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TOOL DETECTION SYSTEM A misplaced tool can be the greatest threat to aircraft safety and flight readiness.

The AEROPROBE Tool Detection System is a potent weapon in the fight against tool Foreign Object Damage (FOD) in the aircraft manufacturing or maintenance environment .
The total responsibility for aircraft safety and reliability rests on the aircraft technician teams shoulders. The pressure of quickly returning an aircraft to the flight line is often intense on maintenance personnel, whether military or commercial and that pressure can lead to mistakes. Errors like misplacing a tool can keep an aircraft grounded; for critical extra hours; until that tool is found. The Aeroprobe has been developed by and for aircraft technicians to reduce the time spent locating misplaced tools which, if not found, could lead to serious damage. Since the Aeroprobe can quickly detect tools lodged in critical areas where visual inspection isnt possible, down time and risk of tool FOD is greatly reduced. With minimal training, Aeroprobe can be integrated into your present aircraft technicians safety program to minimize aircraft downtime and danger of tool FOD. If aircraft safety is your responsibility, Aeroprobe can relieve some of the pressure of your job, helping you keep your aircraft in the sky.

Designed to supplement visual inspection, the AEROPROBE is a totally integrated

system for locating misplaced tools in and around aircraft. It consists of the following:

The activator sensitizes the existing technicians hand tools. No special tools need to be purchased, nor do tools need to be sent away to be treated. The technician simply passes the tools over the activator and they are treated. The activator comes in a foam padded high impact case as shown in the picture to the left.

The Validator is used to verify that a tool has sufficient sensitivity for detection.


The detector is a state of the art portable electronic unit used to pinpoint the location of misplaced tools. It is powered by both rechargeable batteries, and a back up system of replaceable standard 9 volt batteries. The sensing Probe is lightweight, small enough to fit into confined areas, yet provides wide area scanning capability.

A quality headset is used to receive the audio signal from the Detector indicating the presence of a sensitized tool. This headset will normally block out most background noise and still allow the operator to detect the tool.


The Detector Carrying Case is made of a strong weather resistant material with a removable clear vinyl cover so that the Detector can be used in most any condition. The case straps to the operators waist with an adjustable web belt, and has a storage pocket for the Probe when the unit is not in use.


The Detector storage case is made of a high impact polyethylene material. Each component of the Aeroprobe is protected in a pre cut foam pocket for maximum storage and shipping protection. The case holds the balance of the components of the Aeroprobe including the detector, probe, headset, cords and validator for easy transport.


Formerly FOD Technology.

P.O. Box 1057, Rohnert Park, CA 94927 (707) 478-8136, Service/Sales (800) 648-0656 FAX (707) 584-1955

BENEFITS OF USING THE AEROPROBE TOOLFINDER The following are some of the benefits our customers have indicated they have derived after implementing the Aeroprobe() Tool Detection system.

"SAVED MANPOWER HOURS SEARCHING FOR MISPLACED TOOLS" Numerous hours can be expended searching for misplace tools. With the human factor in maintaining aircraft, it is inevitable mechanics will misplace hand tools. One installation reported at least a 60% drop in man hours searching for tools. "REDUCES DOWNTIME OF AIRCRAFT" An FA-18 aircraft was delivered to a new location and the paperwork indicated a two week search had been conducted earlier for a possible missing tool. The crew at the new location used the AEROPROBE and the tool was located within 10 minutes. "TOOLFINDER PREVENTED TEAR DOWN During a change out of a fuel cell on a FA-18A a mechanic dropped a 2" fastener removal tool in the fuselage in the wing joint area. To retrieve it many components would have to be disassembled at an estimated time of 50 to 60 hours. To stay on schedule and to get the job done the maintenance officer used the AEROPROBE from outside the aircraft to pinpoint the location of the tool through the cowling. Using the AEROPROBE , the technician then guided a magnetic tool retriever to the location of the dropped tool. The tool was recovered using this technique within 1.5 hours. A savings of 50 + hours of substantial tear down of the aircraft and saved critical aircraft downtime. "PREVENTS DAMAGE TO AIRCRAFT" At the end of a day shift an inventory was performed and it was determined that a 4" phillips head screwdriver was missing. Flight line maintenance was performed on a number of aircraft that day, so all personnel were required to perform a standard misplaced tool search. After a short time the maintenance officer directed a team to use the AEROPROBE tool finder. With the AEROPROBE , they located the tool that was hidden from sight behind the Z bar located inside the engine bay door on a F404 engine in Just 5 minutes! The estimated cost avoidance to the engine was $2.5 million.

PO Box 1057, Rohnert Park, CA 94927 (800) 648-0656 E-mail

P.O. Box 1057, Rohnert Park, CA 94927 (800) 648-0656 FAX (707) 584-1955


Recommended Usage The proper use of the Aeroprobe audible tool detection system can enhance existing tool control and accountability programs. The Aeroprobe Tool Detection System should be made available for use by any aircraft maintenance technician, as availability can compromise accountability. Use the Aeroprobe early in the tool search and save valuable time, increase your find rate, and prevent tool FOD. The Toolfinder augments a tool search by providing the audible search capability for locating hard to find tools hidden in or behind aircraft structures or tools that blend in making them hard to see. The Aeroprobe is used to find misplaced tools in cockpits, engines, airframe and AGE equipment . Additionally, use the Aeroprobe to assist in tool recovery/extraction or to locate unwanted magnetism for degaussing. Detection Process The Aeroprobe tool Detection System employs a highly sensitive gradiometer designed to detect magnetically conditioned tools while ignoring most aircraft structures. Detect tools through aircraft structures. Scan large areas of a fuselage or wing quickly or probe cavities in the cockpit or engine to detect hidden-hard to see tools. Most aircraft structures and components are non ferrous, such as titanium, aluminum, magnesium, composites and etc. and do not retain a magnetic field nor will they shield the magnetic field given off by a treated tool. While looking for a tool, the operator may encounter varying amounts of magnetic clutter ( existing magnetic fields) produced by ferrous materials and magnetic components on the aircraft. In these areas the operator would decrease probe sensitivity to maximize directional detection. With some practice an operator can detect the difference between most tools and other inherent or stray magnetic clutter on the aircraft. When in doubt use the process of elimination. The skill of the operator will increase with experience. Magnetism Approximately 98% of routine aircraft technicians hand tools have Ferro magnetic properties. Tests on a number of rollaway tool boxes found that on average 20% to 50% of the tools had a measurable amount of magnetism of .5 gauss or more. Because of this, the Aeroprobe has located tools on aircraft where none of the tools had been previously treated. To ensure maximum detection, all tools are passed over the Aeroprobe Activator so that all the tools will have a slight magnetic field. Most treated tools will hold the charge indefinitely; however, since the normal usage of tools may result in some loss of magnetism or some tools may be of inferior quality, it is recommended that the Validator be used to check the sensitivity of the tools during your semi-annual inspection. Any tool not registering a good charge should be re-activated or replaced with a quality tool. Since aircraft avionics components are shielded by design to operate in intense electromagnetic fields (i.e. Lightning strikes; MIL-STD-461, RTCA160C), the relatively low level of magnetism in activated tools should not have any harmful effects on sensitive aircraft equipment. We do not recommend the use of activated tools where strictly prohibited such as an avionic shop..


Implementation Proper implementation of the Aeroprobe is very important!! Installations that are receiving maximum benefit from the use of the Aeroprobe system have found that: 1. Every maintenance or manufacturing activity should have at least one system or more depending on the size of the facility. 2. Maintenance personnel must be made aware of the use and availability of the Aeroprobe. 3. The Aeroprobe should be used soon after visual and tactile senses fail to find a misplaced tool (10 to 15 minutes). 4. Management must establish standard operating procedures for the use of the Aeroprobe. 5. Aircraft technicians and supervisors should be certified at least annually by viewing the training video, reviewing the operation manual and working with the Aeroprobe for a given amount of time. Range Of Operation The range of detection by the Aeroprobe varies depending on the strength of the field emitted from the tool. The strength of the field is determined by the size, shape and carbon content of a tool. Although larger or high carbon tools have been detected up to 30, the average working range of the probe is 16. Smaller tools may have a detection range within 4 to 10 inches depending on the quality of the tool. It is important to note that the probe detects in all directions from the full length of the probe (see the shaded area of diagram # 1). The Aeroprobe offers the critical advantage of allowing the operator the ability to hear a tool that is hidden among or behind components and other structures.
Diagram # 1 Depicts the average detection area (cu. in.) of the Probe. Note for a 6 detection that the area is the shape of a rounded end tube approx. 12 in diameter by 24 long.

Approx. 44


6 6 24 Approx. 32 Approx.


LENGTH WISE SECTION Showing area of detection for 6 radius & 16 radius

CROSS SECTION Showing area of detection for 6 radius & 16 radius

P. O. Box 1057, Rohnert Park, CA 94927 (800-648-0656) - FAX (707) 584 -1955

P.O. Box 1057, Rohnert Park, CA 94927

(800) 648-0656 FAX (707) 584-1955


The Aeroprobe Tool Detection System is a portable electronic self contained gradiometer (magnetic detection system), with a working range of up to 16 inches. It is designed to quickly locate misplaced aircraft mechanics hand tools. An Activator is included in the system to assure that all the hand tools have a slight magnetic signature. The following is the TECHNICAL DATA on the components in the Aeroprobe Tool Detection System: ACTIVATOR AC-2 Dimensions ............................... 14 x 9 1/2 x 3 Weight ...................................... 11 lbs. Activation of tools is done by a ferrite magnet block that has a fairly uniform field strength across the surface of 300-400 gauss with a maximum strength along the outer edges where the gauss readings approximate 1100 gauss. Ferrite was selected because of its ability to impart magnetism to items with lesser magnetic characteristics without loosing its own magnetism. Typically, this magnetic material loses its magnetism at a rate of 1/2 of 1% every 50 years. The measurable magnetic intensity blends to that of earths ambient magnetism at distances greater than 12 to 14 from the activators suitcase. VALIDATOR VL-1 Dimensions................................ 2 1/2 diameter x 1 1/4 height Weight ...................................... .15 lbs. Power requirements ............... none DETECTOR DT-3 Dimensions............................... Weight ...................................... Power supply ........................... Internal .............. 8 1/2x 2 1/2x9 1/4 3.5 lbs. 18 volt DC Battery board with 4 NI-CAD 9 volt DC batteries. Allows unit to operate from internal power source. Circuit protection built in to monitor battery drain and peak charge point. 2 Alkaline 9 volt DC. Housed in rear panel. Internal fully charged = 7 hours or longer External fresh batteries = 7 hours or longer A/C 120 Volt, 60 Hz (standard) A/C 240 Volt, 50 Hz (optional)

External ............ Operation Time

Charging system .....................

AEROPROBE TECHNICAL DATA (CONTINUED) Interface .... Probe ............... Headset ............ Battery Charge External Power Display Battery Charge Status Charge ........... Audio connector, 3 pin. 1/4 Stereo jack IEC 320/VI A/C connector, 3 prong Dual Drawer 9 volt DC battery LED bar graph 10 segment multicolor 3 Red (low), 4 yellow, 3 green (high) LED, Green. Illuminates during internal battery charging. Blinking when batteries are fully charged. LED, Red. Illuminates while unit is powered on via internal or external batteries 2 LEDs, Yellow, Illuminates LEFT LED If left external battery is installed incorrectly relative to positive and negative terminal. Illuminates RIGHT LED if left external battery is installed incorrectly relative to positive and negative terminals. High Impact Plastic Operation -15 to 55 C 10% to 95% Storage -20 to 60C 10% to 95%(non-condensing)

Power ............. Aux. Battery Reversed

Enclosure ............................. Environmental .................... Ambient Temperature Ambient Humidity

PROBE ASSEMBLY PR-2 Dimensions............................ 15 3/4 Length x 3/4 diameter Weight .................................. .75 lbs. Sensing Coil ........................ 384 Hz (Passive) HEADSET HS-1 Weight .................................. Format .................................. Impedance ........................... Noise Reduction Rating ...... BELT CARRYING HARNESS Material ................................. Weight ................................... Belt sizes .............................. SHIPPING CASE SC-3 Dimensions............................ Weight ................................... Material ................................

1.2 lbs. Stereo 8 OHMS 24 DB BH-1 vinyl coated nylon .55 lbs. 48 maximum

20 1/4 x 8 1/4 x 17 1/2 11.5 lbs. High impact polyethylene


To Our Partners in FOD Prevention, Thank you for your interest in the Aeroprobe tool detection/recovery system. Please find enclosed for your review, product information regarding this unique audible tool locator/extractor system. The eternal problem of aircraft technicians misplaced and unaccounted lost tools cost assembly and maintenance operations in productivity, quality, resources and safety. The Aeroprobe technology is designed to enhance a tool control program. Adding the capability to hear a lost tool and recover it quickly is invaluable. Those using this technology have reported substantial contributions to quality production and the safety goals of 0 accident and Operational Risk Management (ORM) programs, by aggressively targeting this prevention effort at the human factor of human error. In aircraft maintenance and assembly an unrecovered lost tool can tell a chilling story of the extreme costs of tool FOD. Now, empowered with this tool recovery technology, tool search operators using the Aeroprobe system have not only found lost tools but saved costly tool search time, downtime, tear down and serious tool FOD damage! During a misplaced / lost tool search, the real advantage of using the audible tool recovery system is adding the capability of hearing a misplaced/ lost tool, even through the skin of an aircraft. Where a visual and tactile search may fail, the audible capability can quickly draw attention to a specific area of a misplaced tool. With the human factor at the foundation of maintaining the highly technical and expensive aircraft of today, tools will be dropped, misplaced and unrecovered. Management, with this technology, can now empower technicians to reduce costs, and enhance quality, production efficiency and accountability by providing a front-line defense against human error. That helps keep your scheduled aircraft-flying tool FOD free. As one customer stated, If the use of the Aeroprobe (Tool Recovery System) saves one life or aircraft it has paid for itself many times fold. If aircraft safety and production efficiency are your concerns why not join other proactive customers that are doing everything they can to help the professional technician keep production on target and help ensure safe airworthy aircraft. For further product information or application assistance please call me at (800) 648-0656. Sincerely, Gene Mitchell Adducent Technology, Inc.