Drilling Anomaly Detection via Axial Force and Torque Signal Analysis

The patent replaces complex non-destructive testing methods with a simplified mechanical sensing approach. By using force sensors to monitor axial force and torque during drilling, the system detects anomalies through mechanical parameter variations rather than requiring sophisticated imaging or testing equipment after drilling. This substitution maintains high detection capability while reducing system complexity.

The patent implements real-time feedback monitoring of drilling parameters (axial force Fz and torque C) to detect anomalies as they occur during the drilling process. The system continuously compares measured values against reference ranges and provides immediate anomaly detection, enabling quality control without adding complex post-processing equipment. The feedback loop allows early detection and potential process adjustment.

The patent performs anomaly detection during the drilling process itself rather than as a separate post-drilling step. By monitoring axial force and torque in real-time and detecting anomalies as they occur, the system eliminates the need for systematic non-destructive testing after drilling. The detection action is preliminary and concurrent with the manufacturing action, maintaining productivity while ensuring quality.

The drilling and detection operations occur simultaneously and continuously throughout the drilling process. The force sensors continuously monitor parameters without interrupting the drilling cycle, and anomaly detection is performed in real-time as data is collected. This continuous concurrent operation eliminates idle time between drilling and testing, maintaining full productivity while providing comprehensive quality control.

The patent extracts and isolates the critical detection parameters (axial force Fz and torque C) from the complex drilling process, focusing measurement efforts on these two key variables. By using simple force sensors to monitor only these essential parameters rather than attempting to measure all possible drilling variables, the system achieves effective anomaly detection with minimal sensor complexity. The extraction of key parameters simplifies the measurement system while maintaining detection precision.

The patent detects anomalies by monitoring changes in mechanical parameters (axial force and torque) rather than requiring direct observation of the anomaly itself. By translating physical anomaly conditions into measurable parameter variations, the system achieves precise detection using simple sensors. The parameter changes approach converts complex anomaly detection into straightforward threshold comparisons of force and torque values.

The patent implements real-time feedback monitoring that provides immediate anomaly detection during drilling, enabling quality control without post-processing delays. The feedback system continuously monitors axial force and torque, compares values against reference ranges, and detects anomalies as they occur, allowing for immediate process adjustment or part rejection before leaving the drilling station. This eliminates the need for slower post-drilling inspection and rework cycles.

The system performs quality verification during the drilling process itself rather than as a subsequent step. By detecting anomalies in real-time and making determination before the drilling cycle completes, the system ensures quality control is built into the manufacturing process. This preliminary detection prevents defective parts from proceeding to post-processing or assembly, maintaining high productivity while ensuring consistent quality.