Automated Bore Diameter Probe for Aircraft Holes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for measuring hole bore diameter as a function of depth in aircraft and spacecraft are inefficient, requiring inspectors to manually hunt for maximum and minimum diameters, which is time-consuming and skill-dependent, often missing true measurements due to uncontrolled depth insertion.
Innovation Solution
A method and apparatus using a diametric probe with a linear distance probe and data acquisition system to measure bore diameter and depth simultaneously, allowing for rapid, accurate measurements at two orientations and providing data on hole quality and material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual hole diameter measurement methods are used, then measurement capability is achieved, but measurement time is excessive (90 seconds per hole) and productivity is low
Solution Approach 1:
The patent replaces manual mechanical measurement with an automated optical measurement system. The probe assembly uses optical sensors and light sources to automatically measure hole diameter at multiple depths, eliminating the need for manual operation and significantly reducing measurement time while maintaining precision
Solution Approach 2:
The measurement system automatically performs depth control, data collection, and analysis without operator intervention. The probe assembly self-regulates descent rate, automatically records measurements at specified depths, and generates reports, freeing inspectors from time-consuming manual hunting for maximum and minimum diameters
2Measurement precision
If manual depth control during measurement is used, then measurement capability is achieved, but depth control precision is poor and true maximum/minimum diameters are often missed
Solution Approach 1:
The patent replaces manual depth control with an automated electronic control system. The probe assembly uses a motorized drive mechanism controlled by a processor to descend at a precise, pre-programmed rate, automatically positioning the measurement probe at exact depths specified in the measurement plan, thereby eliminating operator skill dependence and ensuring true maximum and minimum diameters are captured
Solution Approach 2:
The system incorporates depth sensors and position feedback mechanisms that continuously monitor probe descent and provide real-time feedback to the control system. This closed-loop control ensures the probe reaches exact target depths and maintains precise positioning throughout the measurement process, guaranteeing accurate capture of diameter variations
3Ease of manufacture
If single-orientation measurement is used, then measurement simplicity is maintained, but measurement completeness is insufficient (cannot detect roundness and defects)
Solution Approach 1:
The patent segments the measurement process into multiple orientations and depths. The probe assembly automatically rotates to measure diameter at different angular positions (e.g., 0°, 90°, 180°, 270°) and at multiple depth intervals, collecting comprehensive data that reveals roundness variations, ovality, and internal defects that would be invisible in single-orientation measurements
Solution Approach 2:
The system transitions from two-dimensional single-plane measurement to three-dimensional multi-orientation measurement. By measuring diameter at multiple angular positions around the hole circumference and at multiple depths along the hole axis, the system creates a complete 3D profile of the hole geometry, enabling detection of roundness, ovality, taper, and other geometric deviations
Data Source
Figure 1A~1B
Figure 2
Figure 3A
AI summary
A method and apparatus for measuring the bore diameter of a hole as a function of hole depth is disclosed. In one embodiment, the apparatus comprises a diametric probe, for generating first measured bore diameter data along a diametric probe sensitive axis; a foot, for positioning the diametric probe sensitive axis in a plane parallel to the hole; a linear distance probe, coupled to the diametric probe, for generating first measured depth data describing the depth of the diametric probe sensitive axis within the hole; and a data acquisition system, for recording first measured bore diameter data from the diametric probe and first measured depth data from the linear distance probe of an insertion of the diametric probe into the hole.