Emulation of Network Device Behaviour for Robot Controller Testing

Abstract: The testing of software for robot controllers has become increasingly difficult as robotic systems become more complex. As the complexity of the systems increases, the number of hardware systems that the robot relies on also grows. This poses a challenge in testing robot controllers, which is crucial to ensure that robots function safely and effectively in their intended applications. While simulation can be used as a platform for software testing, it is not feasible to simulate everything in a virtual environment, especially when test cases require physical connections to hardware for input and output signals sent to robot controllers. Therefore, the objective of this thesis is to replicate I/O device network communication in order to enhance virtual testing processes. The approach employed involves capturing real-time network traffic, modifying and rebuilding it, and subsequently replaying it. The work examines existing academic research on these approaches and technologies, and investigates the specific challenges in the testing process by conducting research within a company leading globally in industrial robot development. A conceptual model is proposed, and a prototype is developed. The solution demonstrates potential in addressing the current challenges in robot controller testing by enabling network capture, modification, and level 4 network traffic replay. However, experimental results reveal various limitations, such as significant delays in generating responses. Therefore, further research and development are required if the solution is to be implemented in a real-world setting.