide you with the right resources and the right guidance. Our experienced panel is well versed with the leading technologies and has the perfect knack to pick out the right strategies that would aid your growth.

Leverage our services to stride ahead in the Industrie 4.0 era!

 

The current wave of the industrial revolution, also known as the Industrie 4.0, has proven to improve the production process in various aspects. To realize the promised benefits, a strong communication protocol that allows semantic interoperability among interconnected devices is needed. In manufacturing industries where processes are greatly dependent on the industrial sensors and actuators, there are a few challenges that hinder seamless plant floor communication.

Take for example, the use of 4-20mA analog signals for communication between proximity switches and sensors. Although this produced satisfactory results, it did not provide any scope for diagnostics. So, the issues in the process go unnoticed until the whole system comes to a standstill. The combination of digital and analog devices also requires multiple cable and hence a tedious installation and maintenance process.

To overcome such challenges, the IO-Link Consortium Community, an organization in which key user companies from various industries and leading automation suppliers join forces to support, promote and advance the IO-Link technology. With over 120 members and strong support in Europe, Asia and the Americas, IO-Link has become the leading sensor and actuator interface in the world. The common goal of these companies is to develop and promote a unified and bi-directional communication architecture that involved an easy implementation process and the ability to diagnose the errors at the right time. The IO-Link protocol thus came as a knight in shining armor for the industries to help them gain the best of the Industrie 4.0.

IO-Link is a robust; point-to-point communication protocol specifically designed for devices like actuators and sensors. The IO-Link client is independent of the control network and communicates with an IO-Link master port. This port is placed on a gateway and transfers the data and or signals to the control system for further operations.

IO-Link proves to be beneficial for the factory automation processes especially in the digital era ofIndustrial Automation. With embedded software systems now becoming an inevitable part of industries, more IO-Links help them to leverage the power of Industrial automation and IIoT.

To get a gist of the benefits you can expect through the proper implementation of IO-Links, read the entire blog.

IO-Link Wired setup enhances factory automation communication for Industry 4.0 applications

Incorporating automation processes into an existing manual based manufacturing end processes are a primary challenge that IR4.0 possesses. To overcome this, many factory communication protocols have been introduced by various institutions.

For the device level, the communication IO-Link protocol is the most viable options to choose from. The reason being many, that we shall discuss in the next section. On the factory floor, IO-Link has long been seen as a wired communication network.

A basic IO-Link communication cycle involves:

• A request from the master device
• Waiting Time- for the request to reach the client device
• Processing time of the request from the client device
• Answer from the device to the master.
• Waiting Time- for the answer to reaching the master.

In general, factory automation units have wired IO-Links that offer high flexibility and enhances the communication systems between the controllers and the system actuators and sensors. However, with the advent of reliable wireless networks, industries are now adopting wireless IO-Link set up these days.

The popularity of the IO-Link for the communication between sensors, actuators, and the control level is steadily increasing with each passing year. In a wireless setup, an approximate 5ms maximum cycle is achievable with high probability. In addition to this, it also provides the required flexibility in automation solutions and opens door to the possibility of using battery-powered or energy-harvesting sensors as well.

How IO-Link Benefits OEMs and End Users

As already mentioned, IO-Link be it wired or wireless creates ripples of benefits for OEMs and ends users.As already mentioned, IO-Link be it wired or wireless creates ripples of benefits for OEMs and ends users. One of the advantages of IO-Link is that by incorporating the smart sensors with IO-Link, you can optimize your smart factory with powerful data and diagnostics and prepare them for the future – to increase your uptime and productivity. Along with faster time to market and lower total cost of ownership, OEMs and end usersalso benefit from improved asset utilization and risk management.

Typically a smart sensor functions as a regular sensor unless it’s connected to an IO-Link master. When connected, you can leverage all the advanced configuration data capabilities that IO-Link has to offer.

Let us have a look into some of the key advantages of implementing IO-Link for OEMs and end users.

Enables better maintenance

One of the main reason behind the popularity of the IO-Link is its diagnostic capabilities. It means the servers are informed well in advance about any forthcoming issues. This makes them ready for need-oriented maintenance and a better factory automation system.

Efficient operation

As IO-Link sensors are independent of the control network and their accessibility no longer plays a role in automation, you can place them directly at the point of operation. This means the machining process can be optimized to operate at maximum efficiency in the minimum time frame.

Consistent Network

The IO-Link being a standard communication protocol between IO sensors/actuators and the control network brings consistency in your automation network. So you get to integrate more devices into your IO-Link protocol network and introduce flexibility to your network.

Makes your system versatile and future proof

IO-Link sensors and actuators do more than just process and transmitting data to and from the control network. IO-Link protocol integration facilitates reliable and efficient communication between devices. Having IO-Link devices means your system has access to integrated diagnostics and parameterization which also reduces the commissioning time to a great extent. Overall it imbibes versatility to your system and makes it ready for the future of IIoT.

Enables processing of three types of data

With the IO-Link, you can access and process three types of data namely process data, service data, and event data.

• Process data includes data such as temperature, the pressure that is transmitted by the sensors or actuators upon request from the IO-Link master request.
• Service data refers to the one related to the product and not process and includes manufacturer name, product model number, and the like.
• Event data usually comes from sensors when any event notification has to be raised like an increase in pressure.

Provides IODD for each IO device

IO-Link protocol integration assigns each IO device with an IODD or IO Device Description such that the master manufacturers display the same IODD for each of their devices. This way, the operability of all the IO-Links is uniform irrespective of the manufacturer.

Reduces or eliminates wired networks

Since IO-Link protocol integration allows uniformity among the sensors, actuators, and control system, there is no need for separate wires. This way the number of wires can be reduced to a great extent. As wireless networks reign the IIoT arena, the concept of wireless IO-Link protocol integration is also gaining popularity.

Increases machine availability

With IO-Link protocol porting, you can enjoy an errorless and fast data exchange between sensors, actuators, and the control system. This increases the operation speed and reduces the downtime and improves the commissioning processes. Overall the machine errors are reduced thereby giving you more out of the machines.

Conclusion

The 21st century has paved the way to better industrial processes through the advent of industrial automation or the IR4.0. IO-Link protocol porting and IO-Link protocol integration has greatly helped OEMs and end-users alike, in making their production process in compliance with the IIoT set up. If you are looking for a reliable and flexible IO protocol integration for your plant, we at Utthunga have the state of the art technologies.

 

Embedded systems are a ubiquitous and crucial part of the industrial automation. Whether it’s a small controller, an HVAC, or a complicated system, embedded systems are everywhere in the manufacturing space. You need embedded systems to help in improving the performance, operational and power efficiency and to even control processes in the complex industrial realms. Building and maintaining an embedded system, the software that goes into these systems, is anything but a trivial task. It requires specialized tools like build tools, cross compiler, unit test tools, and documentation generators among others. The process of setting up such an embedded environment in your system could therefore be quite overwhelming. Docker helps in making the whole process a lot easier and manageable. Docker is similar to virtual machines but is a light-weight version of the same. This creates containers that share common components with the Docker installation.

How can Docker run on an embedded system?

Dockers are one of the preferred containers used by software developers these days. Embedded system developers are also now leveraging the benefits containers bring into their software through Dockers. Installing Docker is relatively easy and it supports different OS platforms. Once installed, you need to define a run time environment with a Docker file and create a Docker image. Once this is done, all you are left is to execute the image with the run command and share the files between the host and container. To share, you need to create a bind mount which is created every time you run an image with the “mount” option. Since embedded systems have a fairly slow rate of system update changes, you can use the lightweight Docker on a minimum build then start layering on top of it. However, running Docker on an embedded system comes with its own set of challenges. For example, Docker uses the latest LINUX kernel, which may not match the embedded system’s kernel features. Another important hurdle that developers often face is that Docker image architecture should match the run time environment.

Containers and Industrial Automation

Containerization of software applications is fast gaining popularity and is speculated to disrupt the “industrial automation” as we know today, for good. For developers, the array of container images means the collaborative creation of software deliverables is possible without overlooking the requirements for running an application within a machine environment. With the introduction of containers, industrial automation may also witness an end to the vertically integrated business model, which hasn’t changed much since the times of PLCs and DCSs. This is because the acceptance of containerization has paved the way for an efficient embedded system and easier implementation of the same into the current Industry 4.0 scenarios. It also makes automation accessible and easy to deploy in various machines.

Containers and Maintenance (Sustenance Engineering) of Embedded Systems

The industrial OT world traditionally consists of proprietary embedded systems that focus on reliability, longevity and safety.With technology advancements, maintenance of these older systemshas become a burden. The wide popularity of containerization has made containerization an important maintenance strategy for the embedded systems. Product sustenance or re-engineering is basically fine tuning your released products to add new services and enhance their existing features. It virtually extends your end of the lifecycle or older products with periodic fixes, updates and enhancements that assures reduced maintenance costs, help maximize profits as well as retain your customers. Some of the ways in which containerization adds value to your sustenance engineering are:

• Ready to implement container images reduce the development time needed for application updates, defect fixes or new features enhancements
• Resource utilization and sharing is optimized with better maintenance plans
• Container frameworks and prebuilt tool chains enable the development and maintenance of applications on multiple embedded hardware platforms like STM32, Kinetis, ARM series etc.
• Software containerization and isolation of other processes and applications protects your application from hacks and attacks. This security aspect limits the effect of a vulnerability to that particular container and thus not compromise the entire system.

Key Benefits of Docker Containers on Embedded Systems

There are multiple motivations to leverage Docker containers benefits in an embedded environment. Easy to use, they provide a lightweight and minimal way to solve legacy architecture problems etc.

1. Docker supports Windows, iOS, and Linux
2. Developers can use the tools available in their local development environment. It means they need not install tools to run a Docker on the embedded system
3. Developers can check the code against toolchains without worrying about tools co-existing.
4. Your development team can use the same tools and build environment without having to install them
5. Containers enable edge computing and convergence of services at the edge or gateway level
6. The pre-integrated container platform allows developers to create applications that scale up to their business requirements and deliver qualitytime-to-market solutions in an accelerated manner
7. Containers allows isolation of storage, network, and memory resources among others enabling developers to have an isolated and logical view of the OS
8. Portability of containers allows it to run anywhere allowing greater flexibility in the development and deployment of applications on any OS or development environment.

Conclusion

Even with its set of challenges, Docker seems to be the game-changer in the Industry4.0 era. With embedded systems playing a pivotal role in many industries, your developers can use Docker to deploy automated machines. If you want smart solutions for a decentralized plant floor, you need to get professional development assistance from Utthunga. We help you create embedded systems that truly bring out the best degree of productivity for your company. Leverage Utthunga’s embedded system consultations services and products which have transformed industries across various verticals includingdiscrete, process, oil and gas, and power industries. Contact us to know more.