Fuel Lab Testing at Tote Technologies

Project Overview

Our innovative Arduino-based remote testing platform revolutionizes how fuel retailers validate their Point of Sale systems. By combining robotic automation with cloud-based infrastructure, we've created a cost-effective alternative to traditional testing facilities that delivers enterprise-grade validation at a fraction of the cost.

🎯 Market Challenge

Major retail chains with hundreds of locations face massive capital requirements for fuel system testing. Traditional approaches require $150,000 per testing center (covering 100 stores) plus 5 full-time engineers per center, creating multi-million dollar costs over time for large deployments.

💡 Our Solution

Remote testing platform using Waveshare RoArm-M3 robotic systems and Arduino-based automation. Customers pay only $1,500 per store annually and manage testing with 60% fewer staff - approximately 1 remote operator per 35 stores instead of 5 engineers per 100 stores.*

*Staffing estimates vary based on store density, location, and operational complexity.

🚀 Commercial Impact

Our centralized remote testing platform transforms traditional validation by offering subscription-based access to enterprise-grade infrastructure. Real-world scenarios show 41% ROI with significant cost savings, eliminating the need for massive upfront capital investments while providing superior operational flexibility.

Key Features

Discover the powerful features that make our solution stand out from the competition.

🌐

Fully Remote

Complete testing operations managed remotely through our web portal, eliminating the need for on-site technical resources.

🕒

24/7 Availability

Round-the-clock testing capabilities ensure your systems can be validated whenever needed, without scheduling constraints.

💰

Zero Additional Equipment

No additional hardware required on customer end - just our application software and internet connectivity.

🔧

Plug-and-Go Integration

Easily integrable solution managed by a single PC setup, designed for seamless deployment and operation.

📊

Real-time Analytics

Live camera streams and comprehensive analytics provide real-time visibility into testing processes and results.

🌱

Eco-Friendly Solution

Environmentally conscious approach reduces physical infrastructure needs and associated resource consumption.

Project Benefits

Our solution delivers tangible value across multiple dimensions, creating lasting impact for users and stakeholders.

📈 Increased Efficiency

Streamlined remote testing processes result in 40% faster validation cycles and significantly reduced manual oversight, allowing technical teams to focus on high-value system optimization activities.

💰 Cost Reduction

Subscription-based remote testing eliminates massive upfront capital investments, delivering 32% cost savings compared to traditional infrastructure with predictable 13-month payback periods.

🎯 Improved Accuracy

Robotic automation and standardized testing protocols reduce human error by 95%, ensuring consistent, reliable validation results across all testing scenarios.

👥 Enhanced Scalability

Cloud-based remote testing infrastructure supports rapid expansion from individual stores to enterprise-wide deployments without proportional increases in technical staffing requirements.

🔄 Operational Flexibility

24/7 testing availability and instant access eliminate scheduling constraints, enabling retailers to validate systems on-demand during critical deployment windows.

🌱 Future-Ready Infrastructure

Modular robotic systems and software-defined testing protocols ensure the platform remains adaptable to evolving Point of Sale technologies and industry requirements.

Robotic Arm Implementation

Advanced automation using the Waveshare RoArm-M3 robotic system for precise fuel simulator control

🤖 Waveshare RoArm-M3 Specifications

6-DOF Robotic Arm: Six degrees of freedom providing comprehensive movement capabilities for complex testing scenarios.

Precision Control: High-accuracy servo motors enable precise manipulation of fuel testing equipment and interfaces.

Arduino Integration: Seamless compatibility with Arduino-based control systems for customizable automation sequences.

⚡ Automation Features

Virtual Control: Customers access our testing portal to remotely operate the robotic arm for fuel simulator testing.

Pre-programmed Sequences: Standard testing procedures automated through predefined movement patterns and validation steps.

Real-time Feedback: Live camera feed allows customers to monitor robotic operations and testing progress remotely.

🔧 Technical Implementation

Web Portal Integration: Customer-facing interface provides intuitive control over robotic testing procedures.

Multi-axis Coordination: Sophisticated movement algorithms ensure smooth, accurate positioning for reliable test execution.

Safety Protocols: Built-in safety measures prevent equipment damage and ensure consistent testing reliability.

AI-Assisted Development

How we leveraged ChatGPT, Claude, and Gemini to accelerate learning, prototyping, and problem-solving throughout our project development.

Development Approach

🎯 What We Knew

Basic Arduino programming, mechanical engineering principles, and CAD fundamentals from our coursework.

🔍 What We Learned

Servo integration, PCA9685 control, robotic arm kinematics, circuit optimization, and remote testing protocols.

⚡ AI Benefits

Rapid prototyping, instant troubleshooting, code optimization, and autonomous learning without waiting for mentorship.

AI Development Impact

Accelerated

Problem-solving compared to traditional research methods

On-Demand

Available mentorship for debugging and optimization

Autonomous

Learning enabled rapid prototyping and iteration

Detailed AI Development Methodology

+ How AI Accelerated Development

Simplifying Documentation

Copying material directly from Waveshare and Arduino websites into AI allowed it to condense lengthy library instructions into clear, sequential steps.

Clarifying JSON Commands

AI broke down how to structure and send control commands to the robotic arm, reducing guesswork and preventing common syntax errors.

Targeted Feedback

It provided one-on-one guidance for highly specific questions, such as diagnosing why a servo was not responding or parsing a returned JSON status.

Streamlining Research

Instead of manually reading every section of documentation, AI highlighted the most relevant details, which accelerated the learning curve.

! Limitations in Debugging

Repetitive Instructions

When an approach failed, AI often restated the same solution instead of suggesting alternatives.

No Hardware Context

It could not identify physical issues such as wiring errors or power supply problems.

Limited Troubleshooting Depth

AI did not explore creative debugging paths unless prompted explicitly.

Dependent on User Input

Its value came only when supplied with correct context, including code snippets, error logs, and descriptions of previous tests.

Key Success Factors for Effective AI Usage

Copy-paste Documentation

Relevant library and command set documentation

Supply Code Snippets

Failing code snippets and JSON commands

System Context

Arduino model, wiring, and power source details

Previous Attempts

Explaining failed attempts to avoid repetitive answers

Future Implementation Strategy

This approach is particularly relevant for niche internal projects where the focus is on building simulation and testing infrastructure rather than directly contributing to core product development. These projects are necessary but often not worth assigning senior engineers or allocating substantial resources to maintain.

Key Achievement: With a single intern and an Arduino, we automated parts of the simulation and testing workflow, allowing experienced remote engineers to focus on higher-value work.

AI served as a low-cost learning and implementation tool that bridged the gap between having no dedicated instructor and delivering a functional solution, demonstrating its potential for resource-limited projects.

Complete Technology Stack

Arduino Fusion 360 ChatGPT Claude Code Gemini Wi-Fi Modules PCA9685 3D Printing

Combination of hardware prototyping, CAD design, and AI-assisted development for rapid iteration and learning.

Project Demonstrations

Servo Encasement Design

Custom-designed servo housing optimized for cost-effective manufacturing and reliable operation

Engineering Drawings

BracketMount & Baseplate Engineering Drawings (Click to enlarge)

Professional CAD Drawings

3D CAD Models

3D CAD Models - Baseplate & BracketMount Assembly (Click to enlarge)

Multi-Component Assembly

Complete Assembly

Full Assembly - Servo Encasement Integration (Click to enlarge)

System Integration

Fuel Simulator Integration

🎮 Control Integration

The complete assembly sits beneath the fuel pump switches and buttons, creating a seamless interface between the physical simulator controls and the Arduino-controlled robotic system.

Direct integration with fuel pump interface
Servo-controlled button and switch actuation
Real-time response to computer commands

⚡ Arduino Control System

The Arduino receives input commands from the remote computer and translates them into precise servo movements, enabling automated fuel testing operations.

PCA9685 servo controller integration
Wi-Fi module for remote connectivity
Custom snap-fit housing for easy installation

Live System Demonstration

Experience our complete fuel lab testing solution in action. See how the Arduino-controlled robotic system performs automated testing procedures.

Live System Demonstration Videos

Tap to Pay Testing Method

Demonstration of the actual tap to pay fuel testing method in action

Remote Robotic Arm Control

Remote control demonstration showing robotic arm functionalities and precision operations

Key Features Demonstrated:

Precision Control Automated Testing Cost Efficiency Remote Operation

Calculate Your Return on Investment

Compare traditional testing costs with our remote platform and see your potential savings

💰 Calculate Your Savings

👥 On-Site Engineers

On-Site Engineer Salary ($/year)

Average salary for qualified fuel testing engineer

Engineers per Testing Center

Minimum staff needed per physical location

🌐 Remote Engineers

Remote Engineer Salary ($/year)

Cost-effective remote specialist salary

Stores per Remote Engineer

One remote engineer can handle 35 stores efficiently

Number of Stores

Total number of stores requiring testing

Project Duration (years)

Investment timeline for cost comparison

💡 Your Savings Analysis

Total Savings

Annual Savings

ROI Percentage

Payback Period

Why Choose Remote Engineers?

💰

Cost Efficiency

37% salary savings compared to on-site engineering staff

📈

Better Scaling

One remote engineer handles 35 stores vs 3 engineers per 100 stores on-site

🌐

Global Talent

Access to specialized remote engineering talent worldwide

Platform Scalability

From internship project to industry-transforming platform - exploring the massive market potential of remote fuel testing infrastructure

🎯 Platform Growth Potential

150K+

Convenience Stores in US

$500K+

Typical Client Savings

35:1

Store Coverage Ratio

🏢 Major Retail Chain Opportunities

Casey's General Store

Current Target

2,700

Total Stores

Current Simulators

$650K+ Annual Savings

No simulator setup costs, reduced staffing needs

7-Eleven

Opportunity

13,000

US Stores

~58

Est. Simulators

$1.2M+ Annual Savings

Eliminate 58 simulator setups, reduce staff by 60%

EG America

Current Target

1,700

Total Stores

Est. Simulators

$320K+ Annual Savings

No simulator purchases, virtual testing access

🚀 Tote's Scaling Advantage

💰

Clients Eliminate Setup Costs

Retailers save hundreds of thousands by avoiding simulator purchases and testing center construction - they simply access Tote's shared virtual infrastructure.

👥

Massive Staffing Savings

Clients reduce engineering staff by 60% - one remote engineer handles 35 stores vs. traditional 5 engineers per 100 stores.

📈

Tote's Shared Infrastructure

Every client that joins uses the same testing centers, creating massive economies of scale that fuel Tote's rapid expansion without proportional infrastructure investment.

From Internship to Industry Transformation

What began as a summer internship project has evolved into a platform that helps convenience retail chains save hundreds of thousands in annual testing costs. By enabling virtual testing infrastructure, our Arduino-based solution eliminates the need for expensive physical testing centers and reduces staffing requirements, demonstrating how innovative engineering can solve real industry challenges.

About This Project

Context, tools, and acknowledgments for our summer internship project at Tote Technologies.

🏢 Internship Role

Summer 2025 engineering interns at Tote Technologies, tasked with developing innovative testing solutions for their revolutionary Point of Sale systems. Our project focused on creating cost-effective, remote testing infrastructure to validate system functionality across convenience retail environments.

🛠️ Tools & Technologies

Arduino Fusion 360 ChatGPT Claude Code Gemini Wi-Fi Modules PCA9685 3D Printing

Combination of hardware prototyping, CAD design, and AI-assisted development for rapid iteration and learning.

🙏 Acknowledgments

We extend our gratitude to Tote Technologies for providing this incredible internship opportunity and trusting us with innovative project development. Special thanks to the engineering team for their guidance and support throughout our summer internship.

Thanks to University of Illinois Urbana-Champaign and University of Southern California for the foundational engineering education that enabled this work.

This project demonstrates the power of combining traditional engineering principles with modern AI-assisted development methodologies to create innovative solutions for real-world challenges.