Bench tester vs aircraft harness, the 737 flap fault that proved it
I spent 6 hours chasing a flap position fault that showed fine on the bench tester but dead in the air, and swapping to a full aircraft harness simulation found the broken shield ground in 20 minutes, has anyone else had a bench tester miss a chafed wire that the real install caught?
That same thing happens with cars all the time, a test bench tells you the part is fine but the wiring in the actual car is where the gremlins live. It is like testing a flashlight with fresh batteries on the counter and then wondering why it dies when you put it in the drawer with the junk in it. There is just no substitute for the real thing with all its dirt and bends and rub spots.