Eddy Current Probe Gap Measurement Through Sealants
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Solution Overview
Problem
Existing methods for measuring gaps between conductive aircraft parts, especially through open holes, are inefficient and inaccurate due to reliance on manual visual inspection and feeler gauges, which are time-consuming and prone to errors, and do not account for inaccessible areas or sealants.
Innovation Solution
An automated system utilizing eddy current edge effect with a probe and oscilloscope to measure gaps through open holes in conductive parts, comparing measurements to a reference standard for accuracy and activating an alarm for unacceptable results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection and feeler gauge methods are used to measure gaps, then the measurement process is simple and equipment is minimal, but the measurement time is excessive and accuracy is poor for inaccessible areas
Solution Approach 1:
The patent replaces manual mechanical measurement methods (visual inspection and feeler gauges) with an automated eddy current testing system. The probe contains a coil that generates electromagnetic fields to detect gap dimensions through conductive parts, eliminating the need for manual insertion of feeler gauges and visual inspection through holes. This substitution dramatically reduces measurement time while improving accuracy through automated data processing.
Solution Approach 2:
The eddy current testing system performs self-measurement by automatically detecting gap dimensions through the electromagnetic interaction with conductive parts. The system autonomously processes measurements through the probe and display unit without requiring human operators to manually insert tools or interpret visual information through restricted access areas.
2Ease of operation
If optical devices such as borescope are used to inspect inaccessible gaps, then visibility into holes is improved, but the device diameter is too large to fit through small open holes
Solution Approach 1:
The patent replaces optical measurement devices (borescope) with an eddy current testing probe that uses electromagnetic fields instead of optical pathways. This eliminates the need for a physical optical tube that must fit through holes, as the electromagnetic field can penetrate and interact with conductive parts through much smaller openings. The probe design is compact and can access areas where optical devices cannot physically fit.
3Productivity
If manual methods are used for gap measurement, then equipment cost is low, but labor requirements are high and productivity is low
Solution Approach 1:
The patent implements an automated eddy current testing system that replaces manual measurement operations. The system includes a probe for electromagnetic detection, a display unit for automated data processing and presentation, and integrated measurement capabilities that eliminate manual tool handling. This automation significantly increases measurement throughput and productivity, making the process suitable for high-volume inspection environments despite the increased system complexity.
4Reliability
If sealants are applied to conductive part surfaces for sealing, then sealing performance is improved, but visual inspection capability is reduced by masking gap areas
Solution Approach 1:
The patent replaces visual inspection methods with eddy current electromagnetic detection that can measure gaps through conductive parts regardless of sealant presence. The electromagnetic field interacts with the conductive material to detect dimensional variations, allowing gap measurement through the conductive part even when sealants mask the external surfaces. This eliminates the conflict between sealing requirements and inspection visibility.
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
The system provides rapid, accurate, and automated gap measurements through open holes, allowing for precise inspection of inaccessible areas and visibility through sealants, reducing labor and costs while ensuring compliance with engineering standards.
Implementation Method 1
The probe is inserted into a through hole formed through each of the two conductive parts and uses the eddy current edge effect to take the gap measurement and measure the gap between the two conductive parts
Data Source
AI summary
There is provided a system for using eddy current edge effect to measure a gap between two conductive parts. The system includes the two conductive parts, each having predetermined properties. The system includes a probe having a housing with a coil, and includes a reference gap standard, based on one or more reference gap measurements taken between at least two reference conductive parts separated by a gap distance, as specified by predetermined engineering requirements. The system includes an inspection instrument assembly coupled to the probe and having an inspection apparatus calibrated to the probe and the reference gap standard. The probe with the coil uses the eddy current edge effect to take the gap measurement and measure the gap. The gap measurement is compared to the reference gap standard, to determine whether the gap measurement is an acceptable result or an unacceptable result, based on the predetermined engineering requirements.