Adjustable Bushing Assembly for Drilling Alignment
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Solution Overview
Problem
Existing methods for forming final openings in parts, such as drilling holes for fastener systems, often result in inaccuracies due to pilot holes having offsets relative to the part's surface, leading to holes outside selected tolerances.
Innovation Solution
A bushing assembly with a core element providing rotational and translational degrees of freedom in a free state and zero degrees of freedom in a fixed state, used in conjunction with an alignment system to ensure concentric alignment of tools with initial openings, allowing for precise formation of final openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a jig plate is used to locate the drill relative to the part during drilling operation, then the larger holes are formed in the target locations defined by the pilot holes, but the holes may have a shape and/or size outside of selected tolerances due to offset of pilot holes from the perpendicular axis
Solution Approach 1:
The bushing assembly serves as an intermediary component between the jig plate and the drill. It includes a body portion with an opening that receives the drill, and a core element with bearing surfaces that contact the drill. This intermediary structure provides concentric alignment of the drill with the pilot hole, eliminating the effect of pilot hole offsets and ensuring holes within selected tolerances.
Solution Approach 2:
The core element of the bushing assembly is designed to be movable relative to the body portion, allowing it to self-adjust and self-align with the pilot hole location. This dynamic capability enables the bushing to compensate for offset errors in the pilot holes, automatically positioning the drill concentrically with the pilot hole before drilling begins.
2Manufacturing precision
If pilot holes are formed in the first part and used to identify target locations for larger holes, then the larger holes can be positioned correctly, but offset of pilot holes from the perpendicular axis results in holes outside selected tolerances
Solution Approach 1:
The bushing assembly acts as a mediator that interfaces with the existing pilot holes and guides the drill. The body portion's opening is positioned at the target location defined by the pilot hole, while the core element's bearing surfaces ensure the drill operates concentrically with the pilot hole, thereby achieving accurate hole positioning despite pilot hole offsets.
Solution Approach 2:
The bushing assembly is pre-positioned on the jig plate at the target location before the drilling operation. This preliminary positioning establishes the correct location and orientation, allowing the drill to be simply inserted and operated without complex alignment procedures, thus maintaining ease of operation while achieving high precision.
3Adaptability or versatility
If the core element has rotational and translational degrees of freedom in free state, then it can self-align with offset pilot holes, but it requires a fixed state with zero degrees of freedom for stable drilling
Solution Approach 1:
The core element is designed with the capability to transition between a free state, where it has rotational and translational degrees of freedom for self-alignment with offset pilot holes, and a fixed state, where it is constrained for stable drilling operations. This dynamic state transition enables the bushing assembly to adapt to varying alignment requirements while maintaining operational stability.
Data Source
AI summary
An apparatus, system, and method for creating final openings in a part having initial openings using an alignment system. In one illustrative embodiment, the alignment system comprises a structure having a plurality of openings and a plurality of bushing assemblies. Each of the plurality of bushing assemblies is associated with one of the plurality of openings. Each of the plurality of bushing assemblies comprises a first element, a second element, and a core element located between the first element and the second element. The core element has at least two rotational degrees of freedom and at least two translational degrees of freedom when a bushing assembly is in a free state and zero degrees of freedom when the bushing assembly is in a fixed state.