Bore Locating Target Assembly for Obstructed Bore Alignment
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Solution Overview
Problem
Current methods for aligning workpieces during manufacturing, especially for match drilling, are labor-intensive and time-consuming due to the need for manual intervention and visual inspection, and face challenges when dealing with partially obstructed bores and high-accuracy alignment requirements.
Innovation Solution
A bore metrology method and system that uses a bore locating target assembly with an optical target and camera system to determine the centerline of an initial bore by imaging through a pilot bore, enabling accurate alignment and robotic match drilling with reduced manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment operations are used to align workpieces and locate features, then the operator can accurately register features against cluttered backgrounds, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent replaces manual mechanical alignment operations with an automated optical imaging system. A camera captures images of alignment features (reflectors and patterns) on workpieces, and a controller automatically processes these images to determine workpiece positions and orientations, eliminating the need for manual visual inspection and alignment operations while maintaining high measurement precision
Solution Approach 2:
The patent uses optical copies (images) of alignment features instead of direct mechanical measurement. The camera system creates visual representations of reflectors and patterns on workpieces, allowing the controller to analyze and process alignment data from these optical copies, thereby automating the alignment process and improving productivity
2Measurement precision
If the camera is positioned close to the workpiece using manual intervention, then accurate registration of small features is achieved, but the risk of inadvertent contact and damage increases
Solution Approach 1:
The patent replaces manual camera positioning with automated robotic positioning controlled by a controller. The system uses optical imaging to detect alignment features and automatically adjusts the camera or workpiece position without manual intervention, eliminating the risk of inadvertent contact while maintaining accurate feature registration
Solution Approach 2:
The system performs self-alignment through automated optical detection and control. The camera system automatically locates alignment features, and the controller processes the imaging data to determine precise workpiece positions, enabling the system to align and register features autonomously without manual operation
3Ease of operation
If mechanical feelers or optical sensors are used for close proximity placement, then alignment is achieved, but the process remains time-consuming and requires manual intervention
Solution Approach 1:
The patent replaces mechanical feelers with an optical imaging system that uses cameras to detect alignment features. The controller automatically processes the captured images to determine workpiece positions and orientations, enabling contactless alignment that is both easier to operate and faster than manual mechanical methods
Solution Approach 2:
The system creates optical copies of alignment features through imaging and uses these copies for automated analysis. This approach eliminates the need for physical contact with mechanical feelers while enabling rapid, automated alignment determination through digital image processing
4Extent of automation
If semi-autonomous alignment operations are performed to identify features and derive workpiece coordinate systems, then autonomous robotic assembly can begin, but considerable time is added to the manufacturing operations cycle
Solution Approach 1:
The patent replaces semi-autonomous alignment operations with a fully automated optical measurement system. The camera system automatically identifies alignment features, and the controller processes imaging data to derive workpiece coordinate systems without manual intervention, maintaining autonomous operation capability while significantly reducing alignment preparation time
Solution Approach 2:
The system performs alignment operations continuously and automatically through automated imaging and processing. The camera captures images and the controller processes them in sequence to establish workpiece coordinate systems, enabling continuous automated operation that eliminates the time-consuming manual steps of semi-autonomous alignment
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides high-accuracy, efficient alignment and drilling capabilities by optically measuring the centerline of the initial bore, reducing labor and time in manufacturing operations and accommodating various hole sizes and shapes.
Implementation Method 1
a camera system configured to project a collimated beam of electromagnetic radiation within a field of view
Implementation Method 2
the optical target having a reflector and an optical absorbing feature
Implementation Method 3
the optical absorbing feature defining a pattern on the optical target
Data Source
AI summary
A bore metrology method includes aligning a first structure, which defines an initial bore, with a second structure, which defines a pilot bore, such that the initial bore is partially obstructed by the second structure and the pilot bore is superimposed with the initial bore. The initial bore includes a bore locating target assembly within the initial bore, the bore locating target assembly having an optical target, the optical target having a reflector and an optical absorbing feature, the optical absorbing feature defining a pattern on the optical target. At least a portion of the reflector and at least a portion of the pattern are visible through the pilot bore. The method further includes imaging the portion of the reflector and the portion of the pattern that are visible through the pilot bore. The method further includes determining a centerline of the initial bore based on the imaging.