01 · The challenge
Every firmware release required days of testing on physical modules, with real safety risk when fault cases were exercised. Releases were slowing to a crawl.
02 · What we did
- 01
Designed a cell-emulator board with programmable voltage, temperature and fault injection on every channel.
- 02
Built a test framework in Python that runs scripted scenarios and archives results against each firmware commit.
- 03
Packaged the system in a 19″ rack with interlocks, an e-stop and clear operator documentation.
- 04
Built three rigs and commissioned them on-site.
03 · The outcome
Firmware regression went from nine days to six hours, and fault-case testing no longer needs live cells. The client now runs every pull request through the rig.
“It changed how our firmware team works. Nobody wants to go back.”