Apparatus, system, and method for forming alignment holes from misaligned holes

Abstract

The present invention relates to an apparatus, system, and method for forming aligned holes from misaligned holes. The apparatus includes a reamer having a first portion of a constant diameter and a second, tapered portion. A constant-diameter guide member is attached to the reamer. The tapered portion can be configured to center the reamer and reduce the offset between the apparatus and the centerline of a virtual hole created by the misaligned hole. The constant diameter of the guide member corresponds to the virtual hole, and the constant diameter of the first portion of the reamer corresponds to a clearance hole that is configured to receive an oversize fastener and completely surround the misaligned hole. If the guide member cannot pass through the misaligned hole, an apparatus with a smaller-diameter guide member and a larger-diameter reamer is required to create a clearance hole that completely surrounds the misaligned hole.

Description

Technical Field

[0001] The examples described herein relate to devices, systems, and methods for forming multiple aligned holes from multiple misaligned holes. Background Art

[0002] When multiple objects are joined together, fasteners of various sizes are typically used. Round holes are drilled in each object, and then the objects are placed adjacent to each other such that the corresponding holes overlap. Ideally, the holes through the objects are aligned, and a specified fastener can be inserted through the holes to secure the objects together. However, when the holes through the objects are misaligned, depending on the degree of misalignment, the specified fastener may not be able to be inserted through the holes.

[0003] Common techniques for correcting misaligned holes are to drill a cleanup hole or ream a cleanup hole through the misaligned holes. The cleanup hole is typically centered on one of the misaligned holes and preferably has a diameter large enough to completely surround all of the misaligned holes. Once the cleanup hole has been created, larger fasteners can be used to secure the multiple objects together. Traditionally, the cleanup hole is created on a trial-and-error basis, in which increasingly larger cleanup holes are drilled or reamed until the cleanup hole completely surrounds the misaligned holes. This is a time-consuming process and can also result in a cleanup hole being formed through the multiple objects that is larger than desired. There may be other disadvantages.

[0004] U.S. Patent No. 9,573,209 describes a method for forming a pair of aligned holes. The method includes determining a diameter of a cleanup hole associated with multiple misaligned holes, where the cleanup hole diameter may also correspond to a fastener diameter. Additionally, a tapered reamer is at least partially inserted into a gap defined by the multiple misaligned holes. The tapered reamer has a longitudinal axis and can be configured such that when the tapered reamer is inserted into the gap defined by the multiple misaligned holes, the longitudinal axis is aligned with the center of the cleanup hole. Then, the multiple misaligned holes can be reamed with the tapered reamer to form a cleanup hole defined by multiple aligned holes having the same center and the same diameter.

[0005] U.S. Patent No. 10,213,855 describes a method for forming a plurality of alignment holes. The method includes aligning a first surface defining a first hole with a second surface defining a second hole, wherein the first hole is at least partially aligned with the second hole to form a gap. Measuring a virtual hole diameter, wherein the virtual hole diameter is the diameter of a virtual hole passing through the gap, and the virtual hole diameter is the minimum bisector of the gap. In response to the virtual hole diameter having a first virtual hole diameter, a first clearance hole having a first clearance hole diameter is formed through the gap, wherein the first clearance hole is concentrically aligned with the virtual hole. A first fastener having a first size is inserted into the first clearance hole, and the first surface is attached to the second surface using the first fastener. SUMMARY OF THE INVENTION

[0006] The present disclosure relates to devices, systems, and methods for forming a plurality of alignment holes from a plurality of misaligned holes.

[0007] An example of the present disclosure is a device for forming a plurality of alignment holes from a plurality of misaligned holes. The device includes a reamer. The reamer has a first portion and a second portion, the first portion having a first constant diameter, and the second portion having a first end and a second end. The first end of the second portion is adjacent to the first portion of the reamer. The second portion of the reamer is tapered and has a varying diameter that decreases from the first end to the second end. The device includes a guide member connected to the second end of the second portion of the reamer. The guide member has a second constant diameter.

[0008] The second portion of the reamer can be configured to center the reamer on the centerline of the virtual hole. The tapered portion of the second portion of the reamer can be configured to reduce the offset between the central longitudinal axis of the device and the centerline of the virtual hole. The tapered portion of the second portion of the reamer can include a starting diameter that is greater than the final diameter. The tapered portion of the second portion can be tapered from the final diameter to the starting diameter at an angle between approximately 0.5 degrees and 1.0 degrees on each side.

[0009] The second constant diameter can correspond to a first virtual hole, and the first constant diameter can correspond to a first clearance hole for receiving a first oversize fastener. The second constant diameter can correspond to a second virtual hole, and the first constant diameter can correspond to a second clearance hole for receiving a second oversize fastener. The second constant diameter can correspond to a third virtual hole, and the first constant diameter can correspond to a third clearance hole for receiving a third oversize fastener.

[0010] One example of the present disclosure is a system for forming a plurality of aligned holes from a plurality of misaligned holes. The system includes a first reamer having a first portion and a second portion. The first portion of the first reamer has a first constant diameter. The second portion of the first reamer has a first end and a second end. The first end of the second portion of the first reamer is adjacent to the first portion of the first reamer. The second portion of the first reamer is tapered and has a varying diameter that decreases from the first end to the second end. The system includes a first guiding member connected to the second end of the second portion of the first reamer. The first guiding member has a second constant diameter corresponding to a first virtual hole, and the first constant diameter of the first reamer corresponds to a first clearance hole for receiving a first oversize fastener.

[0011] The system includes a second reamer having a first portion and a second portion. The first portion of the second reamer has a third constant diameter. The second portion of the second reamer has a first end and a second end. The first end of the second portion of the second reamer is adjacent to the first portion of the second reamer. The second portion of the second reamer is tapered and has a varying diameter that decreases from the first end to the second end. The system includes a second guiding member. The second guiding member is connected to the second end of the second portion of the second reamer. The second guiding member has a fourth constant diameter corresponding to a second virtual hole. The third constant diameter of the second reamer corresponds to a second clearance hole for receiving a second oversize fastener. The second oversize fastener has a larger diameter than the first oversize fastener.

[0012] The tapered portion of the second portion of the first reamer can be configured to center the first reamer on the centerline of the first virtual hole. The tapered portion of the second portion of the second reamer can be configured to center the second reamer on the centerline of the second virtual hole. The tapered portion of the second portion of the first reamer can have a first start diameter and a first final diameter. The first start diameter can be substantially the same as the first constant diameter, and the first final diameter can be substantially the same as the second constant diameter. The tapered portion of the second portion of the second reamer can have a second start diameter and a second final diameter. The second start diameter can be substantially the same as the third constant diameter, and the second final diameter can be substantially the same as the fourth constant diameter.

[0013] The second portion of the first reamer can be tapered at an angle between about 0.5 degrees and about 1.0 degrees on each side from the first final diameter to the first start diameter. The second portion of the second reamer can be tapered at an angle between about 0.5 degrees and about 1.0 degrees on each side from the second final diameter to the second start diameter.

[0014] The system can include a third reamer having a first portion and a second portion. The first portion of the third reamer has a fifth constant diameter. The second portion of the third reamer has a first end and a second end. The first end of the second portion of the third reamer is adjacent to the first portion of the third reamer. The second portion of the third reamer is tapered, having a varying diameter that decreases from the first end to the second end. The system can include a third guide member connected to the second end of the second portion of the third reamer. The third guide member has a sixth constant diameter corresponding to a third virtual hole, and the fifth diameter of the third reamer corresponds to a third clearance hole for receiving a third oversize fastener. The third oversize fastener has a larger diameter than the second oversize fastener. The tapered portion of the second portion of the third reamer can have a third start diameter and a third final diameter. The third start diameter can be substantially the same as the fifth constant diameter, and the third final diameter can be substantially the same as the sixth constant diameter. The second portion of the third reamer can be tapered from the third final diameter to the third start diameter at an angle between about 0.5 degrees and about 1.0 degrees on each side.

[0015] An example of the present disclosure is a method for creating an aligned hole from a plurality of misaligned holes. The method includes attempting to insert a first guide member through the plurality of misaligned holes. The first guide member is connected to a first reamer including a first portion and a second portion. The second portion of the first reamer has a first end and a second end. The first end of the second portion is adjacent to the first portion of the first reamer. The first portion of the first reamer has a first constant diameter. The second portion of the first reamer is tapered, having a varying diameter that decreases from the first end to the second end. The first guide member is connected to the second end of the second portion of the first reamer. The first guide member has a second constant diameter corresponding to a first virtual hole diameter, and the first constant diameter of the first reamer corresponds to a first clearance hole for receiving a first fastener. The method includes cutting the first clearance hole through the plurality of misaligned holes with the first reamer as the first guide member is inserted into the plurality of misaligned holes.

[0016] If the first guide member cannot be inserted through the plurality of misaligned holes, the method may include attempting to insert a second guide member into the plurality of misaligned holes. The second guide member is connected to a second reamer that includes a first portion and a second portion. The second portion of the second reamer has a first end and a second end. The first end of the second portion of the second reamer is adjacent to the first portion of the second reamer. The first portion of the second reamer has a third constant diameter. The second portion of the second reamer is tapered and has a varying diameter that decreases from the first end to the second end. The second guide member is connected to the second end of the second portion of the second reamer. The second guide member has a fourth constant diameter corresponding to a second virtual hole, and the third constant diameter of the second reamer corresponds to a second clearance hole for receiving a second fastener. The method may include cutting the second clearance hole through the plurality of misaligned holes with the second reamer as the second guide member is inserted into the plurality of misaligned holes.

[0017] If the second guide member cannot be inserted through the plurality of misaligned holes, the method may include attempting to insert a third guide member into the plurality of misaligned holes. The third guide member is connected to a third reamer having a first portion and a second portion. The second portion has a first end and a second end. The first end of the second portion is adjacent to the first portion of the third reamer. The first portion of the third reamer has a fifth constant diameter, and the second portion of the third reamer is tapered and has a varying diameter that decreases from the first end to the second end. The third guide member is connected to the second end of the second portion of the third reamer. The third guide member has a sixth constant diameter corresponding to a third virtual hole, and the fifth constant diameter of the third reamer corresponds to a third clearance hole for receiving a third fastener. The method may include cutting the third clearance hole through the plurality of misaligned holes with the third reamer as the third guide member is inserted into the plurality of misaligned holes. The method may include inserting a first oversize fastener through the first clearance hole. There are other embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 is a schematic view of an example apparatus for forming a plurality of aligned holes from a plurality of misaligned holes.

[0019] Figure 2 is a schematic view of two components, each having holes that are aligned.

[0020] Figures 3A to 3C is a schematic view showing two misaligned holes.

[0021] Figures 4A to 4C is a schematic view of an example apparatus for forming a plurality of aligned holes from a plurality of misaligned holes.

[0022] Figures 5A to 5CSchematic diagram of a system for forming a plurality of aligned holes from a plurality of misaligned holes.

[0023] Figure 6 Flowchart of an example method for forming a plurality of aligned holes from a plurality of misaligned holes.

[0024] Although the present disclosure is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, it should be understood that the present disclosure is not intended to be limited to the particular forms disclosed. On the contrary, it is intended to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims. Detailed Description

[0025] The embodiments described herein can be used to form a plurality of aligned holes from a plurality of misaligned holes. As used herein, a plurality of misaligned holes refers to two or more holes through which a particular fastener may not be fully insertable due to the misalignment of the holes. As used herein, an oversize fastener is a fastener having a diameter greater than the diameter of a specified fastener that is intended to be inserted through a plurality of holes to fasten two or more components together.

[0026] Figure 1 Schematic diagram of an example device 100 for forming a plurality of aligned holes from a plurality of misaligned holes. Device 100 includes a reamer 101. The reamer 101 has a first portion 110 and a second portion 120. The first portion 110 has a first constant diameter 111. The second portion 120 has a first end 121 and a second end 122. The first end 121 of the second portion 120 is adjacent to the first portion 110 of the reamer 101. The second portion 120 of the reamer 101 is tapered 126 and has a varying diameter 123 - 124 that decreases from the first end 121 to the second end 122. Device 100 includes a guide member 130 connected to the second end 122 of the second portion 120 of the reamer 101. The guide member 130 has a second constant diameter 131.

[0027] The first portion 110 of the reamer 101 has a first length 112. The guide member 130 has a second length 132. The second portion 120 of the reamer 101 is configured to center the reamer 101 on the centerline 205 of a virtual hole VH. The tapered portion 126 of the second portion 120 of the reamer 101 is configured to reduce the offset between the central longitudinal axis 102 of the device 100 and the centerline 205 of the virtual hole VH. The tapered portion 126 of the second portion 120 of the reamer 101 may include a starting diameter 123 that is greater than the final diameter 124. The tapered portion 126 of the second portion 120 tapers at an angle 125 of between approximately 0.5 degrees and approximately 1.0 degrees on each side from the final diameter 124 to the starting diameter 123.

[0028] The second constant diameter 131 may correspond to the first virtual hole VH-A, and the first constant diameter 111 may correspond to the first clearance hole 230A for receiving the first oversize fastener. The second constant diameter 131 may correspond to the second virtual hole VH-B, and the first constant diameter 111 may correspond to the second clearance hole 230B for receiving the second oversize fastener. The second constant diameter 131 may correspond to the third virtual hole VH-C, and the first constant diameter 111 may correspond to the third clearance hole 230C for receiving the third oversize fastener.

[0029] Figure 2 is a schematic view of a system 200 having two components 210, 220, each component having a hole 211, 221, wherein the holes 211, 221 are aligned. The holes 211, 221 form a virtual hole VH having a diameter 240 and a centerline 205. If the holes 211, 221 are aligned, the virtual hole VH has the same respective diameter as each of the holes 211, 221. A fastener designated to connect the two components 210, 220 together can be inserted through the holes 211, 221 to secure the components 210, 220 together. As the degree of misalignment between the two holes 211, 221 increases, the area of the virtual hole VH passing through the multiple holes 211, 221 decreases.

[0030] At a particular degree of misalignment, the designated fastener will not be able to be inserted through the two holes 211, 221. In such a case, a device such as Figure 1 the device 100 of can create a clearance hole that has a diameter surrounding each of the misaligned holes 211, 221. The clearance hole will enable an oversize fastener to be inserted through the clearance hole to secure the two components 210, 220 together. Figure 2 The number, size, location, shape, and / or configuration of the components 210, 220, virtual hole VH, and holes 211, 221 in are shown for illustrative purposes and may vary according to the application.

[0031] Figure 3A is a schematic view showing two misaligned holes 211, 221. For clarity, other parts are not included in the schematic view. The misalignment of the two holes 211, 221 results in the creation of a first virtual hole VH-A that has a diameter 240A smaller than the diameter of each of the two holes 211, 221. The first virtual hole VH-A has a centerline 205A. When the two holes 211, 221 are misaligned to create the first virtual hole VH-A, a first clearance hole 230A is required to surround the two holes 211, 221. The first clearance hole 230A is configured such that a first oversize fastener can be inserted through the first clearance hole 230A.

[0032] Figure 3B is shown with Figure 3A A schematic diagram of two holes 211, 221 shown having a greater degree of misalignment than the two holes 211, 221 is shown. For clarity, other components are not included in the schematic diagram. The misalignment of the two holes 211, 221 results in the creation of a second virtual hole VH-B having a diameter 240B that is smaller than the diameters of the two holes 211, 221. The diameter 240B of the second virtual hole VH-B is also smaller than the diameter 240A of the first virtual hole VH-A. The second virtual hole VH-B has a centerline 205B. When the two holes 211, 221 are misaligned to create the second virtual hole VH-B, a second clean-up hole 230B is required to surround both holes 211, 221. The second clean-up hole 230B is larger than the first clean-up hole 230A. The second clean-up hole 230B is configured to enable a second oversized fastener to be inserted through the second clean-up hole 230B. The diameter of the second oversized fastener is larger than the diameter of the first oversized fastener.

[0033] Figure 3C is shown with Figure 3B A schematic diagram of two holes 211, 221 shown having a greater degree of misalignment than the two holes 211, 221 is shown. For clarity, other components are not included in the schematic diagram. The misalignment of the two holes 211, 221 results in the creation of a third virtual hole VH-C having a diameter 240C that is smaller than the diameters of the two holes 211, 221. The diameter 240C of the third virtual hole VH-C is also smaller than the diameter 240B of the second virtual hole VH-B. The third virtual hole VH-C has a centerline 205C. When the two holes 211, 221 are misaligned to create the third virtual hole VH-B, a third clearing hole 230C is required to surround both holes 211, 221. The third clearing hole 230C is larger than the second clearing hole 230B. The third clearing hole 230C is configured to enable a third oversized fastener to be inserted through the third clearing hole 230B. The diameter of the third oversized fastener is larger than the diameter of the second oversized fastener.

[0034] Figures 4A to 4C is a schematic diagram of an example apparatus for forming a plurality of aligned holes from a plurality of misaligned holes. Figure 4A The apparatus may be used to form a plurality of aligned holes from a plurality of misaligned holes 211 , 221 forming a first virtual hole VH-A. Figure 4B The apparatus may be used to form a plurality of aligned holes from a plurality of non-aligned holes 211 , 221 forming a second virtual hole VH-B that is smaller than the first virtual hole VH-A. Figure 4C The apparatus may be used to form a plurality of aligned holes from a plurality of non-aligned holes 211, 221 forming a third virtual hole VH-C that is smaller than the second virtual hole VH-B.

[0035] Figure 4A FIG. 2 is a schematic view of an exemplary apparatus 100A for forming a plurality of aligned holes from a plurality of misaligned holes. The apparatus 100A includes a first reamer 101A. The first reamer 101A has a first portion 110A and a second portion 120A. The first portion 110A has a first constant diameter 111A. The second portion 120A has a first end 121A and a second end 122A. The first end 121A of the second portion 120A is adjacent to the first portion 110A of the first reamer 101A. The second portion 120A of the first reamer 101A is tapered 126A and has a varying diameter 123A-124A that decreases from the first end 121A to the second end 122A. The apparatus 100A includes a first guide member 130A connected to the second end 122A of the second portion 120A of the first reamer 101A. The first guide member 130A has a second constant diameter 131A.

[0036] The first portion 110A of the first reamer 101A has a first length 112A. The first guide member 130A has a second length 132A. The second portion 120A of the first reamer 101A is configured to center the first reamer 101A on the centerline 205A of a first virtual hole VH-A. The tapered portion 126A of the second portion 120A of the first reamer 101A is configured to reduce the offset between the central longitudinal axis 102A of the apparatus 100A and the centerline 205A of the first virtual hole VH-A. The tapered portion 126A of the second portion 120A may be tapered at an angle 125A between about 0.5 degrees and about 1.0 degrees on each side from a final diameter 124A to a starting diameter 123A.

[0037] The second constant diameter 131A corresponds to the minimum diameter 240A of the first virtual hole VH-A, and the first constant diameter 111A corresponds to a first clearance hole 230A configured to receive a first oversize fastener. The second constant diameter 131A is configured to correspond to the maximum misalignment between two holes 211, 221 that can still be surrounded by the first clearance hole 230A. In other words, the second constant diameter 131A is configured to correspond to the minimum diameter 240A of the first virtual hole VH-A that will still allow the clearance hole 230A created by the first portion 110A of the first reamer 101A to completely surround each of the misaligned holes 211, 221. If the first guide member 130A cannot be inserted through the virtual hole VH-A created by the misaligned holes 211, 221, the clearance hole 230A created by the first reamer 101A will not completely surround each of the misaligned holes 211, 221.

[0038] Figure 4BFIG. 0 is a schematic view of an exemplary apparatus 100B for forming a plurality of aligned holes from a plurality of misaligned holes. The apparatus 100B includes a second reamer 101B. The second reamer 101B has a first portion 110B and a second portion 120B. The first portion 110B has a third constant diameter 111B. The second portion 120B has a first end 121B and a second end 122B. The first end 121B of the second portion 120B is adjacent to the first portion 110B of the second reamer 101B. The second portion 120B of the second reamer 101B is tapered 126B and has a varying diameter 123B - 124B that decreases from the first end 121B to the second end 122B. The apparatus 100B includes a second guide member 130B connected to the second end 122B of the second portion 120B of the second reamer 101B. The second guide member 130B has a fourth constant diameter 131B.

[0039] The first portion 110B of the second reamer 101B has a third length 112B. The second guide member 130B has a fourth length 132B. The second portion 120B of the second reamer 101B is configured to center the second reamer 101B on the centerline 205B of the second virtual hole VH - B. The tapered portion 126B of the second portion 120B of the second reamer 101B is configured to reduce the offset between the central longitudinal axis 102B of the apparatus 100B and the centerline 205B of the second virtual hole VH - B. The tapered portion 126B of the second portion 120B may be tapered at an angle 125B between about 0.5 degrees and about 1.0 degrees on each side from the final diameter 124B to the starting diameter 123B.

[0040] The fourth constant diameter 131B corresponds to the minimum diameter 240B of the second virtual hole VH - B, and the third constant diameter 111B corresponds to a second clearance hole 230B configured to receive a second over - sized fastener. The fourth constant diameter 131B is configured to correspond to the maximum misalignment between the holes 211, 221 that can still be surrounded by the second clearance hole 230B. In other words, the fourth constant diameter 131B is configured to correspond to the minimum diameter 240B of the second virtual hole VH - B, which will still allow the clearance hole 230B created by the first portion 110B of the second reamer 101B to completely surround each of the misaligned holes 211, 221. If the second guide member 130B cannot be inserted through the virtual hole VH - B created by the misaligned holes 211, 221, the clearance hole 230B created by the second reamer 101B will not completely surround each of the misaligned holes 211, 221.

[0041] Figure 4CIt is a schematic diagram of an exemplary device 100C for forming a plurality of aligned holes from a plurality of misaligned holes. The device 100C includes a third reamer 101C. The third reamer 101C has a first portion 110C and a second portion 120C. The first portion 110C has a fifth constant diameter 111C. The second portion 120C has a first end 121C and a second end 122C. The first end 121C of the second portion 120C is adjacent to the first portion 110C of the third reamer 101C. The second portion 120C of the third reamer 101C is tapered 126C, and this second portion has a varying diameter 123C - 124C that decreases from the first end 121C to the second end 122C. The device 100C includes a third guiding member 130C connected to the second end 122C of the second portion 120C of the third reamer 101C. The third guiding member 130C has a sixth constant diameter 131C.

[0042] The first portion 110C of the third reamer 101C has a fifth length 112C. The third guiding member 130C has a sixth length 132C. The second portion 120C of the third reamer 101C is configured to center the third reamer 101C on the centerline 205C of the third virtual hole VH - C. The tapered portion 126C of the second portion 120C of the third reamer 101C is configured to reduce the offset between the central longitudinal axis 102C of the device 100C and the centerline 205C of the third virtual hole VH - C. The tapered portion 126C of the second portion 120C can be tapered at an angle 125C between about 0.5 degrees and about 1.0 degrees on each side from the final diameter 124C to the starting diameter 123C.

[0043] The sixth constant diameter 131C corresponds to the minimum diameter 240C of the third virtual hole VH - C, and the fifth constant diameter 111C corresponds to a third clearance hole 230C configured to receive a third over - sized fastener. The sixth constant diameter 131C is configured to correspond to the maximum misalignment between the holes 211, 221 that can still be surrounded by the third clearance hole 230C. In other words, the sixth constant diameter 131C is configured to correspond to the minimum diameter 240C of the third virtual hole VH - C, which will still enable the clearance hole 230C created by the first portion 110C of the third reamer 101C to completely surround each of the misaligned holes 211, 221. If the third guiding member 130C cannot be inserted through the virtual hole VH - C created by the misaligned holes 211, 221, the clearance hole created by the third reamer 101C will not completely surround each of the misaligned holes 211, 221.

[0044] Figures 5A to 5CFIG. 0 is a schematic side view of a system 200 for forming a plurality of aligned holes from a plurality of misaligned holes 211, 221. The holes 211 through the first member 210 are misaligned with the holes 221 through the second member 220. Figure 5A Shown is a guide member 130 positioned within two misaligned holes 211, 221. A guide block 250 may be positioned on top of the first member 210 to guide the apparatus 100 to position the guide member 130 within the two misaligned holes 211, 221. The guide member 130 has a second constant diameter 131 that corresponds to a predetermined minimum virtual hole VH as discussed herein.

[0045] If the guide member 130 is able to pass through the two misaligned holes 211, 221, the clean-up holes 230A, 230B, 230C created by the first portion 110 of the reamer 101 will surround the two misaligned holes 211, 221. If the guide member 130 is not able to pass through the two misaligned holes 211, 221, an apparatus 100 with a smaller guide member 130 and a larger first portion 110 of the reamer 101 will be needed to create the clean-up holes that surround the two misaligned holes 211, 221. The first member 210 and the second member 220 having the two holes 211, 221 are shown in Figures 5A to 5C for illustrative purposes and may vary depending on the application. For example, the apparatus 100 can be used to form a plurality of aligned holes in two or more members.

[0046] Figure 5B Shown is a portion of the second portion 120 of the reamer 101 positioned within the misaligned holes 211, 221 of the first member 210 and the second member 220. The second portion 120 of the reamer 101 is tapered 126 and has a varying diameter 123 - 124 that decreases from a first end 121 to a second end 122. The second portion 120 of the reamer 101 will begin to form the clean-up holes 230A, 230B, 230C to the extent that the tapered portion 126 of the second portion 120 of the reamer 101 contacts the sidewalls of the two misaligned holes 211, 221. The second portion 120 of the reamer 101 is configured to center the reamer 101 on the centerline 205 of the virtual hole VH created by the misaligned holes 211, 221. The tapered portion 126 of the second portion 120 of the reamer 101 is configured to reduce the offset between the central longitudinal axis 102 of the apparatus 100 and the centerline 205 of the virtual hole VH.

[0047] Figure 5CShown is a first portion 110 of a reamer 101 inserted through both a first component 210 and a second component 220 to cut two aligned clearance holes through components 210, 220. The first portion 110 of the reamer 101 includes a constant diameter 111 configured such that two aligned holes in components 210, 220 create two aligned clearance holes through components 210, 220 that completely surround misaligned holes 211, 221.

[0048] Figure 6 Is a flowchart of an example of a method 300 for creating a plurality of aligned holes from a plurality of misaligned holes. The method 300 includes at 310 attempting to insert a first guiding member 130A through a plurality of misaligned holes 211, 221, the first guiding member 130A being connected to a first reamer 101A. The first reamer 101A includes a first portion 110A and a second portion 120A. The second portion 120A has a first end 121A and a second end 122A adjacent to the first portion 110A of the first reamer 101A. The first portion 110A of the first reamer 101A has a first constant diameter 111A. The second portion 120A is tapered 126A and has a varying diameter 123A - 124A that decreases from the first end 121A to the second end 122A. The first guiding member 130A is connected to the second end 122A of the second portion 120A of the first reamer 101A. The first guiding member 130A has a second constant diameter 131A corresponding to a first virtual hole VH - A. The first constant diameter 111A of the first portion 110A of the first reamer 101A corresponds to a first clearance hole 230A for receiving a first oversize fastener.

[0049] Method 300 includes cutting a first cleaning hole 230A using a first reamer 101A through a plurality of misaligned holes 211, 221. For example, at 320, as a first guiding member 130A is inserted into the plurality of misaligned holes 211, 221, the first cleaning hole 230A is cut using the first reamer 101A. If the first guiding member 130A cannot pass through the plurality of misaligned holes 211, 221, method 300 may include, at 330, attempting to insert a second guiding member 130B into the plurality of misaligned holes, the second guiding member 130B being connected to a second reamer 101B. The second reamer 101B includes a first portion 110B and a second portion 120B. The second portion 120B has a first end 121B and a second end 122B adjacent to the first portion 110B of the second reamer 101B. The first portion 110B of the second reamer 101B has a third constant diameter 111B. The second portion 120B is tapered 126B, the second portion having a varying diameter 123B-124B that decreases from the first end 121B to the second end 122B. The second guiding member 130B is connected to the second end 122B of the second portion 120B of the second reamer 101B. The second guiding member 130B has a fourth constant diameter 131B corresponding to a second virtual hole VH-B. The third constant diameter 111B of the first portion 110B of the second reamer 101B corresponds to a second cleaning hole 230B for receiving a second oversize fastener.

[0050] Method 300 may include cutting a second cleaning hole 230B using the second reamer 101B through the plurality of misaligned holes 211, 221. For example, at 340, as the second guiding member 130B is inserted through the plurality of misaligned holes 211, 221, the second cleaning hole 230B is cut using the second reamer 110B. If the second guiding member 130B cannot pass through the plurality of misaligned holes 211, 221, method 300 may include, at 350, attempting to insert a third guiding member 130C through the plurality of misaligned holes 211, 221, the third guiding member 130C being connected to a third reamer 101C.

[0051] The third reamer 101C includes a first portion 110C and a second portion 120C. The second portion 120C has a first end 121C and a second end 122C adjacent to the first portion 110C of the third reamer 101C. The first portion 110C of the third reamer 101C has a fifth constant diameter 111C. The second portion 120C is tapered 126C and has a varying diameter 123C - 124C that decreases from the first end 121C to the second end 122C. A third guide member 130C is connected to the second end 122C of the second portion 120C of the third reamer 101C. The third guide member 130C has a sixth constant diameter 131C corresponding to the third virtual hole VH-C. The fifth constant diameter 111C of the first portion 110C of the third reamer 101C corresponds to a third clearance hole 230C for receiving a second oversize fastener.

[0052] Method 300 may include, at 360, using the third reamer 101C to cut a third clearance hole 230C through the plurality of misaligned holes 211, 221 as the third guide member 130C is inserted through the plurality of misaligned holes 211, 221. Method 300 may include, at 370, inserting a first oversize fastener through the first clearance hole. Method 300 may include, at 380, inserting a second oversize fastener through the second clearance hole. Method 300 may include, at 390, inserting a third oversize fastener through the third clearance hole.

[0053] In addition, the present disclosure includes implementations according to the following examples:

[0054] Example 1. An apparatus for forming a plurality of aligned holes from a plurality of misaligned holes, the apparatus comprising: a reamer having a first portion and a second portion, the first portion having a first constant diameter and the second portion having a first end and a second end, the first end of the second portion being adjacent to the first portion of the reamer, the second portion of the reamer being tapered and having a varying diameter that decreases from the first end to the second end; and a guide member connected to the second end of the second portion of the reamer, the guide member having a second constant diameter.

[0055] Example 2. The apparatus of Example 1, wherein the second portion of the reamer is configured to center the reamer on the centerline of a virtual hole.

[0056] Example 3. The apparatus of Example 2, wherein the tapered portion of the second portion of the reamer is configured to reduce an offset between a central longitudinal axis of the apparatus and the centerline of the virtual hole.

[0057] Example 4. The device according to any one of Examples 1 to 3, wherein the tapered portion of the second part of the reamer includes a starting diameter that is greater than the final diameter, and the tapered portion of the second part is tapered from the final diameter to the starting diameter at an angle between approximately 0.5 degrees and 1.0 degrees on each side.

[0058] Example 5. The device according to any one of Examples 1 to 4, wherein the second constant diameter corresponds to a first virtual hole, and wherein the first constant diameter corresponds to a first clearance hole for receiving a first oversize fastener.

[0059] Example 6. The device according to any one of Examples 1 to 5, wherein the second constant diameter corresponds to a second virtual hole, and wherein the first constant diameter corresponds to a second clearance hole for receiving a second oversize fastener.

[0060] Example 7. The device according to any one of Examples 1 to 6, wherein the second constant diameter corresponds to a third virtual hole, and wherein the first constant diameter corresponds to a third clearance hole for receiving a third oversize fastener.

[0061] Example 8. A system for forming a plurality of aligned holes from a plurality of misaligned holes, wherein the reamer according to any one of Examples 1 to 7 is a first reamer, and the guiding member according to any one of Examples 1 to 7 is a first guiding member, the system comprising: a second reamer having a first part and a second part, the first part of the second reamer having a third constant diameter, the second part of the second reamer having a first end and a second end, the first end of the second part of the second reamer being adjacent to the first part of the second reamer, the second part of the second reamer being tapered and having a varying diameter that decreases from the first end to the second end; and a second guiding member connected to the second end of the second part of the second reamer, the second guiding member having a fourth constant diameter corresponding to a second virtual hole, and wherein the third constant diameter of the second reamer corresponds to a second clearance hole for receiving a second oversize fastener having a diameter larger than that of the first oversize fastener.

[0062] Example 9. A system for forming a plurality of aligned holes from a plurality of misaligned holes, the system comprising: a first reamer having a first portion and a second portion, the first portion of the first reamer having a first constant diameter, the second portion of the first reamer having a first end and a second end, the first end of the second portion of the first reamer being adjacent to the first portion of the first reamer, the second portion of the first reamer being tapered and having a varying diameter that decreases from the first end to the second end; a first guide member connected to the second end of the second portion of the first reamer, the first guide member having a second constant diameter corresponding to a first virtual hole, and wherein the first constant diameter of the first reamer corresponds to a first clearance hole for receiving a first oversize fastener; a second reamer having a first portion and a second portion, the first portion of the second reamer having a third constant diameter, the second portion of the second reamer having a first end and a second end, the first end of the second portion of the second reamer being adjacent to the first portion of the second reamer, the second portion of the second reamer being tapered and having a varying diameter that decreases from the first end to the second end; and a second guide member connected to the second end of the second portion of the second reamer, the second guide member having a fourth constant diameter corresponding to a second virtual hole, and wherein the third constant diameter of the second reamer corresponds to a second clearance hole for receiving a second oversize fastener having a diameter larger than the diameter of the first oversize fastener.

[0063] Example 10. The system according to Example 8 or 9, wherein the tapered portion of the second portion of the first reamer is configured to center the first reamer on the centerline of the first virtual hole, and wherein the tapered portion of the second portion of the second reamer is configured to center the second reamer on the centerline of the second virtual hole.

[0064] Example 11. The system according to any one of Examples 8 to 10, wherein the tapered portion of the second portion of the first reamer has a first start diameter and a first final diameter, the first start diameter being substantially the same as the first constant diameter, and the first final diameter being substantially the same as the second constant diameter.

[0065] Example 12. The system according to Example 11, wherein the tapered portion of the second portion of the second reamer has a second start diameter and a second final diameter, the second start diameter being substantially the same as the third constant diameter, and the second final diameter being substantially the same as the fourth constant diameter.

[0066] Example 13. The system according to Example 11 or 12, wherein the second portion of the first reamer tapers from the first final diameter to the first starting diameter at an angle between about 0.5 degrees and about 1.0 degrees on each side.

[0067] Example 14. The system according to Example 12 or 13, wherein the second portion of the second reamer tapers from the second final diameter to the second starting diameter at an angle between about 0.5 degrees and about 1.0 degrees on each side.

[0068] Example 15. The system according to any one of Examples 8 to 14, the system further comprising: a third reamer having a first portion and a second portion, the first portion of the third reamer having a fifth constant diameter, the second portion of the third reamer having a first end and a second end, the first end of the second portion of the third reamer being adjacent to the first portion of the third reamer, the second portion of the third reamer being tapered, the second portion having a varying diameter that decreases from the first end to the second end; and a third guide member connected to the second end of the second portion of the third reamer, the third guide member having a sixth constant diameter corresponding to a third virtual hole, and wherein the fifth constant diameter of the third reamer corresponds to a third clearance hole for receiving a third oversize fastener having a diameter larger than the second oversize fastener.

[0069] Example 16. The system according to Example 15, wherein the tapered portion of the second portion of the third reamer has a third starting diameter and a third final diameter, the third starting diameter being substantially the same as the fifth constant diameter, and the third final diameter being substantially the same as the sixth constant diameter.

[0070] Example 17. The system according to Example 16, wherein the second portion of the third reamer tapers from the third final diameter to the third starting diameter at an angle between about 0.5 degrees and about 1.0 degrees on each side.

[0071] Example 18. A method for creating an aligned hole from a plurality of misaligned holes, the method comprising: attempting to insert a guide member according to any one of Examples 1 to 7 through the plurality of misaligned holes; and as the guide member is inserted into the plurality of misaligned holes, cutting a first clearance hole through the plurality of misaligned holes using a reamer according to any one of Examples 1 to 7.

[0072] Embodiment 19. A method for generating an aligned hole from a plurality of misaligned holes, the method comprising: attempting to insert a first guiding member through the plurality of misaligned holes, the first guiding member being connected to a first reamer having a first portion and a second portion, the second portion having a first end and a second end, wherein the first end is adjacent to the first portion of the first reamer, the first portion of the first reamer having a first constant diameter, and the second portion being tapered, the second portion having a varying diameter that decreases from the first end to the second end, wherein the first guiding member is connected to the second end of the second portion of the first reamer, and wherein the first guiding member has a second constant diameter corresponding to a first virtual hole, and wherein the first constant diameter of the first reamer corresponds to a first clearance hole for receiving a first fastener; and cutting the first clearance hole through the plurality of misaligned holes with the first reamer as the first guiding member is inserted into the plurality of misaligned holes.

[0073] Example 20. The method of Example 18 or 19, wherein if the first guiding member cannot be inserted through the plurality of misaligned holes, the method further comprises: attempting to insert a second guiding member into the plurality of misaligned holes, the second guiding member being connected to a second reamer having a first portion and a second portion, the second portion having a first end and a second end, wherein the first end is adjacent to the first portion of the second reamer, the first portion of the second reamer having a third constant diameter, and the second portion of the second reamer being tapered, the second portion having a varying diameter that decreases from the first end to the second end, wherein the second guiding member is connected to the second end of the second portion of the second reamer, and wherein the second guiding member has a fourth constant diameter corresponding to a second virtual hole, and wherein the third constant diameter of the second reamer corresponds to a second clearance hole for receiving a second fastener; and cutting the second clearance hole through the plurality of misaligned holes with the second reamer as the second guiding member is inserted into the plurality of misaligned holes.

[0074] Example 21. The method of Example 20, wherein if the second guide member cannot be inserted through the plurality of misaligned holes, the method further comprises: attempting to insert a third guide member into the plurality of misaligned holes, the third guide member being connected to a third reamer having a first portion and a second portion, the second portion having a first end and a second end, wherein the first end is adjacent to the first portion of the third reamer, the first portion of the third reamer having a fifth constant diameter, and the second portion of the third reamer being tapered, the second portion having a varying diameter that decreases from the first end to the second end, wherein the third guide member is connected to the second end of the second portion of the third reamer, and wherein the third guide member has a sixth constant diameter corresponding to a third virtual hole, and wherein the fifth constant diameter of the third reamer corresponds to a third clearance hole for receiving a third fastener; and as the third guide member is inserted into the plurality of misaligned holes, using the third reamer to cut the third clearance hole through the plurality of misaligned holes.

[0075] Example 22. The method of any one of Examples 18 to 21, the method further comprising inserting a first oversize fastener through the first clearance hole.

[0076] Example 23. A method for producing an alignment hole from a plurality of misaligned holes using the system of any one of Examples 8 to 17 when a first guide member cannot be inserted through the plurality of misaligned holes, the method comprising: attempting to insert the first guide member through the plurality of misaligned holes; as the first guide member is inserted into the plurality of misaligned holes, using the first reamer to cut the first clearance hole through the plurality of misaligned holes; attempting to insert the second guide member into the plurality of misaligned holes; and as the second guide member is inserted into the plurality of misaligned holes, using the second reamer to cut the second clearance hole through the plurality of misaligned holes.

[0077] Although the present disclosure has been described in accordance with certain embodiments, other embodiments that are apparent to those of ordinary skill in the art, including embodiments that do not provide all of the features and advantages set forth herein, are also within the scope of the present disclosure. Accordingly, the scope of the present disclosure is defined only by the appended claims and their equivalents.

Claims

1. An apparatus (100) for forming a plurality of aligned holes from a plurality of misaligned holes, the apparatus comprising: A reamer (101) having a first portion (110) and a second portion (120), the first portion having a first constant diameter (111) and the second portion having a first end (121) and a second end (122), the first end of the second portion being adjacent to the first portion of the reamer, the second portion of the reamer being tapered and having a varying diameter that decreases from the first end to the second end; And A guide member (130) connected to the second end of the second portion of the reamer, the guide member having a second constant diameter (131).

2. The device according to claim 1, wherein The second portion (120) of the reamer (101) is configured to center the reamer on the centerline (205) of a virtual hole (VH).

3. The device according to claim 2, wherein The tapered portion of the second portion (120) of the reamer (101) is configured to reduce the offset between the central longitudinal axis (102) of the apparatus and the centerline (205) of the virtual hole (VH).

4. The device according to claim 1, wherein, The tapered portion of the second portion of the reamer includes a starting diameter (123) that is greater than a final diameter (124), and the tapered portion of the second portion tapers from the final diameter to the starting diameter at an angle (125) between approximately 0.5 degrees and 1.0 degrees on each side.

5. The device according to claim 1, wherein, The second constant diameter (131) corresponds to a first virtual hole (VH-A), and wherein the first constant diameter (111) corresponds to a first clearance hole (230A) for receiving a first oversize fastener.

6. The apparatus according to any one of claims 1 to 5, wherein The second constant diameter (131) corresponds to a second virtual hole (VH-B), and wherein the first constant diameter (111) corresponds to a second clearance hole (230B) for receiving a second oversize fastener.

7. The device according to any one of claims 1 to 5, wherein The second constant diameter (131) corresponds to a third virtual hole (VH-C), and wherein the first constant diameter (111) corresponds to a third clearance hole (230C) for receiving a third oversize fastener.

8. A method for generating aligned holes from a plurality of misaligned holes (211, 221), the method comprising: Attempt (310) to insert a first guiding member (130A) through the plurality of misaligned holes, the first guiding member being connected to a first reamer (101A) having a first portion (110A) and a second portion (120A), the second portion having a first end (121A) and a second end (122A), wherein the first end is adjacent to the first portion of the first reamer, the first portion of the first reamer having a first constant diameter (111A), and the second portion being tapered, the second portion having a varying diameter (123A - 124A) that decreases from the first end to the second end, wherein the first guiding member is connected to the second end of the second portion of the first reamer, and wherein the first guiding member has a second constant diameter (131A) corresponding to a first virtual hole (VH - A), and wherein the first constant diameter of the first reamer corresponds to a first clearance hole (230A) for receiving a first fastener; and As the first guiding member is inserted into the plurality of misaligned holes, cut (320) the first clearance hole through the plurality of misaligned holes using the first reamer.

9. The method according to claim 8, wherein, If the first guiding member cannot be inserted through the plurality of misaligned holes, the method further comprises: Attempt to insert a second guiding member (130B) into the plurality of misaligned holes, the second guiding member being connected to a second reamer (101B) having a first portion (110B) and a second portion (120B), the second portion of the second reamer having a first end (121B) and a second end (122B), wherein the first end of the second portion of the second reamer is adjacent to the first portion of the second reamer, the first portion of the second reamer having a third constant diameter (111B), and the second portion of the second reamer being tapered and having a varying diameter (123B - 124B) that decreases from the first end of the second portion of the second reamer to the second end of the second portion of the second reamer, wherein the second guiding member is connected to the second end of the second portion of the second reamer, and wherein the second guiding member has a fourth constant diameter (131B) corresponding to a second virtual hole (VH - B), and wherein the third constant diameter of the second reamer corresponds to a second clearance hole (230B) for receiving a second fastener; and As the second guiding member is inserted into the plurality of misaligned holes, cut the second clearance hole through the plurality of misaligned holes using the second reamer.

10. The method according to claim 9, wherein, If the second guiding member cannot be inserted through the plurality of misaligned holes, the method further comprises: Attempt to insert a third guiding member (130C) into the plurality of misaligned holes, the third guiding member being connected to a third reamer (101C) having a first part (110C) and a second part (120C), the second part of the third reamer having a first end (121C) and a second end (122C), wherein the first end of the second part of the third reamer is adjacent to the first part of the third reamer, the first part of the third reamer having a fifth constant diameter (111C), and the second part of the third reamer being tapered and having a varying diameter (123C - 124C) that decreases from the first end of the second part of the third reamer to the second end of the second part of the third reamer, wherein the third guiding member is connected to the second end of the second part of the third reamer, and wherein the third guiding member has a sixth constant diameter (131C) corresponding to a third virtual hole (VH-C), and wherein the fifth constant diameter of the third reamer corresponds to a third clearance hole (230C) for receiving a third fastener; and As the third guiding member is inserted into the plurality of misaligned holes, cut the third clearance hole through the plurality of misaligned holes using the third reamer.

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