Drill Assembly Plunge Reduction via Sensor Feedback Control

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Solution Overview

Problem

Current drill bit technologies require manual skill and precision to avoid plunging through workpieces, leading to inefficiencies and potential damage, especially in surgical and manufacturing applications where accurate penetration and retraction are critical.

Innovation Solution

A drill assembly with a motorized system and sensor feedback loop that automatically detects breakthrough and controls the drill bit's advancement and retraction to minimize plunge, maintaining desired stiffness and allowing for precise control of drilling depth.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual drilling with surgeon control is used, then the surgeon can feel the drill bit penetration, but the process is time consuming and requires considerable skill and experience

Engineering Contradiction:

Improvepenetration detection accuracyVSAvoiddrilling time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The system uses sensors to detect drill bit breakthrough and provides automatic feedback to the control system, which then adjusts the motor to retract the drill bit. This automated feedback loop eliminates the need for manual sensing and reduces drilling time while maintaining precision.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The drill system performs self-monitoring and self-adjustment through automated sensors and control mechanisms that detect breakthrough and control retraction without requiring surgeon intervention or skill, thereby reducing time loss.

Inventive Principle:

Principle #25Self-service

2Productivity

If predetermined drilling distance is used in manufacturing, then the drilling process is simple, but the drill bit extends well through the workpiece resulting in wasted movement

Engineering Contradiction:

Improvedrilling efficiencyVSAvoidwasted drill bit movement

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

Sensors detect when the drill bit breaks through the workpiece and provide feedback to the control system, which automatically stops advancement and initiates retraction. This prevents the drill bit from extending excessively through the workpiece, eliminating wasted movement and improving productivity.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically changes the drilling parameters by automatically adjusting the drill bit's position based on real-time sensor feedback about breakthrough detection, optimizing the drilling distance to match the actual workpiece thickness rather than using a fixed predetermined distance.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If manual force application is used to control drill penetration, then the surgeon can control the drilling depth, but applying too much force can result in the drill bit plunging through the bone and damaging sensitive tissue

Engineering Contradiction:

Improvedrilling depth precisionVSAvoidtissue damage risk

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

Sensors continuously monitor drill bit position and breakthrough status, providing immediate feedback to the control system. When breakthrough is detected, the system automatically reduces motor force and retracts the drill bit, preventing plunging and tissue damage while maintaining precise depth control.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The control system acts as an intermediary between the surgeon's command and the drill bit's motion, automatically regulating the motor's force application based on sensor feedback. This intermediary control prevents harmful force application while maintaining precise depth control.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If automatic breakthrough detection is implemented, then drilling precision and safety are enhanced, but the device complexity increases with motorized systems and sensor feedback loops

Engineering Contradiction:

Improvedrilling safetyVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system implements automatic breakthrough detection using sensors that monitor drill bit position and provide feedback to the control system. This automated feedback mechanism enhances safety and precision by eliminating manual sensing errors, despite the increased device complexity from adding sensors and control circuitry.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces manual mechanical sensing and control with automated sensor-based detection and motorized control systems. This substitution of mechanical systems with sensor-motor integration improves reliability and safety while accepting the necessary increase in device complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS8511945B2Drill assembly and method to reduce drill bit plunge

Publication Date: 2013.08.20 QUANSER CONSULTING

AI summary

A drill assembly and method for reducing plunge of a drill bit upon breaking through a workpiece. The drill assembly contains a motor to advance and retract the drill bit, the motor is controlled by a control unit in a feedback loop to achieve a desired stiffness. The control unit determines when the drill bit breaks through the workpiece and stops or retracts the movement of the drill bit.