Aligned Hole Cleanup Using Virtual Diameter Measurement
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Solution Overview
Problem
The existing methods for connecting objects with misaligned holes are labor-intensive and time-consuming, relying on trial-and-error techniques to determine the appropriate size of cleanup holes for fasteners, often requiring larger holes and subjective visual inspections.
Innovation Solution
A method involving a step gage and tapered reamer to measure and align misaligned holes, allowing for the precise determination of cleanup hole diameters and alignment without the need for jigs, enabling the use of appropriately sized fasteners to secure objects together efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If trial-and-error methods with progressively larger cutters are used to create cleanup holes, then misaligned holes can be corrected, but the process becomes labor intensive and time consuming
Solution Approach 1:
The patent applies preliminary action by calculating the optimal cleanup hole diameter before actually drilling the hole. The system determines the required diameter based on the measured misalignment between holes, allowing the operator to drill the correct size hole on the first attempt rather than iteratively trying progressively larger cutters. This pre-calculation eliminates the trial-and-error process and significantly improves productivity while maintaining manufacturing precision.
2Manufacturing precision
If conventional trial-and-error methods are used to determine cleanup hole size, then hole alignment can be achieved, but the process requires multiple inspections and is subjective
Solution Approach 1:
The patent implements feedback by using a measurement system that quantifies the misalignment between holes and feeds this information back to calculate the optimal cleanup hole diameter. The system provides objective numerical data about the misalignment extent and determines the precise cutter size needed, replacing subjective visual inspections with automated measurement and calculation. This feedback loop ensures both manufacturing precision and measurement precision are improved simultaneously.
3Manufacturing precision
If special drill jigs are used to center on misaligned holes, then hole alignment can be corrected, but the device complexity increases and larger diameter holes are required
Solution Approach 1:
The patent applies the taking out principle by extracting the alignment correction function from complex mechanical jigs and relocating it to a computational system. Instead of using physical drill jigs with multiple adjustment mechanisms to center on misaligned holes, the system calculates the optimal cleanup hole diameter and centers the hole automatically based on the measured misalignment. This removes the need for complex positioning devices and reduces device complexity while maintaining manufacturing precision.
4Manufacturing precision
If progressively larger cutters are used incrementally, then cleanup holes can be formed, but the loss of time and material increases
Solution Approach 1:
The patent applies preliminary action by calculating the optimal cleanup hole diameter before drilling begins. The system measures the misalignment, computes the exact cutter size needed, and then drills the hole in a single operation. This eliminates the incremental approach of trying progressively larger cutters, significantly reducing the time lost to multiple drilling operations and material removal, while maintaining the manufacturing precision required for proper hole alignment.
Data Source
AI summary
A method for forming a plurality of aligned holes includes aligning a first surface defining a first hole with a second surface defining a second hole, wherein the first hole at least partially aligns with the second hole to form a gap. A virtual hole diameter is measured, wherein the virtual hole diameter is a diameter of a virtual hole through the gap and the virtual hole diameter is a smallest bisector of the gap. Responsive to the virtual hole diameter having a first virtual hole diameter, a first cleanup hole having a first cleanup hole diameter is formed through the gap, wherein the first cleanup hole is concentrically aligned with the virtual hole. A first fastener having a first size is inserted into the first cleanup hole, and the first surface is attached to the second surface using the first fastener. Additional implementations are described.