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Test cases

Firmware update test cases, for the device that will not boot

Twenty eight cases covering power loss during the write and during first boot, automatic rollback and health confirmation, signature verification and anti rollback, battery thresholds, ordered multi component updates, configuration migration, staged rollouts, halt on failure and a documented recovery path.

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28 worked examples

FW-01

Complete an update on a healthy device

TypeFunctionalPriorityHigh
Test data
A current device updated to the next release over the air
Expected result
Downloads, verifies, installs and reboots into the new version, and the reported version matches the installed image exactly.
FW-02

Survive power loss during the write

TypeStatePriorityHigh
Test data
Cut power at the start, middle and end of the flash write
Expected result
Device boots in every case, on the previous image if the new one is incomplete. This single case is what separates a recoverable fleet from a recall.
FW-03

Survive power loss during the reboot into new firmware

TypeStatePriorityHigh
Test data
Cut power during the switch between images and during first boot
Expected result
Bootloader falls back to the known good image rather than leaving the device in a state where neither partition is marked valid.
FW-04

Roll back automatically when new firmware fails to boot

TypeStatePriorityHigh
Test data
An image that boots but fails its health check, and one that does not boot at all
Expected result
Both revert to the previous image within the watchdog window, and the failure is reported once connectivity returns.
FW-05

Confirm the new image before marking it good

TypeStatePriorityHigh
Test data
A new image that boots and passes checks, and one that boots but cannot reach the network
Expected result
Image is only marked permanent after a successful health check including connectivity, otherwise a working but unreachable device is unrecoverable remotely.
FW-06

Refuse unsigned or tampered firmware

TypeSecurityPriorityHigh
Test data
An unsigned image, one signed by the wrong key, and a valid image with one byte altered
Expected result
All refused before any write to flash, with signature verification performed on the device rather than trusted from the delivery channel.
FW-07

Refuse a downgrade to a vulnerable version

TypeSecurityPriorityHigh
Test data
A correctly signed but older image containing a known vulnerability
Expected result
Refused through anti rollback protection, since a valid signature on old firmware is otherwise a supported path back to a fixed vulnerability.
FW-08

Verify the image after writing, before switching

TypeSecurityPriorityHigh
Test data
Corrupt the written image on flash before the reboot
Expected result
Checksum or signature is verified from flash rather than only on the downloaded stream, so a bad write is caught before it becomes the active image.
FW-09

Resume an interrupted download

TypeStatePriorityHigh
Test data
Interrupt the download at 60 per cent, then reconnect
Expected result
Resumes from the interruption point rather than restarting, which matters when the device is on a metered or very slow connection.
FW-10

Complete an update over a constrained link

TypePerformancePriorityHigh
Test data
An update delivered over the slowest supported connection with high packet loss
Expected result
Completes within the stated window without exhausting the device data allowance, and the device remains functional throughout the download.
FW-11

Refuse to update below a safe battery level

TypeBoundaryPriorityHigh
Test data
Attempt an update at 5 per cent battery and while on external power
Expected result
Refused on battery below the documented threshold and permitted on external power, since running out mid write is the most common cause of a dead device.
FW-12

Defer an update while the device is in use

TypeStatePriorityHigh
Test data
Trigger an update while the device is performing its primary function
Expected result
Deferred to a safe moment or the user is asked, since interrupting an active safety or medical function to install an update is not acceptable.
FW-13

Update dependent components in the correct order

TypeBoundaryPriorityHigh
Test data
A release updating both application firmware and a radio or coprocessor image
Expected result
Ordered so the device remains recoverable at every intermediate point, and a failure partway does not leave two components on incompatible versions.
FW-14

Migrate stored configuration across versions

TypeCompatibilityPriorityHigh
Test data
Device settings and calibration data written by the previous version
Expected result
Migrated and preserved, and a rollback leaves the older firmware able to read what the newer one wrote rather than failing on an unknown format.
FW-15

Update from the oldest firmware still in the field

TypeCompatibilityPriorityHigh
Test data
The oldest shipped version updated directly to the current release
Expected result
Succeeds, or the required intermediate steps are enforced automatically, since devices in the field skip many releases.
FW-16

Preserve buffered data across the update

TypeStatePriorityHigh
Test data
Unsynced readings held on the device when the update begins
Expected result
Buffer survives the update and syncs afterwards, rather than being wiped because the storage layout changed between versions.
FW-17

Stage a rollout to a small cohort first

TypeStatePriorityHigh
Test data
A rollout targeted at a small percentage of the fleet
Expected result
Only the cohort receives it, and cohort membership is stable so a device does not move in and out of the rollout between check ins.
FW-18

Halt a rollout in progress

TypeStatePriorityHigh
Test data
Stop a rollout after failures are detected in the first cohort
Expected result
No further devices start the update within the stated window, and devices mid update either complete safely or roll back cleanly.
FW-19

Detect a failing rollout automatically

TypeStatePriorityHigh
Test data
A cohort where a proportion of devices fail to report after updating
Expected result
Rollout pauses on the documented failure threshold rather than continuing to the whole fleet, which is the difference between an incident and a recall.
FW-20

Avoid every device downloading at once

TypePerformancePriorityHigh
Test data
A rollout released to a large cohort simultaneously
Expected result
Downloads are staggered with randomised delay so the distribution endpoint and the local network are not saturated in the same minute.
FW-21

Report update status accurately

TypeStatePriorityHigh
Test data
Devices in downloading, verifying, installing, succeeded, rolled back and failed states
Expected result
Each is distinguishable in the fleet view, and a device that has gone quiet mid update is shown as unknown rather than as still installing indefinitely.
FW-22

Recover a device that has failed repeatedly

TypeStatePriorityHigh
Test data
A device that has rolled back from the same update three times
Expected result
Stops attempting automatically, is flagged for intervention, and does not loop indefinitely consuming bandwidth and battery.
FW-23

Provide a documented recovery path

TypeStatePriorityHigh
Test data
A device that will not boot either image
Expected result
A documented recovery mode exists and works, so the worst case is a support procedure rather than a physical replacement.
FW-24

Protect the update transport

TypeSecurityPriorityHigh
Test data
Intercept the download, present an invalid certificate, and redirect to another host
Expected result
Device validates the server certificate and refuses the redirect, and signature verification means transport compromise alone cannot install firmware.
FW-25

Refuse an update targeted at a different hardware revision

TypeNegativePriorityHigh
Test data
An image built for another hardware variant or region
Expected result
Refused on a hardware compatibility identifier before writing, since installing the wrong variant is a reliable way to brick a device permanently.
FW-26

Keep secrets out of the firmware image

TypeSecurityPriorityHigh
Test data
Inspect the distributed image for credentials, keys and endpoints
Expected result
No shared secret or private key is present, since the image is distributed publicly and can be extracted by anyone who owns a device.
FW-27

Keep the update audit trail complete

TypeSecurityPriorityHigh
Test data
A rollout including successes, rollbacks and a halt
Expected result
Each device records which version it ran and when, so a field failure can be tied to a specific image rather than inferred from a release date.
FW-28

Communicate update state to the user

TypeAccessibilityPriorityMedium
Test data
A device with a minimal interface updating, and one where the update fails
Expected result
Progress and outcome are indicated through whatever the device has, and a failure is distinguishable from an ordinary fault rather than appearing as an unexplained restart.

What goes in each field

ID

Required

Stable identifier, prefixed by module.

Test case

Required

What is being verified, in one line.

Type

Functional, negative, boundary, security, state, performance, accessibility or compatibility. Use it to check coverage is spread rather than clustered on the happy path.

Priority

Risk based, with recoverability first. Anything that can leave a device unable to boot, accept unsigned firmware, or brick a fleet through a staged rollout is High, because the remedy is physical rather than a redeploy.

Test data

The specific values, including the invalid and boundary ones.

Expected result

Required

The precise observable outcome, including message text where the wording itself is the requirement.

How To Use This

Cut the power halfway through

This is the only set here where the worst outcome is physical. A device that will not boot has to be collected, opened or replaced.

Pull power during the flash write

At the start, the middle and the end. The device must boot on the previous image every time. This single case is the difference between a recoverable fleet and a recall.

Ship an image that boots but cannot connect

A device that passes its own health check and cannot reach the network is unrecoverable remotely. Connectivity has to be part of confirming the image is good.

Sign an old vulnerable version correctly

A valid signature on old firmware is a supported path straight back to a vulnerability you already fixed. Anti rollback protection is what closes it.

Fail a cohort deliberately

The rollout must pause on its own when devices stop reporting. Continuing to the whole fleet after the first cohort fails is how an incident becomes a recall.

What Most Sets Miss

Why firmware defects need a truck

Every other set in this collection describes defects that can be fixed with a deployment. This one does not. A device that will not boot has to be physically collected, opened or replaced, and if the fault reached the whole fleet then the cost is measured in logistics rather than engineering hours. That inverts the usual priorities: recoverability comes before functionality, and the first case is not whether the update works but whether the device survives the update failing.

Power loss during the write is the scenario everything else is arranged around. An A and B partition scheme with a bootloader that only switches after verification means an interrupted write leaves the previous image intact and bootable. Getting this wrong is not a rare edge case: devices lose power, batteries die, and users unplug things. The related case is confirming the new image rather than assuming it: an image that boots but cannot reach the network is functionally bricked from your point of view, because you can no longer send it anything, so connectivity belongs in the health check that marks the image permanent.

Firmware security has one property that application security does not: the image is distributed publicly, so anyone who owns a device can extract it. That makes any embedded secret a fleet wide secret. Signature verification has to happen on the device before writing, because trusting the delivery channel means transport compromise becomes firmware compromise. And anti rollback matters more than it sounds, since a correctly signed older image is a legitimate path back to a vulnerability that was already patched.

Finally, rollouts are a safety mechanism rather than a convenience. Staging to a small cohort, halting automatically when devices stop reporting, and staggering downloads so the fleet does not saturate the distribution endpoint in one minute are all cheap to build and expensive to omit. The case worth running deliberately is the failing cohort: if the rollout does not pause on its own, the operator has to notice and intervene faster than the rollout progresses, and that is not a reliable control.

Suggest an improvement

Testing embedded or connected hardware?

QAble tests firmware delivery end to end, including interrupted writes, rollback behaviour, signature and anti rollback enforcement and staged fleet rollouts.

Embedded testing services

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