Dual-Force Drilling End Effector for Gap-Free Hole Automation
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Solution Overview
Problem
In aerospace manufacturing, the manual attachment of a skin to a frame using fasteners is labor-intensive and time-consuming, particularly for large and complex parts like aircraft fuselages, necessitating the automation of drilling spaced-apart holes for efficient assembly.
Innovation Solution
End effector assemblies with a first force application structure for selectively applying force and a drill bit to drill holes, and a second force application structure for continuous surface contact during transition, integrated into robots to automate the drilling process, reducing the likelihood of gaps between the skin and frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual attachment process is used, then flexibility and adaptability are maintained, but labor intensity and time consumption increase significantly
Solution Approach 1:
The end effector assembly is divided into distinct functional modules: a first force application structure for applying force during drilling, a second force application structure for continuous surface contact, and a drill bit mechanism. This segmentation allows each component to perform its specific function independently, enabling automation while maintaining manageable complexity through modular design.
Solution Approach 2:
The end effector assembly integrates multiple functions into a single device: it can apply force to the workpiece surface, drill holes, and maintain continuous contact during transitions. This multi-functionality reduces the need for multiple separate tools and operators, thereby automating the process while the integrated design keeps overall complexity controlled.
2Productivity
If automated drilling is implemented, then productivity increases, but manufacturing precision may deteriorate due to difficulty in avoiding gaps between skin and frame
Solution Approach 1:
The first force application structure applies force to the workpiece surface before drilling begins and maintains it throughout the drilling operation. This preliminary and continuous force application ensures the skin and frame remain properly positioned and gap-free before, during, and after hole creation, thereby maintaining manufacturing precision while enabling automated high-speed drilling.
Solution Approach 2:
The control system monitors the position and force application of both force application structures throughout the drilling process. This feedback mechanism allows real-time adjustments to maintain optimal contact between the workpiece components, ensuring precision is preserved even as productivity increases through automation.
3Manufacturing precision
If force is applied continuously during drilling, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The force application function is segmented into two distinct structures with different roles: the first force application structure provides intermittent force during drilling operations, while the second force application structure provides continuous force during transitions. This segmentation allows each structure to be optimized for its specific function, achieving precise gap control without requiring a single overly complex force application mechanism.
Data Source
AI summary
End effector assemblies for drilling a plurality of spaced-apart holes in a part, robots including the end effector assemblies, and associated methods are disclosed herein. The end effector assemblies include a first force application structure, an end effector, and a second force application structure. The first force application structure is configured to apply a first force to a surface of the part. The end effector is configured to selectively transition the first force application structure between a retracted state and an extended state and to selectively extend a drill bit into the part and subsequently retract the drill bit from the part. The second force application structure is configured to continuously apply a second force to the surface of the part while the first force application structure is in the retracted state and as the end effector assembly transitions from a first predetermined location to a second predetermined location.