Drilling Robot Control via Acceleration Feedback
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Solution Overview
Problem
Drilling robots experience instability during the drilling process, leading to ovalization and delamination issues due to factors like material irregularity and drill bit wear, resulting in prolonged drilling times and defective cylindrical shapes.
Innovation Solution
A method for controlling a drilling robot that determines the acceleration of the drilling tool at the end of the approach to a drilling position, using an accelerometer to assess stabilization and trigger corrective actions, such as adjusting the drilling cycle or recording quality data, to minimize stabilization periods and ensure precise drilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a preprogrammed stabilization period is used to ensure drilling tool stability, then drilling quality is improved, but drilling cycle duration increases
Solution Approach 1:
The system uses real-time feedback from accelerometers to monitor drilling tool stability and dynamically adjusts the stabilization period duration based on actual stability conditions, rather than using a fixed preprogrammed period. The control device receives acceleration signals, processes them to determine stability, and triggers drilling authorization when stability criteria are met, creating a closed-loop feedback system that optimizes cycle time while ensuring quality
Solution Approach 2:
The stabilization period is transformed from a static, fixed-duration process into a dynamic, variable-duration process that adapts to real-time stability conditions. The system continuously evaluates acceleration data and adjusts the stabilization duration accordingly, allowing shorter periods when stability is achieved quickly and longer periods when needed, thereby optimizing both quality and productivity
2Reliability
If a longer stabilization period is used to account for material irregularities and tool wear, then drilling reliability is improved, but productivity decreases
Solution Approach 1:
Real-time acceleration monitoring provides continuous feedback on actual stability conditions, allowing the system to maintain high reliability by detecting instability caused by material irregularities or tool wear while avoiding unnecessary extended stabilization periods. The system responds to actual conditions rather than assuming worst-case scenarios for all drills
Solution Approach 2:
The system monitors its own stability conditions through onboard accelerometers and autonomously determines when stabilization is sufficient, eliminating the need for conservative, overly-long predetermined stabilization periods. The drilling tool essentially monitors and reports its own readiness for drilling
3Manufacturing precision
If acceleration monitoring and real-time stability assessment are implemented, then drilling precision is improved, but device complexity increases
Solution Approach 1:
The system replaces complex mechanical stabilization control mechanisms with electronic acceleration sensing and digital signal processing. Accelerometers provide electronic measurement of stability, and digital algorithms process the signals to determine drilling authorization, substituting mechanical complexity with electronic and software-based solutions that are more precise and controllable
Solution Approach 2:
The control device performs multiple functions: it manages the drilling cycle, processes acceleration signals, determines stability, and triggers drilling authorization. This multi-functionality consolidates what could be separate complex systems into a single integrated control unit, reducing overall system complexity while maintaining precision
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 approach reduces the duration of the drilling program by optimizing stabilization periods, improving drilling precision, and minimizing the negative effects of instability, thereby enhancing productivity and quality.
Implementation Method 1
an accelerometer secured to the end of a mobilization structure of a drilling tool, the accelerometer being connected to means for measuring, monitoring and testing a logical condition of stabilization
Data Source
Figure 1~2(c)
Figure 3(a)~5
Figure 6~8
AI summary
The invention relates to a drilling robot and to a method for controlling a drilling robot, of the type that comprises a guided mechanical structure (4-7) allowing a drilling tool (12) to be placed in a sequence of drilling positions (14-16), programmed in terms of position and orientation for the drilling of a part (1) such as a technical skin. The method comprises a step of determining the acceleration (Ax, Ay, Az) of the drilling tool (12) at the end of the approach towards a drilling position, followed by testing a condition (CL) of stabilisation of the drilling tool (12), and then establishing a drilling authorisation ((c), Figure 2; (d) Figure 3; (a) Figure 7).