Sai Ram Reddy YP

Client: Analog Devices India Private Limited.

Project Name: Rapid Platform Generation 2 (RPG2) Module. Description: The Rapid Platform Generation 2 (RPG2) module provides support for multiple industrial Ethernet protocols.

EtherCAT Protocol Testing and Validation:

• Orchestrated test execution of over 500 EtherCAT test cases across conformance, regression, system, stability, and evaluation testing.
• Drive 90% of the overall protocol testing effort across multiple firmware releases.
• Executed conformance testing using Beckhoff TwinCAT and ETG CTT to ensure full compliance with ETG standards.
• Configured and validated devices using Beckhoff PLCs, along with managed switches, and network taps.
• Performed DC testing to validate microsecond-level time synchronization across slave devices.
• Validated cable redundancy and hot-connect mechanisms for fault-tolerant, real-time communication.
• Tested configuration, diagnostics, and firmware upgrade functionalities of the embedded web server.

Ethernet/IP Protocol Testing and Validation:

• Spearheaded the execution of over 100 Ethernet/IP test cases, contributing 80% of the total validation effort, covering conformance, regression, evaluation, and security testing.
• Conducted conformance, regression, evaluation, and security testing across multiple firmware releases.
• Executed ODVA CIP conformance testing using CT19 with Rockwell Studio 5000, and Allen-Bradley PLCs.
• Configured industrial Ethernet networks using managed switches and network taps for traffic capture and analysis.
• Performed vulnerability testing using Nessus, Achilles, and Nightwish to identify and mitigate security risks.
• Validated embedded web server functionality, firmware upgrade processes, and post-upgrade regression stability.

Powerlink Protocol Testing and Validation:

• Managed and executed over 100 POWERLINK test cases, representing 90% of the total testing responsibility, focusing on deterministic performance and protocol compliance.
• Executed POWERLINK testing using B&R Automation Studio to ensure deterministic communication and system reliability.
• Validated Dynamic Node Allocation (DNA), PRes chaining, and ring redundancy for high-availability networks.
• Configured switches and hubs to simulate redundancy, failover, and fault scenarios.
• Conducted high-load and stability testing under variable network conditions to ensure robustness.

PROFINET Protocol Testing and Validation:

• Led end-to-end execution of 100+ PROFINET test cases, accounting for 50% of the project testing scope, across system, evaluation, regression, and security domains.
• Delivered comprehensive system and evaluation testing across multiple firmware releases.
• Configured and validated devices using Siemens TIA Portal V19 with S7-1200/1500 PLCs.
• Conducted vulnerability assessments using Nessus, Achilles, and Nightwish tools.
• Verified firmware upgrade processes, and ensured post-upgrade stability and functionality.

KEY ACHIEVEMENTS:

• Created 250+ detailed and reusable test cases for industrial communication protocols, including EtherCAT, Ethernet/IP, POWERLINK, and PROFINET, contributing to robust functional validation, negative testing, interoperability assurance, and regression stability.
• Identified and prevented production issues by detecting over 50 critical defects during QA testing.
• Drove 80-90% of testing efforts across multiple concurrent projects, ensuring on-time delivery.
• PLC and Protocol Expertise: Hands-on experience with Siemens, Rockwell, Beckhoff, ABB, and B&R PLCs across multiple industrial communication protocols.
• Real-Time Ethernet: Strong expertise in real-time communication, redundancy, and time synchronization.
• Network Setup and Analysis: Proficient in configuring industrial networks using switches, hubs, and network taps for protocol testing.
• Security and Reliability Testing: Conducted vulnerability assessments, and ensured secure, stable industrial communication systems.
• Test Documentation: Created and maintained test plans, test cases, and detailed test reports.

Client: Analog Devices India Private Limited.

Project Name: MCU Network System – EagleEye Room Count. | RoomCount (EagleEye v2 Platform).

• Analyzed product requirements and functional specifications to define end-to-end test coverage for MCU-based IoT products.
• Performed end-to-end manual testing across BLE commissioning, Wi-Fi connectivity, UART communication, DSP subsystem integration, and sensor-to-cloud workflows.
• Designed, developed, and maintained a large suite of test cases and test plans, contributing significantly to functional, integration, system, regression, and negative testing.
• Delivered 90% of the total testing effort across multiple product releases, playing a key role in release certification, stability validation, and quality assurance.
• Executed hardware, software integration testing, including sensor validation, communication interface testing, and OTA firmware upgrade validation (with rollback and recovery).
• Validated mobile application commissioning and workflows on Android and iOS platforms.
• Performed functional, performance, stability, UI, and use-case testing across multiple test cycles.
• Identified, logged, tracked, verified, and closed defects using JIRA, collaborating closely with firmware, hardware, and system teams.
• Prepared test execution reports, defect metrics, and quality summaries, and provided testing status updates, risks, and quality insights in weekly stakeholder meetings.