Aircraft Hole Pattern Transfer Tool with Adjustable Bushings
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Solution Overview
Problem
Current methods for duplicating precise hole patterns in aircraft manufacturing are inefficient, costly, and pose ergonomic challenges due to the need for manual match drilling, which can be time-consuming and generates debris, and require expensive equipment like CMMs for accurate measurements.
Innovation Solution
A tool assembly system with a transfer plate and alignment elements that captures and transfers hole patterns from a first structure to a second, allowing for precise alignment and drilling off the aircraft, using oversize holes and holding elements to maintain alignment variation gaps, thus simplifying the process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual match drilling is performed on the aircraft structure, then precise hole pattern duplication is achieved, but manufacturing time increases and ergonomic issues arise
Solution Approach 1:
The patent uses a transfer template with index holes that precisely copies the hole pattern from a first structure to a second structure. The template captures the exact locations and dimensions of the original hole pattern, allowing rapid transfer without manual measurement or repeated drilling operations, thereby maintaining precision while reducing manufacturing time
Solution Approach 2:
The transfer template is pre-positioned on the aircraft structure before drilling operations. The index holes are pre-aligned with the original hole pattern, establishing precise reference points in advance. This preliminary positioning eliminates the need for time-consuming alignment operations during the actual drilling process
2Manufacturing precision
If match drilling is performed on the aircraft structure, then hole pattern is replicated, but debris is generated affecting equipment reliability
Solution Approach 1:
The patent extracts the drilling operation from the confined aircraft structure environment. By using the transfer template to mark hole locations externally, the actual drilling can be performed on detached components or in more accessible locations, removing the source of debris generation from sensitive equipment areas and improving reliability
3Device complexity
If fixed drill bushings are used in transfer template, then simple structure is maintained, but positional tolerance variation is limited
Solution Approach 1:
The patent employs adjustable drill bushings instead of fixed ones, allowing the template to adapt to variations in hole pattern dimensions. The bushings can be repositioned along the template to accommodate different positional tolerances while maintaining the overall simplicity of the transfer template structure, thus resolving the contradiction between complexity and precision
Data Source
AI summary
There is provided a tool assembly for transferring locations and dimensions of a pattern of holes from a first structure to a second structure. The tool assembly has a transfer plate with a transfer plate pattern of transfer plate holes that include a plurality of oversize holes and two transfer plate index holes. The transfer plate pattern is substantially identical to the pattern in the first structure. The tool assembly has one or more alignment elements installed in the plurality of oversize holes. Each alignment element has a through opening in a coaxial alignment with the oversize hole. The oversize hole allows formation of an alignment variation gap between an exterior of the alignment element and an inner wall of the oversize hole. The tool assembly has one or more holding elements coupled to the transfer plate, each with a central through opening in coaxial alignment with the oversize hole.