Scaling test for a wearable fleet.
Rebuilt the hardware-in-the-loop test system across 12 fixtures and built the optical testbed that characterizes the sensor's LEDs.
Inside the testbed
Blocks ambient light so only the LED under test reaches the probe.
Everything bolts to an optical breadboard. Three motor controllers drive the stage, one per axis.
Motorized X, Y and Z translation stages move the probe through space above the device.
A dowel-pinned aluminum bracket on the Z stage carries the fiber probe head. A pocket in the base plate locates the device.
Fiber carries the collected light to Feasa LED and IR analysers that read intensity and color.
Sensor side up in its pocket. The LEDs switch on and the probe maps the light above them.
What it measures
The probe steps through a 3D grid above each LED and records brightness at every point. The result is a map of how the light spreads, compared LED to LED and device to device.
Illustrative model. Swap in exported scan data for the real site.
Bad capacitors, caught from current alone
Firmware streams the battery current over BLE. An FFT exposes ripple a failing capacitor adds, and a logistic regression flags it at 99% accuracy.
Current spectrum of one unit. Illustrative model, not WHOOP data.
A test fleet that scales
Legacy ATE ran every step in series. A DAG scheduler runs independent steps side by side across 12 fixtures. Coverage rose to 95% and false failures fell 40%.
Illustrative step names and timings.