Adjustable Drill Tool Stroke for Precise Bracket Rivet Openings
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Solution Overview
Problem
The formation of precise rivet openings in brackets for fastener hardware is labor-intensive and often results in scrap materials due to dimensional inaccuracies, particularly in applications like the aviation industry where high precision is required.
Innovation Solution
A drill system comprising an upper drill tool with a central chuck, upper and lower components, and a coupling assembly that allows for adjustable drill bit depth and precision through a slidable coupling mechanism, enabling precise control over the stroke length to achieve accurate chamfer or countersink dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual drilling methods are used to form rivet openings in brackets, then the process is simple and equipment cost is low, but the dimensional precision of openings and chamfers is poor leading to high scrap rates
Solution Approach 1:
The drill system incorporates a slidable coupling mechanism that allows dynamic adjustment of the drill bit stroke length. The lower component can slide relative to the upper component, enabling the stroke length to be adjusted based on the specific requirements of different bracket openings and chamfer depths, thereby achieving high dimensional precision while maintaining operational flexibility
Solution Approach 2:
The system enables precise control of drilling parameters through the slidable coupling mechanism. By changing the stroke length parameter (distance the drill bit extends beyond the lower component), the system can achieve different opening depths and chamfer dimensions, allowing adaptation to various precision requirements without changing the entire drilling apparatus
2Productivity
If traditional drilling equipment is used, then the equipment cost and complexity are low, but the productivity is low due to labor-intensive operations and frequent adjustments
Solution Approach 1:
The slidable coupling mechanism allows the stroke length to be pre-adjusted before the drilling operation begins. This preliminary adjustment of the drill bit extension distance ensures that the correct opening depth and chamfer dimensions are achieved in a single operation, eliminating the need for multiple trial-and-error drilling cycles and frequent adjustments during production
Solution Approach 2:
The drill system is divided into separable upper and lower components connected by the slidable coupling. This segmentation allows the lower component with the drill bit to be independently adjusted and replaced, enabling quick changes for different drilling requirements while maintaining the overall system structure, thus improving productivity without requiring complete system redesign
3Adaptability or versatility
If fixed stroke length drilling is used, then the device structure is simple, but the adaptability to different opening depths and chamfer requirements is poor
Solution Approach 1:
The system transforms the fixed stroke length into a dynamic, adjustable parameter through the slidable coupling mechanism. The lower component can slide along the upper component to achieve different stroke lengths, providing adaptability to various opening depths and chamfer requirements while maintaining a relatively simple mechanical structure without complex electronic controls
Solution Approach 2:
The slidable coupling acts as an intermediary mechanism between the upper and lower components of the drill system. It mediates the transmission of drilling force while allowing relative sliding motion, enabling stroke length adjustment without requiring complex actuation systems, thus achieving versatility with minimal added complexity
Data Source
AI summary
An upper drill tool including a central chuck, an upper component, a lower component and a coupling assembly. The central chuck has a chuck base and a chuck structurally configured to retain a drill bit. The upper component is attached to the central chuck and has a lower stop surface. The lower component has a central body and an outer ring that threadedly engages the central body, with the outer ring having an upper stop. The coupling assembly is configured to facilitate the slidable movement of the lower component from a first orientation wherein the upper stop is spaced apart from the lower stop surface and a second orientation wherein the upper stop is in abutting engagement with the lower stop surface, with the first orientation and the second orientation defining a stroke.