Automating factory acceptance testing for a sensor device with a dedicated .NET software suite
Our client needed a reliable way to validate each unit of their bespoke sensor data collection device before shipment. Previously, engineers carried out acceptance checks manually, a time-consuming process that was prone to human error and lacked traceable results.
We were asked to design and build an automated test suite that could run the full set of factory acceptance checks, capture detailed pass/fail data, and produce a report suitable for both production use and fault investigation.
Challenge
The test software had to cover the full scope of the device’s features while remaining reliable even when used with faulty units. It also needed to provide results that were logical, structured, and detailed enough for engineers to diagnose failures when they occurred.
Project Overview
As part of scaling up production for a bespoke sensor data collection device, our client wanted to move from manual to automated factory acceptance testing. Each unit needed to be validated across a range of hardware and communication features before shipment, but manual checks were slow, inconsistent, and difficult to trace.
We were commissioned to develop a dedicated .NET software suite that could automate the full set of production tests, capture detailed results, and generate clear, traceable reports for quality assurance and fault investigation.
Action
The device under test already included a USB command-line interface with commands for various self-test routines. We used this as the basis for communication between the PC application and the device.
Working with the client, we defined a sequence of automated tests, the required outputs, and the format for reporting results. We then developed a .NET application that controlled and interrogated the device over USB, ran the agreed test routines, and presented progress to the operator in real time.
Tests included:
- Checking battery voltage was within range
- Verifying that external storage is mounted correctly at boot
- Confirming data logging could be activated and deactivated
- Ensuring wireless connections over BLE and WiFi were established
- Checking data integrity from the logger
- Measuring the rate of wireless data offload
At the end of each test sequence, the application generated a CSV report containing both the individual pass/fail results and metadata for traceability.
OUTCOME
The automated test suite gave our client a reliable and repeatable way to validate each device after production. The software reduced reliance on manual checks, increased speed and consistency, and produced a traceable report for every unit shipped.
By automating the process, our client achieved greater confidence in product quality, minimised the time engineers spent on routine testing, and gained a tool that supports efficient scaling of production.