Magnetic Tool Positioning for Aircraft Manufacturing Precision
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Solution Overview
Problem
Conventional manufacturing processes face challenges in achieving accurate locational precision on materials without surface reference features, particularly in structures like aircraft, and are hindered by tooling variations and material thickness inconsistencies, leading to inefficiencies and potential over-drilling issues.
Innovation Solution
The use of a sensor-connected machine head that detects magnetic fields to accurately position itself relative to a tool with embedded magnetic material, allowing for precise location and performance of manufacturing operations without the need for surface reference features, thereby reducing manufacturing time and preventing over-drilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing processes are used without surface reference features, then manufacturing operations can be performed on materials like aircraft structures, but locational accuracy deteriorates due to tooling variations and inability to establish precise reference points
Solution Approach 1:
The patent replaces mechanical reference features and validation procedures with a magnetic field-based detection system. A sensor detects magnetic fields generated by magnetic material embedded in the tool, enabling the machine head to automatically determine its position and orientation relative to the tool without requiring mechanical reference features on the material surface or complex validation steps
Solution Approach 2:
The patent introduces magnetic material as an intermediary between the tool and the machine head sensor. This magnetic material generates a detectable magnetic field that serves as a reference, allowing the sensor to accurately locate the machine head's position and orientation relative to the tool without direct mechanical contact or surface reference features
2Manufacturing precision
If validation steps are increased to account for tooling variations, then manufacturing accuracy improves, but manufacturing time increases
Solution Approach 1:
The magnetic material is pre-positioned in the tool during tool manufacturing, and the sensor is pre-calibrated to detect the magnetic field signature. This preliminary setup eliminates the need for time-consuming validation steps during each manufacturing operation, as the reference system is already in place and the sensor can immediately detect position and orientation
Solution Approach 2:
The patent replaces time-consuming mechanical validation procedures with rapid magnetic field detection. The sensor can quickly determine the machine head's position and orientation by detecting the magnetic field, eliminating the need for multiple validation steps and significantly reducing manufacturing time while maintaining accuracy
3Ease of manufacture
If material thickness variations are not accounted for, then manufacturing process remains simple, but over-drilling conditions occur leading to undesirable results
Solution Approach 1:
The sensor provides real-time feedback by detecting the magnetic field strength and characteristics as the machine head approaches the tool. This feedback allows the system to automatically adjust for material thickness variations and determine the precise stopping point for drilling operations, preventing over-drilling while maintaining process simplicity
Solution Approach 2:
The patent replaces complex mechanical measurement systems for detecting material thickness with a magnetic field-based detection system. The sensor detects changes in the magnetic field as it approaches the material surface, automatically compensating for thickness variations without requiring additional mechanical measurement devices or complex procedures
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 enhances locational accuracy, reduces manufacturing time, and prevents over-drilling by utilizing magnetic fields to guide the machine head, simplifying the manufacturing process and improving the quality of the final product.
Implementation Method 1
A sensor, attached to a machine head, is calibrated to detect magnetic fields
Data Source
AI summary
A method is presented. A machine head is positioned in a desired location relative to a material on a tool using a sensor connected to the machine head and calibrated to detect magnetic material in the tool. An operation is performed on the material using the machine head starting at the desired location.