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Case study · TestOS

TestOS BDD PLC testing

After every PLC program change it should be clear whether sequences, signals, safety conditions and communication still behave correctly. TestOS turns this into a repeatable test process instead of manual checking by feeling.

TestOSBDDSquash TMJenkinsGiteaPLCHIL
TestOS BDD PLC testing
Focus
PLC regression testing
Tools
Squash TM, Jenkins, Gitea
Execution
TestOS runner
Use
HIL, wiring, sequences

Challenge

PLC projects change during development, commissioning and service. Without repeatable tests it is difficult to prove that a new change has not broken an existing function.

manual tests are slow and depend on the person executing them
requirements, test cases and results are not always linked
signal or sequence faults are often found only on the real machine

Solution

TestOS links BDD test cases with execution on the PLC system. Scenarios are managed in Squash TM, source code and configuration are stored in Gitea, and Jenkins starts repeatable test runs.

BDD scenarios for I/O signals, sequences and conditions
automatic or semi-automatic execution through TestOS
reports usable for commissioning, service and regression checks

Value

Instead of a one-time manual check, the project gets a test framework that can be reused after every program, wiring or configuration change.

faster validation of changes
better traceability from requirements to results
less repetitive manual work during commissioning

Concrete result

1

Test cases are documented so they can be repeated later.

2

PLC changes are checked with the same method, not only manual inspection.

3

Reports improve communication between development, commissioning and service.

4

The project gets a base for further automated testing.

Need repeatable PLC tests?

Send a description of the PLC system, signals and typical scenarios you want to verify.

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