Fiber Optic Hole Scanning for Interface Gap Measurement
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Solution Overview
Problem
Determining the size of gaps within interface regions in fabricated parts, particularly in aerospace components, is complicated, time-consuming, and operator-dependent, especially when measuring multiple holes, as current methods involve manual insertion of feeler gauges.
Innovation Solution
Utilizing a hand tool with a fiber optic probe and actuator to perform Low-Coherence Interferometry, automatically scanning the hole walls to detect interface gaps, sealant, and Foreign Object Debris, and reporting gap dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual feeler gauge insertion is used to measure interface gaps, then measurement capability is achieved, but measurement time and labor intensity increase significantly
Solution Approach 1:
The patent replaces manual mechanical feeler gauge insertion with an automated optical measurement system. The system uses optical sensors and image processing to automatically detect and measure interface gaps, eliminating the need for manual insertion of physical gauges and significantly reducing measurement time while maintaining precision.
Solution Approach 2:
The measurement system performs self-measurement by automatically capturing images of the interface region, processing the images to identify gap locations and dimensions, and generating measurement results without requiring operator intervention for each individual measurement point.
2Reliability
If visual inspection of multiple holes is performed, then gap detection is possible, but time consumption and operator dependency increase
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical inspection system that uses cameras or optical sensors to capture images of multiple holes simultaneously. Image processing algorithms automatically analyze the images to detect interface gaps, eliminating operator dependency and significantly reducing inspection time while maintaining or improving detection reliability.
Solution Approach 2:
The system enables continuous measurement across multiple holes by automatically moving between measurement points or capturing multiple views in sequence without requiring operator repositioning or manual intervention between measurements, thereby maintaining continuous productive action throughout the inspection process.
3Manufacturing precision
If iterative feeler gauge insertion is performed to find appropriate shim size, then gap measurement is achieved, but measurement complexity and operator skill dependency increase
Solution Approach 1:
The patent replaces the iterative mechanical process of inserting feeler gauges of different sizes with a single optical measurement that directly captures the gap dimension. The optical system measures the gap size in one operation, eliminating the need for iterative trial-and-error insertion and providing immediate, accurate shim size requirements without increasing process complexity.
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 reliable and efficient measurement of interface gaps, reducing labor and time required, and providing accurate data for fastener installation without manual shim insertion.
Implementation Method 1
perform Low-Coherence Interferometry
Data Source
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AI summary
Systems and methods are provided for inspection. One embodiment is a method for 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.