Capacitive Probe Drilling Machine for Real-Time Hole Measurement
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Solution Overview
Problem
Existing methods for drilling precise holes in aircraft manufacturing do not effectively detect damaged drill bits in real-time, leading to out-of-tolerance holes that are only identified during quality assurance inspections, resulting in unnecessary drilling and potential defects.
Innovation Solution
A system comprising a drilling machine equipped with a capacitive probe and a probe deployment system, including a piezoelectric motor, that allows for immediate measurement of hole diameter and circularity at different depths, enabling real-time detection of out-of-tolerance holes and preventing further drilling with damaged bits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If holes are inspected only during quality assurance inspection, then the inspection process is simple, but out-of-tolerance holes are not identified until after drilling is complete
Solution Approach 1:
The capacitive probe performs preliminary measurement of hole diameter and circularity immediately after drilling each hole, before the drilling process continues. This preliminary action detects damaged drill bits in real-time, preventing further out-of-tolerance holes from being drilled, thus resolving the contradiction between maintaining simple inspection processes and achieving timely detection of quality issues.
2Measurement precision
If a capacitive probe and probe deployment system are added to the drilling machine, then real-time hole measurement is enabled, but device complexity increases
Solution Approach 1:
The capacitive probe, probe deployment system, and measurement processing are merged into an integrated inspection system mounted on the drilling machine. This combination enables real-time measurement of hole diameter and circularity at different depths, providing precise measurement capability while managing the complexity through systematic integration of components.
Solution Approach 2:
The capacitive probe serves multiple functions: measuring hole diameter, assessing circularity, and detecting drill bit damage conditions. This multi-functionality justifies the added device complexity by providing comprehensive measurement capabilities that improve measurement precision and enable real-time quality control.
3Reliability
If continuous measurement of all holes is performed, then the number of out-of-tolerance holes is minimized, but productivity decreases
Solution Approach 1:
The system continuously measures hole diameter and circularity, providing real-time feedback on drilling quality. When a hole is found to be out-of-tolerance or the drill bit is detected as damaged, the system immediately alerts the operator to stop drilling, preventing further defective holes. This feedback mechanism maintains high quality control while minimizing unnecessary drilling, thereby balancing reliability and productivity.
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
This solution minimizes the number of out-of-tolerance holes by allowing for immediate identification and correction of worn or chipped drill bits, reducing waste and improving quality control by ensuring each hole meets tolerance standards before subsequent drilling.
Implementation Method 1
a capacitive probe including a rod and a plurality of capacitive sensors about the rod
Implementation Method 2
a piezoelectric motor for incrementally moving the probe to different depths in the drilled hole
Data Source
AI summary
A system comprises a drilling machine; a capacitive probe; and a probe deployment system, mounted to the drilling machine, for moving the capacitive probe inside a hole drilled by the machine to measure the drilled hole at different depths.