Eddy Current Probe for Fillet Seal Edge Detection

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Solution Overview

Problem

The precise location of a covered edge in a fillet seal, obscured by sealant material, poses a challenge for measuring and validating the dimensions of structural joints in aircraft and other assemblies, particularly when using thin sheet metal components or fasteners with exposed heads.

Innovation Solution

A tool comprising an edge detection probe mounted to a fixture, an electronic control unit, and a display screen, which outputs an interrogation signal to locate the covered edge and translate the return signal into XY coordinates, facilitating measurements of the fillet seal's dimensions using a seal measurement device.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If sealant material is applied to form a fillet seal, then sealing quality and protection against moisture ingress are improved, but the covered edge location becomes obscured and measurement reference is lost

Engineering Contradiction:

Improvesealing qualityVSAvoidedge location measurement

Core Design Contradiction:

ReliabilityVSMeasurement precision

Solution Approach 1:

The patent replaces manual mechanical measurement methods with an automated eddy current probe system. The probe uses electromagnetic fields to detect the covered edge location through the sealant material, eliminating the need for direct visual or physical contact with the obscured edge, thereby resolving the measurement precision issue while maintaining sealing quality

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The eddy current probe acts as an intermediary between the measurement system and the covered edge. It transmits electromagnetic signals through the sealant material to detect the edge location indirectly, allowing measurements to be taken without exposing or removing the sealant, thus preserving both sealing quality and measurement capability

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If manual touch gauges are used to measure fillet seal dimensions, then measurement process is simple, but measurements cannot be taken when edge is hidden behind sealant material

Engineering Contradiction:

Improvemeasurement process simplicityVSAvoidcovered edge detection

Core Design Contradiction:

Ease of operationVSDifficulty of detecting and measuring

Solution Approach 1:

The patent replaces simple mechanical touch gauges with an automated eddy current detection system. The probe automatically scans and detects the covered edge location through electromagnetic fields, eliminating the need for manual intervention while overcoming the limitation of hidden edges, thus maintaining operational simplicity while solving the detection difficulty

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The eddy current probe performs self-directed measurement by automatically detecting the covered edge location without requiring manual positioning or visual guidance. The system independently identifies the edge through electromagnetic signal changes, enabling measurements to be taken even when the edge is completely obscured by sealant material

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables accurate measurement and validation of fillet seal dimensions, conforming to industry standards, even when the edge is hidden beneath sealant material, by precisely locating the covered edge and determining its thickness and shape.

Implementation Method 1

The probe is configured to output an interrogation signal as a waveform... The probe thereafter receives a return signal indicative of a location of the covered edge

Methodology Applied

Scientific EffectEddy current: Eddy Currents

Data Source

PatentUS11421987B2Lap joint fillet seal measurement tool when lap edges are sealed

Publication Date: 2022.08.23 THE BOEING CO

AI summary

A tool for detecting a covered edge of a structural member through sealant material of a fillet seal includes an edge detection probe mounted to a fixture. The probe outputs an interrogation signal toward the covered edge and receives a return signal indicative of a location of the covered edge. The tool includes an electronic control unit (“ECU”) in communication with the edge detection probe and a display screen. The ECU is configured to generate, from the return signal, one or more XY coordinates indicative of the edge location, and to display the edge location on the display screen. Additionally, the tool includes a seal measurement device. In response to the edge location, the device measures a predetermined dimension of the fillet seal, including a thickness and/or a shape of the fillet seal. A method includes detecting the covered edge using the tool.