Electronic Feeler Gauge for 3D Gap Measurement
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Solution Overview
Problem
The process of measuring non-uniform gaps between aircraft components for precise assembly is time-consuming and tedious, requiring custom-sized shims and specialized installation procedures, which increases manufacturing cycle time.
Innovation Solution
An electronic feeler gauge with a sensor blade equipped with transmission and reception induction coils, capable of measuring separation distances in three dimensions, providing a thickness map to select or verify shims for precise fitting and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional gap measurement methods are used, then measurement precision can be achieved, but manufacturing cycle time increases significantly
Solution Approach 1:
The patent replaces traditional mechanical measurement tools (such as mechanical feeler gauges and manual measurement devices) with an electronic measurement system that uses electromagnetic fields. The electronic feeler gauge employs induction coils to generate and detect electromagnetic signals, automatically determining gap dimensions without manual intervention, thus maintaining high precision while dramatically reducing measurement time.
Solution Approach 2:
The patent transforms the measurement process by changing from manual parameter reading to automated electronic parameter detection. The system measures multiple gap parameters (length, width, depth) simultaneously using electromagnetic field interactions, converting physical gap dimensions into electrical signals that can be processed and displayed automatically, eliminating time-consuming manual measurement steps.
2Manufacturing precision
If custom-sized shims are prepared for non-uniform gaps, then fit precision improves, but device complexity and preparation time increase
Solution Approach 1:
The patent performs preliminary measurement of the entire gap volume before shim fabrication. The electronic feeler gauge maps the complete three-dimensional geometry of the gap, providing comprehensive dimensional data that enables precise shim design. This preliminary action ensures that custom shims are accurately sized and shaped to fit non-uniform gaps, improving fit precision while streamlining the preparation process through automated data collection.
Solution Approach 2:
The patent transitions from two-dimensional gap measurement to three-dimensional gap characterization. By measuring gap dimensions in three dimensions (length, width, and depth) and mapping the entire gap volume, the system provides comprehensive geometric information necessary for creating precisely fitted custom shims, accounting for variations in all spatial dimensions.
3Measurement precision
If multiple measurement sites are used to map non-uniform gaps, then measurement accuracy improves, but measurement time increases
Solution Approach 1:
The patent merges multiple measurement functions into a single integrated electronic feeler gauge device. The system combines multiple induction coils, signal generation circuits, detection circuits, and data processing capabilities into one unified tool that can simultaneously measure all three dimensions of the gap and map the entire gap volume, eliminating the need for multiple separate measurement operations.
Solution Approach 2:
The patent enables continuous measurement of the gap throughout its entire volume. The electronic feeler gauge continuously scans and maps the gap geometry as it is inserted, collecting data from multiple measurement sites simultaneously and continuously, rather than requiring discrete, sequential measurements at individual points. This continuous action dramatically reduces measurement time while maintaining comprehensive accuracy.
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
Facilitates efficient and accurate measurement of gap dimensions, enabling the precise selection and installation of shims, thereby reducing assembly time and improving the reliability of aerospace structures.
Implementation Method 1
The transmitting system is configured to drive direct electrical current across the transmission induction coils to produce transmitted probe signals from the transmission induction coils
Implementation Method 2
The receiving system is configured to receive response signals from the reception induction coils due to the transmitted probe signals
Data Source
AI summary
An electronic feeler gauge comprises a sensor blade, a transmitting system, and a receiving system. The sensor blade comprises transmission induction coils, reception induction coils, and measurement sites, spaced in two dimensions about the sensor blade. Each of the measurement sites is associated with at least one of the transmission induction coils and at least one of the reception induction coils. The transmitting system is configured to drive modulated signals across the transmission induction coils to produce transmitted probe signals from the transmission induction coils. The receiving system is configured to receive response signals from the reception induction coils due to the transmitted probe signals.