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EP-4741760-A1 - SYSTEMS AND METHODS FOR DETERMINING BORE CHARACTERISTICS OF A HOLE

EP4741760A1EP 4741760 A1EP4741760 A1EP 4741760A1EP-4741760-A1

Abstract

A system for determining bore characteristics of a hole includes a measuring tool and a controller. The measuring tool is configured to measure a hole and generate data representing the hole. The controller is in communication with the measuring tool and is configured to determine at least one of the bore characteristics based on the data from the measuring tool.

Inventors

  • SISCO, FARAHNAZ
  • CHAN, KWOK TUNG
  • HOLLINGSHEAD, Michael
  • DEVLIN, Jeff
  • MCRAE, Nathan

Assignees

  • The Boeing Company

Dates

Publication Date
20260513
Application Date
20250922

Claims (15)

  1. A system (100) for determining bore characteristics (200) of a hole (300), the system (100) comprising: a measuring tool (102) configured to measure the hole (300) and generate data (110) representing the hole (300); and a controller (104) in communication with the measuring tool (102) and configured to determine at least one of the bore characteristics (200) based on the data (110) from the measuring tool (102).
  2. The system (100) of Claim 1, further comprising a user interface (108) in communication with the controller (104) and configured to visually display the at least one of the bore characteristics (200).
  3. The system (100) of Claim 1 or 2, wherein the measuring tool (102) comprises: an optical probe (114) configured to be positioned within the hole (300), scan a wall (302) of the hole (300), and generate the data (110); and a probe drive (116) configured to translate and rotate the optical probe (114) within the hole (300); and optionally wherein the optical probe (114) comprises a laser interferometer (120).
  4. The system (100) of Claim 3, wherein the probe drive (116) comprises: a linear drive (132) that positions the optical probe (114) along a scan axis (130); and a rotary drive (134) that positions the optical probe (114) about the scan axis (130); and optionally wherein the linear drive (132) comprises: a motor (142); a transmission (144) that transfers motion from the motor (142) to the optical probe (114); a pair of limiting switches (146); and an encoder (148) that measures a linear position of the optical probe (114).
  5. The system (100) of Claim 3, wherein: the measuring tool (102) further comprises: a housing (112); and a collet (118) coupled to the housing (112) and configured to engage a portion of the hole (300); and the optical probe (114) extends through the collet (118); and optionally wherein the measuring tool (102) further comprises: a sleeve (122) that couples the collet (118) to the housing (112); a mandrel (124) that moves relative to the collet (118) to expand the collet (118); and an actuator (126) that positions the mandrel (124) relative to the collet (118).
  6. The system (100) of Claim 5, wherein the measuring tool (102) further comprises a plurality of collets (128) that are configured to be interchangeably coupled to the housing (112).
  7. The system (100) of Claim 5, wherein the controller (104) is configured to: generate a three-dimensional point cloud (150) comprising XYZ-coordinates (152) and reflective intensity (154) of the wall (302) of the hole (300) and a portion of the collet (118) positioned in the hole (300); perform a transformation of the three-dimensional point cloud (150) with a model (156) of the collet (118); and determine at least one of the bore characteristics (200) based on the three-dimensional point cloud (150) as fit to the model (156) of the collet (118); and optionally wherein the bore characteristics (200) comprise at least one of a diameter (202) of the hole (300), an offset (204) of the hole (300), a gap (206) at an interface (320) of the hole (300), a length (208) of the hole (300), a bore straightness (212), and a bore orientation (214).
  8. The system (100) of Claim 6, wherein the bore characteristics (200) further comprises at least one of a smoothness (216) of the hole (300), debris (218) at an interface (320), and sealant (222) at the interface (320).
  9. A measuring tool (102) for measuring a hole (300), the measuring tool (102) comprising: a housing (112); a collet (118) coupled to the housing (112) and configured to engage a portion of the hole (300); an optical probe (114) configured to extend through the collet (118) and into the hole (300), scan a wall (302) of the hole (300), and generate data (110) representing the wall (302) of the hole (300); a linear drive (132) that positions the optical probe (114) along a scan axis (130); and a rotary drive (134) that positions the optical probe (114) about the scan axis (130).
  10. A method (1000) for determining bore characteristics (200) of a hole (300), the method (1000) comprising: extending an optical probe (114) into the hole (300) along a scan axis (130); rotating the optical probe (114) within the hole (300) about the scan axis (130); scanning a wall (302) of the hole (300); generating data (110) representing the wall (302) of the hole (300); and determining at least one of the bore characteristics (200) based on the data (110).
  11. The method (1000) of Claim 10, wherein scanning comprises performing laser interferometry.
  12. The method (1000) of Claim 10, wherein generating comprising generating a three-dimensional point cloud (150) comprising XYZ-coordinates (152) and reflective intensity (154) of the wall (302) of the hole (300).
  13. The method (1000) of Claim 12, further comprising: positioning a portion of a collet (118) in the hole (300); expanding the collet (118); engaging the wall (302) of the hole (300) with the collet (118); scanning a portion of the collet (118) positioned in the hole (300); and generating the data (110) representing the portion of the collet (118); and optionally wherein determining comprises: processing the data (110) using a dynamic starting origin operation; and further processing the data (110) using a coordinate solving operation.
  14. The method (1000) of Claim 13, further comprising compensating for environment (252); or optionally
  15. The method (1000) of Claim 13, wherein determining comprises: processing the data (110) using a dynamic starting origin operation; and further processing the data (110) using a coordinate solving operation; and wherein determining comprises determining at least one of a diameter (202) of the hole (300), an offset (204) of the hole (300), a gap (206) at an interface (320) of the hole (300), a length (208) of the hole (300), a bore straightness (212), a bore orientation (214), a smoothness (216) of the hole (300), debris (218) at the interface (320), and sealant (222) at the interface (320).

Description

PRIORITY This application claims priority from U.S. Ser. No. 63/718,799 filed on November 11, 2024. FIELD The present disclosure relates generally to manufacturing and inspection and, more particularly, to systems and methods for determining bore characteristics of a hole formed through a fabricated part. BACKGROUND Parts fabricated from a stackup of material layers, such as composite materials, metallic materials, or polymeric materials, are often affixed together using fasteners that extend through aligned holes in the material layers. However, such material stacks may exhibit misaligned holes, gaps in interface regions, or other nonconformities. While such nonconformities may be small, even small nonconformities may be out of tolerance, depending on the intended field of use of the resulting part. For example, aerospace parts may have particularly tight tolerances. Hence, identifying and addressing such nonconformities may be desirable. Unfortunately, identifying such nonconformities and determining bore characteristics of the holes remains complicated and time-consuming. Accordingly, those skilled in the art continue with research and development efforts in the field of inspection and analysis during manufacturing and assembling of parts. SUMMARY Disclosed are examples of a system for determining bore characteristics of a hole, a measuring tool for measuring a hole, and a method for determining bore characteristics of a hole. The following is a non-exhaustive list of examples, which may or may not be claimed, of the subject matter according to the present disclosure. In an example, the disclosed system includes a measuring tool and a controller. The measuring tool is configured to measure a hole and generate data representing the hole. The controller is in communication with the measuring tool and is configured to determine at least one of the bore characteristics based on the data from the measuring tool. In another example, the disclosed measuring tool includes a housing, a collet, an optical probe, a linear drive, and a rotary drive. The collet is coupled to the housing and is configured to engage a portion of the hole. The optical probe is configured to extend through the collet and into the hole, scan a wall of the hole, and generate data representing the wall of the hole. The linear drive positions the optical probe along a scan axis. The rotary drive positions the optical probe about the scan axis. In an example, the disclosed method includes steps of: (1) extending an optical probe into a hole along a scan axis; (2) rotating the optical probe within the hole about the scan axis; (3) scanning a wall of the hole; (4) generating data representing the wall of the hole; and (5) determining at least one of a plurality of bore characteristics based on the data. Other examples of the system, the measuring tool, and the method will become apparent from the following detailed description, the accompanying drawings, and the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic block diagram of an example of a system for determining bore characteristics of a hole;Fig. 2 is a flow diagram of an example of a method for determining bore characteristics of a hole;Fig. 3 is a schematic illustration of an example of the system;Fig. 4 is a schematic illustration of an example of a measuring tool of the system;Fig. 5 is a schematic illustration of an example of a probe drive of the measuring tool in a retracted state;Fig. 6 is a schematic illustration of an example of the probe drive of the measuring tool in an extended state;Fig. 7 is a schematic illustration of an example of a portion of the probe drive;Fig. 8 is a schematic illustration of an example of a portion of the probe drive;Fig. 9 is a schematic, exploded, perspective view of an example of a portion of the measuring tool;Fig. 10 is a schematic, section view of an example of a portion of the measuring tool;Fig. 11 is a schematic illustration of an example of the measuring tool interacting with a hole;Fig. 12 is a schematic illustration of an example of a plurality of interchangeable collets of the measuring tool;Fig. 13 is a schematic diagram of an example of the system;Fig. 14 is an illustration of a point cloud generated based on data collected by the system;Fig. 15 is a schematic illustration of an example of a hole having a gap at an interface;Fig. 16 is a schematic illustration of an example of a hole having an offset;Fig. 17 is a schematic illustration of an example of a hole having debris at an interface;Fig. 18 is a schematic illustration of an example of a hole having sealant at an interface;Fig. 19 is a schematic illustration of an example of a hole having debris at an interface;Fig. 20 is a flow diagram of an example of a dynamic starting origin method;Fig. 21 is a flow diagram of an example of a coordinate solving method;Fig. 22 is a schematic illustration of an example of an aircraft; andFig. 23 is a flow diagram of an exam