Adjustable Bushing Holder for Bulkhead Drilling Alignment
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Solution Overview
Problem
In the aircraft industry, aligning and drilling through pilot holes in bulkhead structures with varying dimensions and limited space is challenging due to part-to-part variations and the need for consistent 'true' and 'round' openings for fastening, especially when using series of bushings with stepwise increases in inner diameter and corresponding drill bits.
Innovation Solution
A drilling aid apparatus with a bushing holder and adjustable coupling members that aligns with pilot holes, allowing for sequential use of bushings with stepwise increases in inner diameter to guide drill bits, ensuring consistent drilling through bulkhead structures and stacked outer sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a series of bushings with stepwise increases in inner diameter are used to guide drill bits through pilot holes, then the desired sized opening for fastening can be formed, but consistent alignment of bushings and drilling 'true' and 'round' openings is challenging due to part-to-part variation in pilot hole location
Solution Approach 1:
The bushing holder is made adjustable rather than fixed, allowing it to adapt to variations in pilot hole locations across different bulkhead parts. The coupling members can be repositioned to accommodate part-to-part variation while maintaining consistent drilling precision.
Solution Approach 2:
The bushing holder assembly is designed to work with multiple bushing sizes in a series, allowing the same device to guide drill bits for creating openings of different final diameters by simply changing the bushing, rather than requiring different specialized tools for each size.
2Manufacturing precision
If bushings are used to guide drill bits through pilot holes in bulkhead structures, then openings of desired size can be formed, but limited working space between interior webs and bulkhead outer structure makes alignment challenging
Solution Approach 1:
The alignment device is divided into separate functional components: the bushing holder that positions the bushing, and coupling members that attach to the bulkhead. This segmentation allows each component to be optimized for its specific function within the limited space.
Solution Approach 2:
The coupling members extend perpendicular to the bulkhead surface, utilizing the third dimension (depth) rather than requiring additional lateral working space. This allows alignment adjustments to be made along the Z-axis while working within the constrained XY-plane space.
3Manufacturing precision
If pilot holes are machined in bulkhead outer sections with varying dimensions, then location guidance for drilling can be provided, but considerable part-to-part variation in pilot hole location affects consistent drilling alignment
Solution Approach 1:
The coupling members are designed with adjustable positioning capabilities, allowing them to be reconfigured for each bulkhead part to match the specific pilot hole location, thereby maintaining consistent drilling alignment despite part-to-part variations.
Solution Approach 2:
The device allows for adjustment of geometric parameters (position, orientation) of the bushing holder relative to the bulkhead, enabling adaptation to different pilot hole locations while maintaining the same drilling precision and opening quality.
Data Source
AI summary
Drilling aid apparatuses and methods for drilling a structure are provided. In one example, a drilling aid apparatus includes a bushing holder portion. The bushing holder portion has a first surface for facing a first structure portion, a second surface on a side opposite the first surface, and an opening formed through the bushing holder portion extending from the first surface to the second surface. The opening is configured to receive a bushing that is sized for guiding a drill bit for drilling into the first structure portion. A first coupling member is coupled to the bushing holder portion and is configured to couple to a second structure portion for supporting the bushing holder portion in a fixed position relative to the first structure portion.