Meyer Tool, Inc.

Dwight Evans Kimberlin

Ronald E Forrester

Gregory J Lang

A method for forming a complex hole through a wall of a structure. The complex hole has a smaller cross-sectional area within the wall and an outer portion with a larger cross-sectional area adjacent a first surface of the wall. The complex hole further has an inner portion extending between the smaller cross-sectional area and an inlet opening on a second surface of the wall. The method uses an EDM process to automatically first, form an entry hole in the wall extending from the first surface to a first location inside the wall, and second, form the outer portion of the complex hole in a direction moving from the first location inside the wall toward the first surface, and third, form the inner portion of the complex hole.

Complex hole shaping

A hole inspection system having a light source emitting light over its length and a multi-axes machine having a camera mounted thereon. After the light source is inserted into a cavity intersecting the complex holes, a control commands the multi-axes machine to move the camera to an inspection position associated with one of the complex holes. The control processes substantially only light intensity values received from the camera that represent light shining through the one of the complex holes. Next, a maximum intensity value of light received by the camera from the one of the complex holes is determined. The maximum intensity value is compared to a threshold value, and error data is created that identifies the one of the complex holes in response to the maximum intensity value being less than the threshold value.

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Cincinnati, OH, United States of America

Dwight Evans Kimberlin