Sensor Head for Locating Fasteners Under Coatings

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Solution Overview

Problem

Current methods for locating fasteners under thick aircraft coatings, such as low observable and anti-erosion coatings, are imprecise and time-consuming, often leading to costly errors and delays due to the subtlety of coating depression and the need for expensive infrared equipment and training.

Innovation Solution

A fastener locating tool equipped with a sensor head and probes that generate electrical signals to detect the presence of fasteners, allowing for precise alignment and marking or removal of coatings, either manually or automatically, using a rotatable or multi-probe design that can be integrated with robotic systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the poke test method is used to locate fasteners under thick coating, then the maintainer can physically search for fasteners, but the method is imprecise and may lead to removing coating in the wrong area

Engineering Contradiction:

Improveease of fastener locationVSAvoidprecision of fastener location

Core Design Contradiction:

Ease of operationVSMeasurement precision

Solution Approach 1:

The patent replaces the mechanical poke test method with an electromagnetic sensing system. The sensor head with probes detects fasteners through electromagnetic interaction with the conductive fastener material, eliminating the need for physical poking and providing precise electronic detection instead of subjective tactile feedback.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a sensor head as an intermediary between the maintainer and the hidden fastener. The sensor head contains probes that generate electromagnetic fields to detect the fastener's presence and position, serving as a mediator that translates invisible subsurface features into detectable signals without direct physical contact with the fastener.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If infrared imaging system is used to detect hidden fasteners, then the fasteners become visible on the infrared readout, but the method requires expensive equipment and training

Engineering Contradiction:

Improveprecision of fastener locationVSAvoidcomplexity of detection equipment

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent employs a relatively simple, portable sensor head that can be easily manufactured and deployed without the need for expensive infrared imaging systems. The sensor head is a cost-effective solution that provides sufficient detection capability for maintenance operations without requiring major equipment investments.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The sensor head is designed to be self-contained and portable, allowing maintenance personnel to perform fastener location independently without requiring complex equipment setups or specialized training. The device operates autonomously, generating its own electromagnetic signals and processing detections on-site.

Inventive Principle:

Principle #25Self-service

3Ease of operation

If coating is removed to access fasteners, then the fasteners become accessible, but incorrect location may adversely impact underlying structure

Engineering Contradiction:

Improveaccessibility of fastenerVSAvoiddamage to underlying structure

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent performs preliminary detection of fastener location using the sensor head before any coating removal takes place. The electromagnetic sensing identifies the precise position of fasteners subsurface, allowing maintenance personnel to plan and execute coating removal accurately, thereby preventing damage to underlying structure from incorrect fastener location.

Inventive Principle:

Principle #10Preliminary action

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

The tool provides a reliable and repeatable method for accurately locating fasteners without damaging the underlying structure, reducing re-work and repair costs, and enabling efficient maintenance operations.

Implementation Method 1

the sensor head includes at least one probe which is configured to generate electrical signals which indicate the presence of a fastener beneath a coating when the probe is within a detection range of the fastener

Methodology Applied

Scientific EffectElectrical signal transduction:

Data Source

PatentUS11747127B2Tool for precise locating of fasteners under coatings

Publication Date: 2023.09.05 THE BOEING CO

AI summary

A fastener locating tool equipped with a sensor head having one or more probes and a method for operating such a tool for precisely locating a fastener that is hidden or buried under a thick coating applied on a surface of a structure. The fastener locating tool may be manually or automatically operated. The fastener locating tool includes a platform having a central opening, means for temporarily attaching the platform to a coated surface, and a sensor head that may be easily mechanically coupled to and then later decoupled from the platform. Optionally, the fastener locating tool also includes a multi-stage positioning system with X and Y stages which may be used to adjust the position of the sensor head. The sensor head includes at least one probe which generates electrical signals indicating the presence of a fastener beneath a coating when the probe is within a detection range.