Helical Sensor Mandrel for Bolt Hole Inspection
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Solution Overview
Problem
Current non-destructive evaluation (NDE) techniques face challenges in effectively inspecting challenging material locations such as holes, particularly in determining the condition of bolt holes for safety and maintenance purposes.
Innovation Solution
A system and method utilizing a sensor cartridge with a helical portion to which a sensor array is attached, allowing the sensor to be inserted into or pressed against the wall of a hole. The system includes a scanner for quick connection and change of mandrels for different hole sizes and sensor configurations, along with a data processing algorithm using a signature library for enhanced detection and sizing of features like cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is inserted into a hole for inspection, then the detection capability is improved, but the device complexity increases due to the need for expansion elements and torque application mechanisms
Solution Approach 1:
The sensor system is divided into modular components: a sensor array attached to a helical expansion element, which is separate from the insertion mechanism. This segmentation allows the sensor to be positioned against the hole wall without requiring the entire sensor assembly to be complex, as only the expansion element needs the helical mechanism while the sensor array remains relatively simple.
Solution Approach 2:
The helical expansion element provides dynamic adaptability by allowing the sensor radius to be increased or decreased through applied torque. This dynamic adjustment enables the sensor to fit different hole sizes and apply appropriate pressure against the hole wall, improving detection capability while using a relatively simple mechanical mechanism.
2Measurement precision
If the sensor radius is adjusted by applying torque to the helical portion, then the sensor can be precisely positioned against the hole wall, but the ease of operation decreases due to the manual torque application process
Solution Approach 1:
The helical expansion element is designed to automatically adjust the sensor radius when torque is applied during insertion. The mechanical helical structure converts the insertion motion into radial expansion, allowing the sensor to self-position against the hole wall without requiring separate manual adjustment mechanisms, thereby maintaining ease of operation while achieving precise positioning.
3Productivity
If a scanner with quick connection capability is used to switch between different mandrels, then the productivity is improved, but the device complexity increases due to the connection and change mechanisms
Solution Approach 1:
The scanner is designed with a universal quick-connection interface that can accommodate multiple different mandrels with varying hole sizes and sensor configurations. This universal interface allows inspectors to quickly switch between mandrels without requiring complex customization mechanisms, improving productivity while keeping the connection system relatively simple and standardized.
Data Source
AI summary
A system and method are provided for inspecting challenging material locations such as holes. The system may include a sensor cartridge (“mandrel”) for hole inspection that has a helical portion to which a sensor array is attached. The radius of the helical portion can be increased or decreased by applying a torque to the helical portion thereby allowing the sensor to be inserted into a hole or pressed against the wall of the hole. A scanner is described to which mandrels can be quickly connected and changed enabling an inspector to quickly switch between different mandrels (e.g., for different holes sizes and sensor configurations). Also disclosed is an inspection procedure and data processing algorithm for performing an inspection. The data processing algorithm utilizes a signature library for enhancing the detection or sizing of features of interest such as cracks. The algorithm and library can account for material edges, various material types.