Fiber Optic Hole Probe for Automated Interface Gap Measurement
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Solution Overview
Problem
Current methods for measuring interface gaps between sheets of material, especially in aerospace parts, are time-consuming and labor-intensive, requiring manual insertion of feeler gauges and are challenging for parts with tight tolerances and curved surfaces.
Innovation Solution
Automated systems using insertable probes for interferometry to measure interface gaps between sheets of material, synchronized with automated hole drilling and fastener insertion, enabling efficient and accurate gap measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual feeler gauge measurement is used, then measurement capability is achieved, but time consumption and labor intensity increase significantly
Solution Approach 1:
The patent replaces manual mechanical feeler gauge insertion with an automated optical measurement system using a robot and interferometry probe. The system uses optical interference patterns to automatically detect and measure gap sizes, eliminating the need for manual mechanical gauge insertion and reading, thereby dramatically increasing measurement speed while maintaining precision
Solution Approach 2:
The measurement system is designed to autonomously perform gap detection and measurement without human intervention. The robot automatically positions the probe, the interferometry system automatically captures measurements, and the system self-calibrates using reference surfaces, making the entire process self-service and eliminating labor-intensive manual operations
2Measurement precision
If visual inspection of gaps is performed, then gap detection is possible, but physical clearance requirements and time consumption increase
Solution Approach 1:
The patent replaces visual inspection with optical interferometry. Instead of requiring physical access and visual observation of gaps, the system uses light interference patterns to detect gap presence and measure dimensions. This substitution eliminates the need for physical clearance for viewer access while maintaining detection capability
Solution Approach 2:
The patent introduces light as an intermediary medium to detect gaps. Rather than requiring direct visual access to the gap, light waves are used to probe the gap space, and the interference patterns created by light reflecting from gap surfaces provide measurement data. This intermediary approach allows measurement without physical clearance for human viewing
3Productivity
If automated interferometry measurement is implemented, then measurement time and labor are reduced, but system complexity increases
Solution Approach 1:
The patent integrates multiple functions into a single automated system. The robot performs both drilling operations and measurement operations, while the interferometry system serves as both a measurement device and a calibration reference system. This multi-functionality reduces the need for separate dedicated equipment, thereby managing complexity while maintaining high productivity
Solution Approach 2:
The system incorporates feedback mechanisms where measurement data is immediately processed and used to adjust subsequent operations. The interferometry measurements provide real-time feedback on gap conditions, which feeds back into the manufacturing process for quality control and adjustment, creating a closed-loop system that manages complexity through intelligent control
4Measurement precision
If feeler gauge iteration method is used, then shim size determination is achieved, but skill dependency and time consumption increase
Solution Approach 1:
The patent replaces the iterative mechanical feeler gauge method with a single-shot optical measurement system. The interferometry probe directly measures gap dimensions in one operation, eliminating the iterative process of trying different gauge sizes. This substitution provides immediate, precise measurement data for shim size determination without time-consuming iteration
Solution Approach 2:
The system performs preliminary calibration using reference surfaces before actual measurement. This preliminary action establishes accurate measurement baselines, ensuring that subsequent gap measurements are precise from the first measurement, eliminating the need for iterative adjustments and skill-dependent calibration that characterize the feeler gauge method
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
Significantly reduces the time and labor required for gap measurement, increases production efficiency, and allows for precise measurement of gaps in complex geometries like aircraft fuselage sections.
Implementation Method 1
utilizing insertable probes that perform interferometry in order to determine the sizes of gaps between sheets of material
Data Source
AI summary
Systems and methods are provided for inspection. One embodiment is a method for automatically measuring a hole. The method includes driving a fiber optic probe into the hole, determining a profile by scanning the hole via the fiber optic probe, and determining whether an interface gap exists at the hole based on the profile.