The test rig supports a wide spectrum of aerospace and defense use cases through the entire lifecycle of pressure switches: • Production Calibration & Validation Every switch manufactured goes through this rig to verify that it meets its set/reset tolerances under controlled conditions. This ensures no faulty unit enters integration. • Quality Assurance & Certification Provides documentation (test data, certificates) necessary for audits, regulatory compliance, and traceability of component performance. • Maintenance, Repair & Overhaul (MRO) During aircraft servicing cycles, switches removed from systems are re-tested and certified using this rig. Drift over service life can be detected and compensated or replaced. • R&D and Prototyping Engineers designing new switch models use this rig to assess behavior under different ramp rates, hysteresis tolerances, temperature/pressure combinations, and endurance cycling. • Endurance & Fatigue Testing The rig supports long-term cycling (thousands to millions of operations) to simulate life expectancy conditions and detect wear, drift, or failure modes. • Leak & Stability Validation At high pressure or during dwell periods, the switch and fixture connection are held to check for pressure decay or leaks, verifying integrity. • Multi-condition Simulation By combining varied ramp slopes, dwell times, and pressure cycles, the rig can simulate real-use scenarios and corner-case conditions for switch validation. Because similar test benches are used in aerospace labs to test altitude switches, environmental control system switches, and hydraulic/pneumatic safety devices, this rig fits well in OEM, lab, and defense settings (for instance, Neometrix offers an Absolute Pressure Switch Test Rig for aviation-level altitude switches). Additionally, in broader industrial test bench domains, systems combining pressure, flow, temperature, and force regulation are increasingly common to test multi-physics components.
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Overview In high-stakes aerospace systems, gauge pressure switches play a silent but crucial safeguarding role. They continuously monitor internal pressures in hydraulic, pneumatic, fuel, and lubrication circuits and trigger mechanical or electrical actions if pressure strays beyond safe thresholds. Their correct operation is non-negotiable—if a switch misfires or drifts (i.e. activates too early or too late), it can lead to failure of critical functions such as landing gear operation, fuel system isolation, engine protection, cabin pressurization, or hydraulic safety cutoffs. Because of this, aerospace-grade pressure switches must be validated under controlled, repeatable test conditions before being cleared for deployment. The Gauge Pressure Switch Test Rig is engineered precisely for this requirement: it simulates accurate pressure profiles, captures actuation and deactuation behavior with fine resolution, enforces safety constraints, and delivers traceable data that demonstrates compliance to stringent aerospace and defense quality regimes. This test rig bridges engineering rigor with operational usability—designed for use in production calibration, R&D, and maintenance labs—serving as a foundational instrument in the validation chain of mission-critical devices. Key Features • Dual-Threshold Verification Measures both actuation (set) and reset (deactuation) pressures, computing switch hysteresis and verifying that the switching action lies within allowed tolerances. • Precision Sensing & Instrumentation Uses high-accuracy digital pressure transducers and calibrated gauges (with traceability to ISO/IEC 17025) to minimize measurement uncertainty. The design supports fast data capture to track transient behavior during switch activation. • Programmable Pressure Profiles Employs a precision electro-pneumatic regulator and flow/bleed control valves to create smooth, repeatable pressure ramping. Rise and fall rates can be programmed (for example, slow ramp for sensitive switches, faster cycles for endurance testing). • PC/PLC Control & Data Logging A user interface (GUI) enables creation of pressure sequences, real-time monitoring, and automatic logging of actuation/reset points. Finish reports (CSV, PDF) are generated with timestamps and that can interface into quality assurance systems or databases. • Robust Safety Mechanisms Multiple redundant safety features: over-pressure relief valves, burst discs, hardware interlocks, emergency-stop functionality, and software limits prevent unsafe pressures or operations. • Modular & Flexible Design The rig is modular, enabling adaptation to different switch sizes, pressure ranges, and test protocols. Interchangeable fittings, mounting options, and sensor modules allow quick configuration for different switch variants. • Compliance-Ready Construction Built with aerospace-grade materials, EMC/EMI shielding, and design practices aligned to military and aviation standards. Technical Specifications (Indicative)
