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A method for model-based test generation of safety-critical embedded applications using Programmable Logic Controllers and implemented in a programming language such as Function Block Diagram (FBD) is described. The FBD component model is based on the IEC 1131 standard and it is used primarily for embedded systems, in which timeliness is an important property to be tested. Our method involves the transformation of FBD programs with timed annotations into timed automata models which are used to automatically generate test suites. Specifically we demonstrate how to use model transformation for formalization and model checking of FBD programs using the UPPAAL tool. Many benefits emerge from this method, including the ability to automatically generate test suites from a formal model in order to ensure compliance to strict quality requirements including unit testing and specific coverage measurements. The approach is experimentally assessed on a train control system in terms of consumed resources.

In model-driven development, testers are often focusing on functional model-level testing, enabling verification of design models against their specifications. In addition, in safety-critical software development, testers are required to show that tests cover the structure of the implementation. Testing cost and time savings could be achieved if the process of deriving test cases for logic coverage is automated and provided test cases are ready to be executed. The logic coverage artifacts, i.e., predicates and clauses, are required for different logic coverage, e.g., MC/DC. One way of dealing with test case generation for ensuring logic coverage is to approach it as a model-checking problem, such that model-checking tools automatically create test cases. We show how logic coverage criteria can be formalized and used by a model-checker to provide test cases for ensuring this coverage on safety-critical software described in the Function Block Diagram programming language. Based on our experiments, this approach, supported by a tool chain, is an applicable and useful way of generating test cases for covering Function Block Diagrams.

In this paper we present a new testing tool for safety critical applications described in Function Block Diagram (FBD) language aimed to support both a model and a search-based approach. Many benefits emerge from this tool, including the ability to automatically generate test suites from an FBD program in order to comply to quality requirements such as component testing and specific coverage measurements. Search-based testing methods are used to generate test data based on executable code rather than the FBD program, alleviating any problems that may arise from the ambiguities that occur while creating FBD programs. Test cases generated by both approaches are executed and used as a way of cross validation. In the current work, we describe the architecture of the tool, its workflow process, and a case study in which the tool has been applied in a real industrial setting to test a train control management system.