Hinged Aperture Gauge for Hole-Countersink Alignment

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Solution Overview

Problem

Existing manufacturing processes for forming holes and countersinks in workpieces often result in non-concentric centerlines, leading to alignment issues that do not meet predetermined tolerances.

Innovation Solution

A gauge is provided with a body featuring a hole gauge portion and a countersink gauge portion connected by a hinge, allowing relative movement, and an indicator to determine if the angularity between the hole and countersink centerlines is within a predetermined tolerance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If separate drilling processes are used to form holes and countersinks, then manufacturing flexibility is improved, but manufacturing precision deteriorates due to non-concentric centerlines

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidcenterline alignment

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The gauge serves as an intermediary measurement tool that bridges the hole and countersink to detect centerline misalignment. It includes a hole gauge portion inserted into the hole and a countersink gauge portion engaged with the countersink, connected by a hinge mechanism that allows relative movement while maintaining measurement capability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The gauge provides visual feedback through an indicator that shows whether the centerlines are within predetermined tolerance. The indicator moves relative to a scale or reference mark based on the angularity between the hole and countersink, giving immediate feedback on alignment quality

Inventive Principle:

Principle #23Feedback

2Stability of the object's composition

If a rigid gauge structure is used, then structural stability is improved, but adaptability deteriorates due to inability to accommodate centerline variations

Engineering Contradiction:

Improvestructural stabilityVSAvoidtolerance to centerline misalignment

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The hinge connection between the hole gauge portion and countersink gauge portion introduces dynamic capability to the gauge. This allows the countersink gauge portion to move relative to the hole gauge portion, enabling the gauge to adapt to centerline misalignments while maintaining structural integrity through controlled movement rather than rigid fixation

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20260078994A1Gauge for inspecting an aperture of a workpiece and a method

Publication Date: 2026.03.19 THE BOEING CO

AI summary

A gauge for inspecting an aperture of a workpiece includes a body having a hole gauge portion configured to be disposed in a hole portion of the aperture and a countersink gauge portion configured to be disposed in a countersink portion of the aperture. The gauge includes a hinge connecting the hole gauge portion and the countersink gauge portion to allow the countersink gauge portion to move relative to the hole gauge portion. The gauge includes an indicator coupled to the body. The indicator is configured to indicate whether a predetermined tolerance is obtained between the countersink portion and the hole portion of the aperture. A method of determining a predetermined tolerance of an aperture of a workpiece uses the gauge.