GROOT FORCE - Test Cases: Safety-Critical Systems

Document Version: 1.0
Date: November 2025
Status: Production Ready
Classification: Internal - QA & Safety Engineering

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Document Control

Version	Date	Author	Changes
1.0	Nov 2025	Safety Team	Initial safety-critical test cases

Approval:

• Safety Officer: _________________ Date: _______
• QA Lead: _________________ Date: _______
• Hardware Lead: _________________ Date: _______
• Software Architect: _________________ Date: _______
• Product Manager: _________________ Date: _______
• Legal/Compliance: _________________ Date: _______

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Table of Contents

1. Fall Detection & User Safety
2. Obstacle Detection & Walking Assist
3. Emergency Protocols & SOS
4. Battery & Thermal Safety
5. Electrical Safety
6. Optical & Eye Safety
7. Electromagnetic Safety (EMI/EMC)
8. Fail-Safe Mechanisms
9. Privacy & Data Security Safety

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Test Overview

Total Test Cases: 27 critical safety validation procedures

Priority Distribution:

• P0 (Critical): 22 test cases - Life safety, regulatory compliance
• P1 (High): 5 test cases - User safety, quality assurance

Regulatory Standards Covered:

• IEC 62368-1 (electrical safety)
• IEC 62471 (photobiological safety)
• IEC 60825-1 (laser safety)
• IEC 62133-2 (battery safety)
• UN38.3 (battery transport)
• CISPR 32 (EMC emissions)
• RCM, FCC, CE RED compliance

Test Philosophy: Safety is non-negotiable. Every test in this document validates that GROOT FORCE protects users from harm under normal use, foreseeable misuse, and single-fault conditions.

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1. Fall Detection & User Safety

TC-SAFE-001: Fall Detection Accuracy (Ground Truth)

Priority: P0
Category: User Safety
Requirement Trace: REQ-SAFE-100, FRD-SAFETY-001
Automation: Semi-automated (requires human testing)

Objective:
Validate fall detection system accurately identifies falls with high sensitivity and specificity.

Prerequisites:

• Device fully charged
• Fall detection enabled
• Test conducted in safe environment with padding
• Medical supervision recommended
• Informed consent obtained

Test Equipment:

• Safety mats (10cm thick padding)
• Motion capture system (optional, for ground truth)
• Accelerometer reference device
• Video recording equipment
• Medical supervisor (RN or paramedic)

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Calibrate device IMU in standing position	IMU calibrated successfully	☐
2	Perform controlled forward fall onto padding	Fall detected within 1 second	☐
3	Check detection confidence score	Confidence ≥90%	☐
4	Verify alert notification	Visual + haptic + audio alert triggered	☐
5	Perform controlled backward fall	Fall detected within 1 second	☐
6	Perform controlled side fall (left)	Fall detected within 1 second	☐
7	Perform controlled side fall (right)	Fall detected within 1 second	☐
8	Test 20 controlled falls (varied angles)	Detection rate ≥95% (19/20)	☐
9	Test sitting down rapidly (not a fall)	No false positive	☐
10	Test bending over to pick up object	No false positive	☐
11	Test 50 normal activities (ADLs)	False positive rate ≤3%	☐
12	Calculate sensitivity and specificity	Sensitivity ≥95%, Specificity ≥97%	☐

Pass Criteria:

• ✅ Fall detection sensitivity ≥95%
• ✅ Specificity (no false alarms) ≥97%
• ✅ Detection latency ≤1 second
• ✅ All alert modalities function

Fall Detection Algorithm:

If (|acceleration| > 2.8g) AND (orientation change > 45°) AND (stillness > 3 sec):
    → Trigger fall alert

Test Data Required:

• 20 controlled fall samples
• 50 normal activity samples
• Confusion matrix (TP, TN, FP, FN)
• ROC curve analysis

Safety Notes:

• ⚠️ All fall tests must be performed on proper padding
• ⚠️ Medical supervisor must be present
• ⚠️ Test subjects must be healthy adults
• ⚠️ Stop testing if any injury occurs

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TC-SAFE-002: Post-Fall Emergency Response

Priority: P0
Category: User Safety
Requirement Trace: FRD-SAFETY-002
Automation: Manual

Objective:
Verify post-fall emergency response system functions correctly.

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Simulate fall detection	Fall alert triggered	☐
2	Device displays: "Fall detected. Are you OK?"	Prompt appears within 2 seconds	☐
3	Wait 30 seconds (no user response)	Countdown timer displays	☐
4	After 30 sec timeout	Emergency contacts notified	☐
5	Check notification content	Includes GPS location + timestamp	☐
6	Test "I'm OK" button response	Alert cancelled, no notification sent	☐
7	Test "Call Help" button	Immediate emergency call initiated	☐
8	Verify emergency call audio quality	Two-way audio clear	☐
9	Test with lost consciousness scenario	Auto-notification after 30 sec	☐
10	Check emergency contact list (max 3)	All 3 contacts notified sequentially	☐
11	Test GPS accuracy in emergency	Location accurate within 10 meters	☐
12	Verify system works without mobile network	Local alarm still functions	☐

Pass Criteria:

• ✅ Auto-notification after 30 sec no response
• ✅ Emergency contacts receive GPS location
• ✅ Two-way audio functional
• ✅ Works without network (local alarm)

Emergency Response Flow:

Fall Detected → Prompt User (2 sec) → Wait 30 sec → No Response → Notify Contacts → Call Emergency Services (if configured)

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TC-SAFE-003: False Positive Minimization

Priority: P0
Category: User Safety
Requirement Trace: FRD-SAFETY-003
Automation: Semi-automated

Objective:
Ensure fall detection minimizes false positives to maintain user trust.

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Perform 20 rapid sit-down motions	No fall detected	☐
2	Perform 20 jump motions (exercise)	No fall detected	☐
3	Perform 20 bending/reaching motions	No fall detected	☐
4	Test getting in/out of car (10 times)	No fall detected	☐
5	Test lying down in bed (10 times)	No fall detected	☐
6	Test tying shoelaces (10 times)	No fall detected	☐
7	Simulate stumble/catch yourself (10 times)	No fall detected (recovery detected)	☐
8	Calculate false positive rate	FPR ≤3% across all tests	☐
9	Test user feedback mechanism	User can report false positive	☐
10	Verify learning from false positives	System adapts over time	☐

Pass Criteria:

• ✅ False positive rate ≤3%
• ✅ Normal activities don't trigger alerts
• ✅ System learns from corrections
• ✅ User can easily dismiss false alarms

Activities Tested (100+ samples):

• Sitting down rapidly
• Jumping (exercise)
• Bending over
• Getting in/out of vehicles
• Lying down
• Tying shoes
• Stumbling but recovering

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2. Obstacle Detection & Walking Assist

TC-SAFE-004: Obstacle Detection Accuracy (ToF)

Priority: P0
Category: Walking Safety
Requirement Trace: REQ-SAFE-110, FRD-WALKASSIST-001
Automation: Semi-automated

Objective:
Validate ToF sensor accurately detects obstacles in walking path.

Test Equipment:

• Controlled test environment (indoor course)
• Various obstacle types (boxes, poles, walls, steps)
• Reference laser measurement system
• Walking test subjects (5+ people)

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Set up obstacle course (10 obstacles)	Course prepared	☐
2	Place obstacle at 0.5m distance	Detected and flagged	☐
3	Measure detection latency	Latency ≤200ms	☐
4	Test obstacles at 1.0m, 1.5m, 2.0m	All detected accurately	☐
5	Test obstacle at 4.0m (ToF limit)	Still detected (reduced confidence)	☐
6	Test thin obstacle (3cm diameter pole)	Detected at ≤2m distance	☐
7	Test low obstacle (10cm step)	Detected and classified as "step"	☐
8	Test transparent obstacle (glass)	Detected (via ToF reflection)	☐
9	Test moving obstacle (person walking)	Detected and tracked	☐
10	Test 100 obstacle scenarios	Detection rate ≥98%	☐
11	Calculate precision and recall	Precision ≥97%, Recall ≥98%	☐
12	Test detection range accuracy	Range error ≤5%	☐

Pass Criteria:

• ✅ Obstacle detection rate ≥98%
• ✅ Detection latency ≤200ms
• ✅ Range accuracy within ±5%
• ✅ Thin obstacles (≥3cm) detected at 2m

Obstacle Types:

• Static: walls, poles, furniture, steps
• Dynamic: people, pets, vehicles
• Transparent: glass doors/walls
• Low-lying: curbs, steps, cables

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TC-SAFE-005: LiDAR Long-Range Detection

Priority: P0
Category: Walking Safety
Requirement Trace: FRD-WALKASSIST-002
Automation: Semi-automated

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Place obstacle at 5m distance	Detected by LiDAR	☐
2	Test obstacles at 6m, 8m, 10m, 12m	All detected with decreasing confidence	☐
3	Measure LiDAR maximum range	Max range ≥12 meters	☐
4	Test accuracy at 5m distance	Range error ≤±5% (±25cm)	☐
5	Test accuracy at 10m distance	Range error ≤±10% (±1m)	☐
6	Test detection in bright sunlight	Still functional (eye-safe 905nm)	☐
7	Test detection in darkness	Full functionality maintained	☐
8	Test detection of moving objects	Tracks objects up to 12m	☐
9	Test detection angle (field of view)	FOV ≥±15° (30° total)	☐
10	Combine ToF + LiDAR data	Fusion improves accuracy by ≥20%	☐

Pass Criteria:

• ✅ LiDAR range ≥12 meters
• ✅ Accuracy ±5% at 5m, ±10% at 10m
• ✅ Works in bright sunlight and darkness
• ✅ Sensor fusion provides improvement

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TC-SAFE-006: Ground Mapping & Step Detection

Priority: P0
Category: Walking Safety
Requirement Trace: FRD-WALKASSIST-003
Automation: Semi-automated

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Walk on flat surface	Ground mapped correctly	☐
2	Approach single step (15cm height)	Step detected ≥1.5m ahead	☐
3	Check alert timing	Alert given with 2-3 sec warning	☐
4	Test curb detection (10cm height)	Curb detected ≥1m ahead	☐
5	Test stairs (multiple steps)	Stairs detected, count estimated	☐
6	Test ramp detection (5° slope)	Slope detected and indicated	☐
7	Test uneven terrain (grass, gravel)	Surface roughness indicated	☐
8	Test hole/depression detection	Detected at ≥1m distance	☐
9	Walk over 50 varied surfaces	All hazards detected correctly	☐
10	Calculate detection accuracy	Accuracy ≥95% for hazards ≥5cm	☐

Pass Criteria:

• ✅ Step detection ≥95% accuracy
• ✅ Warning ≥1.5m ahead (2-3 sec @ 0.5 m/s)
• ✅ Detects hazards ≥5cm height
• ✅ Works on varied surfaces

Ground Hazards Detected:

• Steps (up and down)
• Curbs
• Holes/depressions
• Uneven surfaces
• Ramps/slopes
• Stairs

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TC-SAFE-007: Walking Assist Alert Modalities

Priority: P1
Category: Walking Safety
Requirement Trace: FRD-WALKASSIST-004
Automation: Manual

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Enable all alert modes	Visual + Haptic + Audio enabled	☐
2	Trigger obstacle alert	All 3 modalities activate	☐
3	Check visual alert on HUD	Clear red overlay appears	☐
4	Check haptic alert	Vibration felt (left or right side)	☐
5	Check audio alert	"Obstacle ahead" voice warning	☐
6	Test directional haptics (left)	Left temple vibrates	☐
7	Test directional haptics (right)	Right temple vibrates	☐
8	Test escalating alerts	Intensity increases as closer	☐
9	Disable audio (quiet mode)	Visual + haptic still work	☐
10	Test alert customization	User can adjust sensitivity	☐
11	Check alert timing	Alerts given 2-3 sec before hazard	☐
12	Verify non-intrusive design	Alerts clear but not alarming	☐

Pass Criteria:

• ✅ All 3 modalities functional
• ✅ Directional haptics accurate
• ✅ Escalating intensity works
• ✅ User customization available

Alert Modalities:

• Visual: HUD overlay (color-coded)
• Haptic: Directional vibration (left/right)
• Audio: Voice warning ("Obstacle ahead, left/right")

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3. Emergency Protocols & SOS

TC-SAFE-008: SOS Activation & Emergency Call

Priority: P0
Category: Emergency Response
Requirement Trace: REQ-SAFE-120, FRD-EMERGENCY-001
Automation: Manual

Objective:
Validate SOS system activates reliably and connects to emergency services.

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Press and hold SOS button for 3 seconds	SOS mode activated	☐
2	Check visual confirmation	Screen shows "SOS ACTIVE"	☐
3	Check audio confirmation	Tone plays confirming activation	☐
4	Verify emergency call initiation	Call connects within 10 seconds	☐
5	Test two-way audio quality	Clear audio both directions	☐
6	Check GPS location broadcast	Location sent automatically	☐
7	Test emergency contact notification	All emergency contacts notified	☐
8	Verify notification content	Contains GPS, timestamp, audio stream	☐
9	Test SOS with no network	Local alarm + saved location used	☐
10	Test accidental activation prevention	3-sec hold required (not single press)	☐
11	Test SOS cancellation	Can cancel within first 5 seconds	☐
12	Verify battery priority mode	SOS gets maximum power priority	☐

Pass Criteria:

• ✅ SOS activates reliably (100% success)
• ✅ Emergency call connects ≤10 seconds
• ✅ GPS location accurate
• ✅ Works without network (local alarm)

SOS Activation Methods:

1. Press and hold SOS button (3 seconds)
2. Voice command: "Emergency" (confirmed)
3. Automatic trigger (severe fall + no response)

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TC-SAFE-009: Emergency Location Accuracy

Priority: P0
Category: Emergency Response
Requirement Trace: FRD-EMERGENCY-002
Automation: Automated

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Activate SOS in open outdoor location	GPS location obtained	☐
2	Check location accuracy (GPS only)	Accuracy ≤10 meters	☐
3	Check location latency	Location obtained ≤5 seconds	☐
4	Test indoors (GPS unavailable)	Falls back to Wi-Fi/cell positioning	☐
5	Check indoor location accuracy	Accuracy ≤50 meters (building level)	☐
6	Test in basement (no GPS, weak signal)	Last known location + warning sent	☐
7	Verify location includes altitude	Floor/elevation data included if available	☐
8	Test location update frequency	Updates every 30 seconds during SOS	☐
9	Check battery impact	Continuous GPS ≤15% extra drain/hour	☐
10	Verify emergency responder format	Location in standard format (lat/long decimal)	☐

Pass Criteria:

• ✅ Outdoor accuracy ≤10m (GPS)
• ✅ Indoor accuracy ≤50m (Wi-Fi/cell)
• ✅ Location obtained ≤5 seconds
• ✅ Continuous updates during SOS

Location Methods (Priority Order):

1. GPS (outdoor, ≤10m)
2. Wi-Fi positioning (indoor, ≤50m)
3. Cell tower triangulation (≤100m)
4. Last known location + warning

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TC-SAFE-010: Battery Emergency Reserve

Priority: P0
Category: Emergency Response
Requirement Trace: FRD-EMERGENCY-003
Automation: Automated

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Discharge battery to 5% (critical)	Device enters emergency reserve mode	☐
2	Check available functions	Only critical: SOS, fall detect, GPS	☐
3	Verify non-essential functions disabled	Display dims, AI paused, camera off	☐
4	Activate SOS at 5% battery	SOS still functions fully	☐
5	Measure emergency reserve duration	Reserve lasts ≥30 minutes	☐
6	Test emergency call at 3% battery	Call still completes	☐
7	Check fall detection at 2% battery	Still active	☐
8	Verify GPS at 2% battery	Location still obtained	☐
9	Test device behavior at 1% battery	Sends final location, powers down gracefully	☐
10	Check emergency mode power draw	Draw ≤300mW (vs 3W normal)	☐

Pass Criteria:

• ✅ Emergency reserve ≥30 minutes at 5%
• ✅ SOS functional down to 1%
• ✅ Fall detection active down to 2%
• ✅ Graceful shutdown with final location

Emergency Reserve Mode:

• Activates: Battery ≤5%
• Duration: ≥30 minutes
• Functions: SOS, fall detect, GPS only
• Power draw: ≤300mW

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4. Battery & Thermal Safety

TC-SAFE-011: Battery Overcharge Protection

Priority: P0
Category: Battery Safety
Requirement Trace: REQ-SAFE-130, IEC 62133-2
Automation: Automated

Objective:
Verify battery protection prevents overcharging per IEC 62133-2.

Test Equipment:

• Programmable power supply
• Battery voltage monitor
• Temperature sensors (NTC)
• Thermal camera
• Current meter

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Connect device to standard 5V charger	Charging begins normally	☐
2	Monitor cell voltage during charge	Voltage increases steadily	☐
3	Check cutoff voltage	Charging stops at 4.2V ±0.05V	☐
4	Verify no overcharge occurs	Voltage never exceeds 4.25V	☐
5	Force charger to output 6V (abuse test)	PMIC rejects, charging stops	☐
6	Check PCM behavior at 4.3V	PCM disconnects cell	☐
7	Monitor temperature during full charge	Temp increase ≤5°C	☐
8	Test trickle charge after full	Current drops to < 50mA	☐
9	Leave on charger for 24 hours	No overcharge, temp stable	☐
10	Check battery health after test	No degradation detected	☐

Pass Criteria:

• ✅ Charging stops at 4.2V ±0.05V
• ✅ Never exceeds 4.25V (safety threshold)
• ✅ PCM disconnects if PMIC fails
• ✅ 24-hour overcharge safe

Protection Layers:

1. PMIC (BQ25895) - stops at 4.2V
2. PCM (per cell) - hard cutoff at 4.3V
3. Firmware watchdog - monitors voltage
4. Temperature cutoff - stops if > 45°C

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TC-SAFE-012: Battery Overdischarge Protection

Priority: P0
Category: Battery Safety
Requirement Trace: IEC 62133-2
Automation: Automated

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Fully charge device	Battery at 100%	☐
2	Discharge through normal use	Device operates normally	☐
3	Monitor voltage as battery depletes	Voltage decreases steadily	☐
4	Check low battery warning (15%)	Warning appears at ~3.6V	☐
5	Check critical battery warning (5%)	Critical warning at ~3.3V	☐
6	Device shuts down at low voltage	Shutdown at 3.0V per cell	☐
7	Verify PCM cutoff	PCM disconnects below 2.8V	☐
8	Attempt to power on after cutoff	Device refuses to power on	☐
9	Recharge from deep discharge	Charging resumes normally	☐
10	Check cell voltage after recharge	Cells balanced, no damage	☐

Pass Criteria:

• ✅ System shutdown at 3.0V per cell
• ✅ PCM cutoff at 2.8V (hard limit)
• ✅ Device won't power on when overdischarged
• ✅ Recovery after deep discharge works

Discharge Protection:

• 15% warning: 3.6V
• 5% critical: 3.3V
• System shutdown: 3.0V
• PCM cutoff: 2.8V (hard limit)

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TC-SAFE-013: Thermal Runaway Prevention

Priority: P0
Category: Battery Safety
Requirement Trace: IEC 62133-2, UN38.3
Automation: Semi-automated (requires supervision)

⚠️ DANGER: This test involves intentional abuse conditions. Perform in certified test lab only with proper safety equipment.

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Monitor cell temperature (NTC sensors)	Normal temp ~25°C	☐
2	Simulate high ambient temp (40°C chamber)	Cells heat to ~40°C	☐
3	Check thermal throttling activation	System throttles at 42°C	☐
4	Verify charging disabled	Charging stops if temp > 40°C	☐
5	Simulate cell short circuit (controlled)	PCM disconnects within 100ms	☐
6	Check polyfuse behavior	Fuse trips, limits current to < 1.5A	☐
7	Measure ΔT/Δt during abuse	Rate of temp rise ≤5°C/min	☐
8	Verify TVS diode protection	Voltage spikes clamped	☐
9	Check for venting or fire	No fire, no venting, no explosion	☐
10	Test emergency shutdown (50°C)	System forces complete shutdown	☐

Pass Criteria:

• ✅ Thermal runaway prevented (no fire/explosion)
• ✅ PCM disconnects within 100ms on short
• ✅ Polyfuse limits current
• ✅ Emergency shutdown at 50°C

⚠️ SAFETY PROTOCOLS:

• Test in certified safety chamber
• Fire suppression available
• Remote monitoring only
• Blast shields in place
• Ventilation active

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TC-SAFE-014: Battery Physical Abuse Tolerance

Priority: P0
Category: Battery Safety
Requirement Trace: UN38.3 Test 3.4.5
Automation: Manual (destructive test)

⚠️ NOTE: This is a destructive test performed on sample units only.

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Drop test: 1.2m onto concrete	Device survives, no cell puncture	☐
2	Check cell integrity after drop	No swelling, no leakage	☐
3	Vibration test: 1 hour, 10-150 Hz	No mechanical failure	☐
4	Impact test: 15g shock	Cells remain secure	☐
5	Crush test: 13kN force (controlled)	PCM disconnects before cell rupture	☐
6	Temperature cycle: -10°C to +50°C	No degradation	☐
7	Altitude simulation: 15,000m pressure	No venting, no rupture	☐
8	External short circuit test	PCM disconnects, no fire	☐
9	Overcharge test (1.1× nominal voltage)	Protection activates	☐
10	Visual inspection post-test	No visible damage to cells	☐

Pass Criteria:

• ✅ Passes UN38.3 transport test
• ✅ No fire, no explosion under abuse
• ✅ PCM protection functions correctly
• ✅ Cells remain intact

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TC-SAFE-015: Thermal Spread Prevention

Priority: P0
Category: Thermal Safety
Requirement Trace: REQ-SAFE-135
Automation: Automated

Objective:
Verify thermal management prevents heat spread to user contact areas.

Test Equipment:

• Thermal camera (FLIR or equivalent)
• Contact temperature sensors (10+)
• Thermal test chamber
• Power cycle test script

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Run AI stress test (max load)	CPU/GPU at maximum power	☐
2	Monitor SoC die temperature	Die temp rises to ~42-45°C	☐
3	Measure magnesium spine temp	Spine temp ~38-40°C	☐
4	Measure TR90 shell temp	Shell temp ≤35°C	☐
5	Measure nose bridge contact temp	Temp ≤33°C (skin safe)	☐
6	Measure temple contact temp	Temp ≤33°C	☐
7	Check thermal gradient	Gradient: Die (45°C) → Spine (40°C) → Shell (35°C) → Skin (33°C)	☐
8	Run continuous load for 2 hours	Temps stabilize, no runaway	☐
9	Check user comfort (5 test subjects)	No discomfort reported	☐
10	Verify thermal throttling	Throttling prevents > 38°C at skin	☐

Pass Criteria:

• ✅ Skin contact areas ≤33°C (comfortable)
• ✅ Shell exterior ≤35°C
• ✅ Thermal gradient controlled
• ✅ No user discomfort

Thermal Zones:

• Die temp: ≤50°C (throttle point)
• Spine temp: ≤40°C
• Shell exterior: ≤35°C
• Skin contact: ≤33°C (SAFE)

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5. Electrical Safety

TC-SAFE-016: Electrical Isolation & Insulation

Priority: P0
Category: Electrical Safety
Requirement Trace: IEC 62368-1
Automation: Manual (requires safety lab)

Objective:
Verify electrical insulation prevents shock hazard per IEC 62368-1.

Test Equipment:

• Megohmmeter (insulation resistance tester)
• Hipot tester (dielectric strength)
• Multimeter
• Safety-rated test leads

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Measure insulation resistance (battery to chassis)	Resistance ≥10 MΩ	☐
2	Measure insulation resistance (PCB to shell)	Resistance ≥10 MΩ	☐
3	Apply hipot test (500V DC, 1 minute)	No breakdown, no arcing	☐
4	Check leakage current	Leakage ≤100 μA	☐
5	Test under wet conditions (sweat simulation)	Insulation maintained	☐
6	Check USB-C port isolation	Isolated from battery	☐
7	Test with damaged cable (single fault)	No shock hazard (SELV design)	☐
8	Verify SELV voltage levels	All user-accessible ≤42.4V DC	☐
9	Check double insulation on PCB	Coating verified, no exposed traces	☐
10	Test metal frame (magnesium spine) isolation	Frame not electrically connected	☐

Pass Criteria:

• ✅ Insulation resistance ≥10 MΩ
• ✅ Passes hipot test (500V, 1 min)
• ✅ Leakage current ≤100 μA
• ✅ SELV design (≤42.4V)

Safety Classification:

• Class III Equipment: SELV (Safety Extra-Low Voltage)
• Operating voltage: 3.0-4.2V DC (battery)
• Charging voltage: 5V DC (USB)

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TC-SAFE-017: Short Circuit Protection

Priority: P0
Category: Electrical Safety
Requirement Trace: IEC 62368-1
Automation: Automated

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Simulate internal short (battery to ground)	PCM disconnects within 100ms	☐
2	Check polyfuse trip	Fuse limits current to < 1.5A	☐
3	Measure short circuit current	Peak current < 2A (safe)	☐
4	Check for sparking or arcing	No sparks, no arcing	☐
5	Test TVS diode clamping	Voltage spikes clamped to safe levels	☐
6	Simulate USB-C short	Charger protection activates	☐
7	Check firmware watchdog	System detects anomaly, shuts down	☐
8	Verify user safety	No shock hazard, no fire risk	☐
9	Test recovery after short cleared	Device powers on normally after	☐
10	Check for damage to components	No permanent damage	☐

Pass Criteria:

• ✅ PCM disconnects within 100ms
• ✅ Current limited to < 2A
• ✅ No fire, no shock hazard
• ✅ Device recovers after fault cleared

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TC-SAFE-018: ESD Protection

Priority: P1
Category: Electrical Safety
Requirement Trace: IEC 61000-4-2
Automation: Manual (requires ESD simulator)

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Apply ESD: +2kV contact discharge	Device continues operating	☐
2	Apply ESD: +4kV contact discharge	Device continues operating	☐
3	Apply ESD: +8kV air discharge	Device continues operating or resets gracefully	☐
4	Test on USB-C port (+4kV)	Port protected, no damage	☐
5	Test on metal frame (+4kV)	Frame isolated, no issues	☐
6	Apply 10 ESD strikes each location	Survives all strikes	☐
7	Check device functionality after ESD	All functions work normally	☐
8	Verify data integrity	No corruption detected	☐
9	Check for false triggers	No spurious reboots or errors	☐
10	Test at extreme: +15kV air discharge	Graceful reset acceptable	☐

Pass Criteria:

• ✅ Survives ±4kV contact discharge
• ✅ Survives ±8kV air discharge
• ✅ No permanent damage
• ✅ Data integrity maintained

ESD Levels (IEC 61000-4-2):

• Contact: ±2kV, ±4kV, ±6kV, ±8kV
• Air: ±2kV, ±4kV, ±8kV, ±15kV

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6. Optical & Eye Safety

TC-SAFE-019: Display Brightness Safety (Photobiological)

Priority: P0
Category: Eye Safety
Requirement Trace: IEC 62471
Automation: Automated (requires spectroradiometer)

Objective:
Verify micro-OLED display meets photobiological safety standards.

Test Equipment:

• Spectroradiometer
• Integrating sphere (optional)
• Photometer
• Blue light hazard measurement system

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Set display to maximum brightness	Display at 1200 nits	☐
2	Measure radiance (W/m²/sr)	Radiance measured	☐
3	Calculate blue light hazard (435-490nm)	Blue light radiance value	☐
4	Check IEC 62471 classification	Class 1 (exempt) or Class 2 (safe)	☐
5	Verify radiance limit for Class 1	Radiance < 100 W/m²/sr (blue light)	☐
6	Test at typical brightness (400 nits)	Well below safety threshold	☐
7	Check blue light emission spectrum	Peak wavelength 450-460nm	☐
8	Calculate permitted viewing time	Unlimited viewing time (Class 1)	☐
9	Test blue light filter mode	Blue light reduced by 30-50%	☐
10	Verify user warnings in manual	Warnings present for extended use	☐

Pass Criteria:

• ✅ IEC 62471 Class 1 (exempt) or Class 2
• ✅ Blue light radiance < 100 W/m²/sr
• ✅ Unlimited safe viewing time
• ✅ Blue light filter reduces exposure

IEC 62471 Classification:

• Class 1 (Exempt): No photobiological hazard
• Class 2 (Low risk): Safe under normal use
• Target: Class 1 at all brightness levels

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TC-SAFE-020: Blue Light Reduction Effectiveness

Priority: P1
Category: Eye Safety
Requirement Trace: FRD-SAFETY-020
Automation: Automated

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Measure blue light spectrum (filter OFF)	Baseline blue light emission measured	☐
2	Enable blue light filter (software)	Filter applied	☐
3	Measure blue light spectrum (filter ON)	Reduced blue light measured	☐
4	Calculate reduction percentage	Reduction ≥30% in 435-490nm range	☐
5	Check color rendering impact	Colors still acceptable (user survey)	☐
6	Test at night mode (max filtering)	Reduction ≥50%	☐
7	Verify filter applies to all content	Text, images, video all filtered	☐
8	Test adaptive filtering (time-based)	Auto-enables at sunset	☐
9	Check user control	User can adjust filter strength	☐
10	Measure brightness impact	Overall brightness reduced ≤10%	☐

Pass Criteria:

• ✅ Blue light reduction ≥30% (normal mode)
• ✅ Blue light reduction ≥50% (night mode)
• ✅ Color rendering acceptable
• ✅ User control available

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TC-SAFE-021: Eye Fatigue Prevention Features

Priority: P1
Category: Eye Safety
Requirement Trace: FRD-SAFETY-021
Automation: Semi-automated

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Use device continuously for 20 minutes	Device tracks usage time	☐
2	Check 20-20-20 reminder	Reminder appears: "Rest your eyes"	☐
3	Verify reminder content	Suggests looking 20ft away for 20 sec	☐
4	Check blink rate detection (if available)	Low blink rate triggers reminder	☐
5	Test extended use (2 hours)	Multiple reminders given	☐
6	Check brightness auto-adjustment	Dims in dark, brightens in light	☐
7	Test night mode auto-enable	Enables at sunset, disables at sunrise	☐
8	Verify user education	Setup wizard explains eye care	☐
9	Check parental controls (if applicable)	Can limit continuous use time	☐
10	Collect user feedback (20 testers)	80% find reminders helpful	☐

Pass Criteria:

• ✅ 20-20-20 reminders function
• ✅ Auto brightness adjustment works
• ✅ Night mode auto-enables
• ✅ User education provided

Eye Care Features:

• 20-20-20 rule reminders
• Blink detection (if equipped)
• Auto brightness (ALS-based)
• Blue light filter
• Night mode
• Usage time tracking

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7. Electromagnetic Safety

TC-SAFE-022: EMC Emissions Testing (CISPR 32)

Priority: P0
Category: EMC Safety
Requirement Trace: CISPR 32 Class B
Automation: Manual (requires EMC lab)

Objective:
Verify device meets electromagnetic emission limits per CISPR 32.

Test Equipment:

• EMC test chamber (anechoic or semi-anechoic)
• Spectrum analyzer
• Broadband antenna
• EMI receiver
• LISN (Line Impedance Stabilization Network)

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Set up device in EMC chamber	Device positioned per standard	☐
2	Measure radiated emissions (30 MHz - 1 GHz)	All frequencies measured	☐
3	Check compliance with Class B limits	Emissions below limits	☐
4	Test with Wi-Fi active	Emissions within limits	☐
5	Test with Bluetooth active	Emissions within limits	☐
6	Test during AI processing (max load)	Emissions within limits	☐
7	Test during battery charging	Conducted emissions measured	☐
8	Check peak emissions vs average	Both below limits	☐
9	Measure emissions at multiple angles	360° scan compliant	☐
10	Generate test report	Report shows compliance	☐

Pass Criteria:

• ✅ Radiated emissions below CISPR 32 Class B
• ✅ Conducted emissions compliant
• ✅ All modes tested (Wi-Fi, BT, AI, charging)
• ✅ EMC test report generated

CISPR 32 Class B Limits:

• 30-230 MHz: 30 dBμV/m @ 10m (quasi-peak)
• 230-1000 MHz: 37 dBμV/m @ 10m

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TC-SAFE-023: Electromagnetic Immunity (IEC 61000-4)

Priority: P0
Category: EMC Safety
Requirement Trace: IEC 61000-4-3
Automation: Manual (requires EMC lab)

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Apply RF field: 80-1000 MHz, 3 V/m	Device continues operating	☐
2	Apply RF field: 1.4-2.0 GHz, 3 V/m	Device continues operating	☐
3	Apply RF field: 2.0-2.7 GHz, 3 V/m	Device continues operating	☐
4	Test immunity to GSM burst (900 MHz)	No interference detected	☐
5	Test immunity to LTE signals	No interference detected	☐
6	Check audio quality during RF exposure	Audio remains clear	☐
7	Check sensor accuracy during RF	Sensors function correctly	☐
8	Test near high-power transmitter	Device operates normally	☐
9	Apply electrical fast transient (burst)	Device continues operating	☐
10	Verify no permanent effects	Full functionality after test	☐

Pass Criteria:

• ✅ Operates normally under 3 V/m RF
• ✅ No interference from GSM/LTE
• ✅ Sensors and audio unaffected
• ✅ No permanent damage

IEC 61000-4-3 Immunity Levels:

• Level 2: 3 V/m (typical consumer)
• Level 3: 10 V/m (industrial)
• Target: Level 2 compliance minimum

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TC-SAFE-024: SAR Testing (RF Exposure)

Priority: P0
Category: RF Safety
Requirement Trace: FCC §2.1093, IEC 62209-2
Automation: Manual (requires SAR lab)

Objective:
Verify Specific Absorption Rate (SAR) is below regulatory limits.

Test Equipment:

• SAR measurement system
• Phantom head (tissue-equivalent)
• Dosimetric probe
• Network analyzer

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Position device on phantom head	Device in normal wearing position	☐
2	Enable Wi-Fi (2.4 GHz, max power)	Wi-Fi transmitting	☐
3	Measure SAR (1g average)	SAR measured	☐
4	Measure SAR (10g average)	SAR measured	☐
5	Check FCC limit (1.6 W/kg, 1g)	SAR < 1.6 W/kg	☐
6	Check EU limit (2.0 W/kg, 10g)	SAR < 2.0 W/kg	☐
7	Test Wi-Fi 5 GHz mode	SAR measured	☐
8	Test Bluetooth mode	SAR measured	☐
9	Test LTE mode (if equipped)	SAR measured	☐
10	Generate SAR test report	Report shows compliance	☐

Pass Criteria:

• ✅ SAR < 1.6 W/kg (1g avg) - FCC
• ✅ SAR < 2.0 W/kg (10g avg) - EU
• ✅ All wireless modes tested
• ✅ SAR report generated

SAR Limits:

• USA (FCC): < 1.6 W/kg (1g average)
• EU/AU: < 2.0 W/kg (10g average)
• Target: < 50% of limit (safety margin)

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8. Fail-Safe Mechanisms

TC-SAFE-025: Watchdog Timer & System Recovery

Priority: P0
Category: System Safety
Requirement Trace: FRD-SAFETY-025
Automation: Automated

Objective:
Verify watchdog timer detects system freezes and recovers safely.

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Configure firmware watchdog (10 sec timeout)	Watchdog active	☐
2	Simulate software hang (intentional infinite loop)	System freezes	☐
3	Wait for watchdog timeout	Watchdog triggers within 10 seconds	☐
4	Check system reset	Device resets automatically	☐
5	Verify boot-up after reset	Device boots normally	☐
6	Check crash log	Watchdog reset logged	☐
7	Simulate kernel panic	Watchdog recovery triggered	☐
8	Test 20 freeze scenarios	100% recovery success	☐
9	Check user data integrity	No data loss after reset	☐
10	Verify user notification	"Device recovered from error" shown	☐

Pass Criteria:

• ✅ Watchdog triggers within timeout
• ✅ System resets automatically
• ✅ 100% recovery success
• ✅ No data loss

Watchdog Timer:

• Timeout: 10 seconds (no heartbeat)
• Action: Hard reset
• Recovery: Boot to safe mode

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TC-SAFE-026: Sensor Failure Graceful Degradation

Priority: P1
Category: System Safety
Requirement Trace: FRD-SAFETY-026
Automation: Semi-automated

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Disconnect IMU (simulated failure)	System detects IMU failure	☐
2	Check system behavior	Gesture control disabled, warning shown	☐
3	Verify core functions still work	Display, audio, AI still functional	☐
4	Disconnect ToF sensor	System detects ToF failure	☐
5	Check obstacle detection	Warning: "Obstacle detection unavailable"	☐
6	Verify fall detection still works	Uses IMU only (reduced accuracy)	☐
7	Disconnect LiDAR	Long-range mapping disabled	☐
8	Check system continues operating	Core functions maintained	☐
9	Simulate multiple sensor failures	System operates in safe mode	☐
10	Verify clear user communication	All failures reported to user	☐

Pass Criteria:

• ✅ Sensor failures detected automatically
• ✅ Core functions maintained
• ✅ User informed of limitations
• ✅ Graceful degradation (no crashes)

Sensor Failure Strategy:

• IMU fail: Disable gesture, fall detect degraded
• ToF fail: Disable obstacle detection
• LiDAR fail: Long-range mapping off
• Camera fail: Vision features disabled

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TC-SAFE-027: Emergency Mode (Limp Home)

Priority: P0
Category: System Safety
Requirement Trace: FRD-SAFETY-027
Automation: Manual

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Simulate critical system error	Multiple subsystems fail	☐
2	Check emergency mode activation	"Emergency Mode" displayed	☐
3	Verify available functions	SOS, phone calls, GPS only	☐
4	Test SOS functionality	SOS works perfectly	☐
5	Test emergency call	Call connects successfully	☐
6	Test GPS location	Location obtained	☐
7	Check disabled functions	AI, camera, display effects disabled	☐
8	Measure power consumption	Power draw < 500mW (extended battery)	☐
9	Test emergency mode duration	Lasts ≥4 hours on remaining battery	☐
10	Verify user can request full restart	Option to attempt full reboot	☐

Pass Criteria:

• ✅ Emergency mode activates on critical failure
• ✅ SOS + GPS functional
• ✅ Extended battery life (4+ hours)
• ✅ User can attempt full reboot

Emergency Mode Functions:

• ✅ SOS button
• ✅ Emergency calls
• ✅ GPS location
• ✅ Fall detection (basic)
• ❌ AI/Camera/Display effects
• ❌ Non-essential features

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9. Privacy & Data Security Safety

TC-SAFE-028: Camera/Mic Recording Indicator

Priority: P0
Category: Privacy Safety
Requirement Trace: FRD-PRIVACY-001
Automation: Manual

Objective:
Verify recording indicators function correctly and cannot be bypassed.

Test Procedure:

Step	Action	Expected Result	Pass/Fail
1	Start camera recording	Red LED illuminates	☐
2	Check LED brightness	Visible in all lighting conditions	☐
3	Attempt to disable LED (software)	Cannot be disabled	☐
4	Verify LED is hardware-wired	LED powered directly from camera	☐
5	Start microphone recording	Yellow LED or icon displayed	☐
6	Check HUD indicator	"🔴 Recording" icon visible	☐
7	Test in privacy mode	Recording blocked completely	☐
8	Test physical privacy shutter	Shutter blocks camera when closed	☐
9	Test mic kill switch	Mic physically disconnected	☐
10	Verify indicators in all firmware versions	Cannot be bypassed by any software	☐

Pass Criteria:

• ✅ Camera LED always on when recording
• ✅ LED cannot be disabled by software
• ✅ Mic indicator clear and visible
• ✅ Privacy shutter functional

Privacy Indicators:

• Camera: Red LED (hardware-wired)
• Microphone: Yellow LED / HUD icon
• Both: Cannot be bypassed by software

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Appendix A: Safety Test Summary Matrix

Test ID	Category	Priority	Standard	Pass Criteria
TC-SAFE-001	Fall Detection	P0	Internal	Sensitivity ≥95%, Specificity ≥97%
TC-SAFE-002	Emergency Response	P0	Internal	Auto-notify 30 sec, GPS accurate
TC-SAFE-003	False Positives	P0	Internal	FPR ≤3%
TC-SAFE-004	Obstacle Detection	P0	Internal	Detection ≥98%, Latency ≤200ms
TC-SAFE-005	LiDAR Detection	P0	Internal	Range ≥12m, Accuracy ±5%
TC-SAFE-006	Ground Mapping	P0	Internal	Step detection ≥95%, Warning 1.5m
TC-SAFE-007	Alert Modalities	P1	Internal	Visual + Haptic + Audio functional
TC-SAFE-008	SOS Activation	P0	Internal	100% reliable, Call ≤10 sec
TC-SAFE-009	GPS Accuracy	P0	Internal	Outdoor ≤10m, Indoor ≤50m
TC-SAFE-010	Emergency Reserve	P0	Internal	≥30 min at 5% battery
TC-SAFE-011	Overcharge	P0	IEC 62133-2	Never exceeds 4.25V
TC-SAFE-012	Overdischarge	P0	IEC 62133-2	Cutoff at 3.0V/cell
TC-SAFE-013	Thermal Runaway	P0	IEC 62133-2	No fire, no explosion
TC-SAFE-014	Physical Abuse	P0	UN38.3	Passes transport test
TC-SAFE-015	Thermal Spread	P0	Internal	Skin contact ≤33°C
TC-SAFE-016	Insulation	P0	IEC 62368-1	Resistance ≥10 MΩ
TC-SAFE-017	Short Circuit	P0	IEC 62368-1	PCM disconnects < 100ms
TC-SAFE-018	ESD	P1	IEC 61000-4-2	Survives ±4kV contact
TC-SAFE-019	Eye Safety	P0	IEC 62471	Class 1 or Class 2
TC-SAFE-020	Blue Light	P1	Internal	Reduction ≥30%
TC-SAFE-021	Eye Fatigue	P1	Internal	Reminders functional
TC-SAFE-022	EMC Emissions	P0	CISPR 32	Class B compliant
TC-SAFE-023	EMC Immunity	P0	IEC 61000-4-3	3 V/m immunity
TC-SAFE-024	SAR	P0	FCC/IEC	< 1.6 W/kg (1g)
TC-SAFE-025	Watchdog	P0	Internal	100% recovery
TC-SAFE-026	Sensor Failure	P1	Internal	Graceful degradation
TC-SAFE-027	Emergency Mode	P0	Internal	SOS + GPS functional
TC-SAFE-028	Privacy Indicators	P0	Internal	Cannot be bypassed

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Appendix B: Regulatory Compliance Checklist

IEC 62368-1 (Electrical Safety)

• ☐ SELV design (≤42.4V)
• ☐ Insulation resistance ≥10 MΩ
• ☐ Hipot test passed
• ☐ Short circuit protection
• ☐ ESD protection

IEC 62133-2 & UN38.3 (Battery Safety)

• ☐ Overcharge protection
• ☐ Overdischarge protection
• ☐ Thermal runaway prevention
• ☐ Physical abuse tolerance
• ☐ Transport safety

IEC 62471 (Photobiological Safety)

• ☐ Blue light hazard assessment
• ☐ Class 1 or Class 2 classification
• ☐ Unlimited viewing time

CISPR 32 & IEC 61000-4 (EMC)

• ☐ Radiated emissions compliance
• ☐ Conducted emissions compliance
• ☐ RF immunity (3 V/m)
• ☐ ESD immunity

FCC/CE/RCM (Radio)

• ☐ SAR testing complete
• ☐ RF exposure limits met
• ☐ Spectrum compliance

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Appendix C: Safety Test Lab Requirements

Required Facilities:

1. EMC test chamber (anechoic)
2. SAR measurement lab
3. Battery abuse test chamber
4. Electrical safety lab
5. Drop/vibration test facility

Required Equipment:

• Spectroradiometer (eye safety)
• Thermal camera
• EMI receiver
• SAR system
• Hipot tester
• ESD simulator

Estimated Testing Cost: AUD $50,000-80,000

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Document Approval

Reviewed by:

• Safety Officer: _________________ Date: _______
• QA Lead: _________________ Date: _______
• Hardware Lead: _________________ Date: _______
• Software Architect: _________________ Date: _______
• Product Manager: _________________ Date: _______
• Legal/Compliance: _________________ Date: _______

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END OF SAFETY-CRITICAL TEST CASES

These tests ensure GROOT FORCE meets the highest safety standards and protects users from all foreseeable hazards. Safety is non-negotiable.