Testing & Validation Procedures

This document defines the comprehensive testing procedures, validation protocols, and acceptance criteria for the EsoCore edge-to-cloud monitoring system.

Testing Categories

Unit Tests (Firmware)

Sensor drivers: Individual sensor initialization, reading, and error handling
CRC calculations: Data integrity verification algorithms
File rotation: SD card file management and rotation logic
Clock drift: RTC accuracy and NTP synchronization
Event logging: System event capture and formatting
Safety I/O response: Safety input detection and response timing

Hardware-in-Loop (HIL) Testing

Vibration Testing

Shaker table: Controlled vibration patterns for accelerometer validation
Frequency response: 1-3 kHz sampling validation
Amplitude accuracy: Calibration verification across operating range

Motor Testing

Motor rig: Programmable load for torque/current mapping
Current sensor calibration: Verify torque proxy accuracy
Drive simulation: Various motor types and operating conditions

Safety I/O Testing

Response time verification: Confirm <10ms response for safety inputs
Safety circuit diagnostics: Verify built-in safety circuit monitoring
Emergency stop sequences: Test complete safety shutdown procedures
Light curtain integration: Verify optical safety barrier functionality
Safety edge testing: Pressure-sensitive edge response validation

Power Management Testing

Supercapacitor Testing

Charge/discharge cycles: Verify 50,000+ cycle capability
Temperature range: Test -40°C to +65°C operation
Safe shutdown timing: Confirm ≥30 second runtime capability
Voltage monitoring: Verify accurate power level detection

Brownout Detection

Voltage threshold testing: Verify early warning system
Graceful degradation: Test system behavior during voltage sags
Recovery procedures: Validate system restart after power restoration

Sync & Connectivity Testing

Soak Tests

Packet loss simulation: Various network conditions
Long offline periods: 72+ hour disconnection testing
Power-loss during write: Data integrity during unexpected shutdowns
Network quality variations: Different bandwidth and latency conditions

Event Simulation Tests

Network disconnection: Controlled connectivity loss scenarios
Power cycling: Repeated power on/off sequences
Server failures: Backend unavailability simulation
SD card errors: Storage failure and recovery testing
Safety activations: Triggered safety events during operation

Workflow Automation Testing

Alert triggering: Verify notification system responsiveness
Escalation timers: Test time-based escalation chains
Notification delivery: Confirm email, SMS, and webhook delivery
Event correlation: Validate cascading event detection

Security Testing

Key revocation: Authentication key invalidation procedures
TLS downgrade resistance: Protocol security validation
OTA rollback: Firmware update failure recovery
Tamper detection: Physical security monitoring
Authentication bypass attempts: Security penetration testing

Cloud Platform Testing

API idempotency: Duplicate request handling verification
Partition pruning: Database performance optimization
RBAC: Role-based access control validation
Multi‑tenant leakage checks: Data isolation verification

Acceptance Criteria

Performance Requirements

Offline tolerance: Device tolerates 72 h offline and fully backfills within 6 h at 10 Mbps
Data integrity: Data loss < 0.01% over 30‑day soak with 10 forced reboots/day
Clock accuracy: Clock error < ±2 s/day with daily NTP; server corrects within ±500 ms on ingest if requested
OTA reliability: OTA success rate > 99.5% across 50 devices/staged rollout

Event System Requirements

Event logging: All system events captured and transmitted within 30 s of connectivity restoration
Safety I/O response: Safety inputs respond within <10ms; safety events logged with <1ms timestamp accuracy
Power management: Supercap provides ≥30s safe shutdown time; graceful shutdown completes in <20s
Safe shutdown reliability: 100% data integrity during 1000+ simulated power loss events

Automation Requirements

Workflow automation: Critical events trigger notifications within 60 s; escalation rules function correctly
Event correlation: Detect and report cascading failure patterns across device fleet

Test Environments

Development Environment

Hardware: Development boards with debug interfaces
Software: JTAG debuggers, logic analyzers, oscilloscopes
Network: Controlled network conditions with packet injection
Load simulation: Door movement simulators and motor test rigs

Staging Environment

Production hardware: Final hardware revision testing
Real doors: 5-10 pilot door installations
Network diversity: Various connectivity types (Ethernet, Wi-Fi, PoE)
Environmental conditions: Temperature and humidity variations

Production Environment

Fleet testing: Staged rollout across device population
Monitoring: Real-time performance and reliability tracking
Customer feedback: User acceptance and satisfaction metrics

Validation Protocols

Functional Validation

Sensor accuracy: Compare readings against calibrated reference instruments
Event detection: Verify proper categorization and logging of system events
Safety response: Validate safety system response times and reliability
Communication protocols: Test all API endpoints and data formats

Performance Validation

Throughput testing: Maximum data processing and transmission rates
Latency measurement: End-to-end response times for critical events
Resource utilization: CPU, memory, and storage usage optimization
Battery/supercap life: Power consumption and backup duration testing

Reliability Validation

MTBF calculation: Mean time between failures across device fleet
Failure mode analysis: Comprehensive failure scenario testing
Recovery procedures: Automatic and manual recovery validation
Data consistency: Verification of data integrity across system restarts

Security Validation

Penetration testing: External security audit and vulnerability assessment
Encryption validation: TLS implementation and key management testing
Access control: Authentication and authorization mechanism verification
Data privacy: Compliance with GDPR, HIPAA, and industry standards

Quality Assurance Metrics

Reliability Metrics

Device uptime: >99.9% operational availability
False positive rate: <5% for maintenance alerts
False negative rate: <1% for safety-critical events
Mean time to repair: <2 hours for critical issues

Performance Metrics

Response time: <1 second for anomaly detection
Data transmission efficiency: >90% reduction through intelligent filtering
Network utilization: Optimized bandwidth usage
Storage efficiency: Effective use of local SD card capacity

User Experience Metrics

Setup time: <30 minutes for device installation and configuration
Dashboard responsiveness: <3 seconds for data visualization loading
Alert relevance: >95% of alerts result in actionable maintenance
Customer satisfaction: >90% positive feedback on system effectiveness

Certification & Compliance Testing

Safety Certifications

EN ISO 13849 compliance verification for safety-related systems
IEC 61508 functional safety standard validation
EN 60204-1 electrical safety compliance

EMC Testing

EN 61000-6-2/-6-4 electromagnetic compatibility
IEC 61000-4-2/-4-4/-4-5 immunity and emissions testing

Environmental Testing

Operating temperature: -20°C to +60°C validation
Humidity resistance: 5-95% RH non-condensing
Vibration resistance: Industrial environment simulation
IP rating verification: IP54-IP65 enclosure protection

Continuous Integration & Testing

Automated Testing Pipeline

Code commit triggers: Automatic test execution on code changes
Unit test suite: Comprehensive firmware and software testing
Integration tests: End-to-end system validation
Performance benchmarks: Automated performance regression detection

Quality Gates

Code coverage: >90% test coverage requirement
Static analysis: Zero critical security vulnerabilities
Performance regression: <5% performance degradation tolerance
Documentation: Complete test documentation and traceability