Laser-Guided Drill Positioning for Normal Fastener Alignment
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Solution Overview
Problem
In aircraft maintenance, accurately positioning a drill bit relative to fasteners is challenging, often resulting in damaged substructures and increased costs due to misalignment, and existing solutions are either costly, time-consuming, or labor-intensive.
Innovation Solution
A positioning device with a cage that surrounds the drill bit and includes a laser projector to project an illuminated dot onto the workpiece surface, ensuring the drill bit is aligned normal to the surface and centered on the fastener, facilitating precise alignment without requiring extensive rework or expensive equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a punch and hammer are used to create an indentation for centering the drill bit, then the drill bit can be centered with the fastener, but the drill bit may still be out of normal with the component surface
Solution Approach 1:
The patent introduces a positioning device with a base and positioning member as an intermediary tool between the operator and the drilling operation. The base provides a reference plane that contacts the component surface, while the positioning member guides the drill bit, ensuring both centering and proper orientation simultaneously through the mechanical relationship between these components.
Solution Approach 2:
The positioning device combines multiple functions into a single tool: it centers the drill bit with the fastener, orients the drill bit normal to the component surface, and provides a reference for drilling location. This multi-functional approach eliminates the need for separate operations using punch/hammer for centering and separate guide tools for orientation.
2Manufacturing precision
If hand drills with guide attachments are used to orient the drill bit normal to the component surface, then the drill bit orientation is improved, but alignment with the center of the fastener is not aided
Solution Approach 1:
The patent merges the centering function and orientation function into a single integrated positioning device. The base provides the reference plane for orientation, while the positioning member with its specific geometry simultaneously establishes both the correct orientation (normal to surface) and the correct centering location (aligned with fastener center), eliminating the need for separate guide attachments.
3Measurement precision
If magnetic targets are placed inside the component structure to enable positioning, then drilling accuracy is improved, but access to the inside of the aircraft is required, increasing cost, time, and labor
Solution Approach 1:
The patent extracts the positioning function from the component structure itself and places it on the drilling tool side through the positioning device. Instead of requiring magnetic targets to be installed inside the aircraft structure, the positioning functionality is contained in the portable positioning device that works with the external surface of the component, eliminating the need for internal access.
4Manufacturing precision
If automated robotic drilling machines are used, then drilling precision is improved, but expensive equipment and considerable software programming investment are required
Solution Approach 1:
The patent employs a simple, inexpensive positioning device that can be easily manufactured and deployed without requiring expensive automated equipment. The positioning device uses basic mechanical components (base, positioning member) rather than complex robotic systems, providing accurate positioning through clever mechanical design rather than expensive automation technology.
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 solution reduces damage to the workpiece and substructures, decreases the number of broken drill bits, and lowers the costs, time, and labor required for drilling operations by ensuring accurate alignment and normal orientation of the drill bit.
Implementation Method 1
a laser projector mounted to the cage such that the laser projector is configured to project an illuminated dot onto the workpiece surface that indicates where the centerline axis of the drilling tool intersects the workpiece surface
Data Source
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AI summary
A positioning device (104, 204, 304) for positioning a drilling tool (106, 206, 306) of a drilling apparatus (102, 202, 302) relative to a workpiece includes a cage (124, 224, 324) mounted to the drilling apparatus such that the cage at least partially surrounds the drilling tool. The cage includes an end portion (128, 228, 328) that includes an alignment surface (130, 230, 330) that is configured to be engaged in physical contact with a workpiece surface (110) of the workpiece (108). The alignment surface of the cage is oriented relative to a centerline axis of the drilling tool such that the centerline axis (120, 220, 320) extends normal to the workpiece surface when the alignment surface of the cage is in contact with the workpiece surface. The positioning device also includes a laser projector (142, 242, 342) mounted to the cage such that the laser projector is configured to project an illuminated dot onto the workpiece surface that indicates where the centerline axis of the drilling tool intersects the workpiece surface.