Cross-Platform Fault Reporting Architecture for Scalable and Reliable Wearable Systems

Wearable devices need fast and reliable fault reporting across different systems and networks. We built a cross-platform reporting system with a unified event format, compact encoding, on-device redaction, store-and-forward buffers, and priority queues. We tested it on 60,412 devices over 180 days across Wear OS, watchOS, and an RTOS, and in 1,200 lab sessions with controlled faults. Reports were sent over Wi-Fi, LTE, and BLE, including poor links. Median time-to-report fell from 74 s to 41 s (−44.6%). p95 and p99 fell to 97 s and 226 s. The share of reports delivered within 60 s rose from 0.61 to 0.83. Loss dropped from 1.9% to 0.6% per device, and duplication from 0.7% to 0.2%. Using a single event format reduced incident clusters by 35–39% and cut median time-to-detect by 28%. On an instrumented subset (n = 96), energy per delivered report fell by 23%, with 31% less CPU time for encoding and 29% less DRAM traffic. These results show that a common event format and a small on-device reporter can improve speed and reliability while lowering overhead on different wearable platforms. Limits include no large-scale tests on low-duty-cycle wide-area radios and no long rural outages. Future work will add NB-IoT/eDRX tests, longer field runs, and combined tests with secure boot and attestation.