Force-Based Hole Deformation Detection in Structural Drilling
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Solution Overview
Problem
Existing automated probe inspection systems are inefficient and inaccurate in identifying deformations in formed holes of components, particularly in structural components like those used in aircraft manufacturing.
Innovation Solution
A system comprising a control unit that receives force signals from force sensors coupled to a tool or end effector, compares these forces with reference force data from a aligned hole, and determines if the formed hole has caused a deformation based on differences in force data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated probe inspection systems are used to identify hole deformations, then inspection speed is improved, but measurement precision deteriorates
Solution Approach 1:
The patent replaces mechanical probe inspection systems with a force-based sensing system. Force sensors mounted on the drilling tool measure axial and radial forces during the drilling operation itself, substituting post-drilling mechanical probing with real-time force measurement during the drilling process. This enables both high speed and high precision by using the drilling operation's own force characteristics to detect hole alignment issues.
2Measurement precision
If manual inspection methods are used to determine hole deformations, then measurement precision is maintained, but productivity deteriorates
Solution Approach 1:
The patent enables continuous inspection by measuring forces during the entire drilling operation rather than performing separate inspection steps. The force sensors continuously monitor axial and radial forces throughout the drilling process, allowing deformation detection to occur simultaneously with hole formation, thereby maintaining high precision while dramatically improving productivity through eliminated idle inspection time.
3Measurement precision
If force sensors are coupled to the tool or end effector for real-time detection, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent makes the drilling tool or end effector serve dual functions: both performing the drilling operation and conducting deformation detection through integrated force sensors. The same tool that drills the hole also measures the forces during drilling, eliminating the need for separate inspection equipment and reducing overall system complexity while maintaining high measurement precision.
Solution Approach 2:
The drilling tool performs self-diagnosis by using its own force sensors to detect alignment issues and deformations during the drilling process. The system monitors its own operational parameters (axial and radial forces) to identify problems, enabling the tool to self-assess hole quality without external inspection equipment, thereby simplifying the overall system architecture.
Data Source
AI summary
A system includes a control unit configured to receive one or more force signals from one or more force sensors coupled to one or both of a tool or an end effector. The one or more force signals are indicative of one or more forces exerted in relation to the tool or the end effector as the tool operates on one or more components to form an expanded hole. The control unit is further configured to compare the one or more forces in relation to force data associated with a reference expanded hole that is aligned with an alignment hole of the one or more components. The control unit is further configured to determine that the expanded hole caused a deformation when the one or more forces differ from the force data.