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Introduction The Fuel Contents Gauging (FCG) Probe Test Rig is a specialized ground-based equipment designed for the Light Combat Helicopter (LCH) program. Accurate fuel measurement is vital in combat aviation, where missions often involve high altitudes, demanding maneuvers, and extended flight durations. Pilots must trust their instruments completely, and that trust depends on the performance of the FCG probes and associated level switches inside the aircraft’s fuel tanks. These probes function on capacitive principles, converting immersion depth into electronic signals that are processed by the Fuel Quantity Indicating System (FQIS). A faulty probe or switch could lead to misleading fuel readings, endangering missions and lives. This test rig acts as the quality gatekeeper, performing pre-installation checks, calibrations, and functional verifications to ensure every probe meets HAL’s stringent requirements before flight integration. System Overview The rig provides a controlled environment where FCG probes and level switches are tested under simulated tank conditions. It employs a stainless-steel wet test tank with a transparent glass level tube and millimetre scale, enabling precise correlation between actual fuel level and probe output. The probe’s output is measured as a time-period signal, which is logged and analyzed against fluid height to check linearity, repeatability, and stability. In addition, the rig verifies input current consumption, insulation resistance, dielectric withstand strength, and switch actuation points. All results are captured through an automated data acquisition (DAQ) system and compiled into traceable test reports. Working Principle At the heart of the system is the wet functional test. The probe under test is immersed in a surrogate aviation fuel (such as Isopar M or Isopar K). As the liquid level rises or falls, the probe generates a changing time-period output corresponding to fuel height. This output is measured with microsecond resolution by a period counter, while the level is simultaneously tracked by the graduated glass tube. The test rig thus creates a time-period versus fuel level curve, which is compared against acceptance limits. The process is repeated in both directions to account for hysteresis. Parallel measurements of current consumption, switch actuation, and insulation integrity complete the qualification cycle. Key Features • Wet Testing Capability: Uses a calibrated tank and surrogate fuel to replicate real tank conditions. • High-Resolution Output Measurement: Captures probe output as a time-period variable with microsecond precision. • Level Switch Validation: Verifies actuation and reset levels with millimetre accuracy. • Electrical Integrity Checks: Includes insulation resistance and dielectric withstand testing. • Automated Data Handling: DAQ-based system generates real-time graphs, stores results, and produces PDF certificates. • Safety & Reliability: Features include grounding, overcurrent protection, spill trays, and optional explosion-proofing. Technical Specifications
