Metrology-Guided Drill Jigs for Precise Mounting Hole Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Aerospace systems, such as rocket systems, face challenges in achieving precise alignment and connection of large components due to manufacturing tolerances, which can lead to misalignment and require cumbersome assembly fixtures.
Innovation Solution
The use of drill jigs and shims, combined with metrology processes, to correct variations in attachment features and align components precisely, allowing for the achievement of Class 1 tolerance levels without the need for match drilling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If match drilling is used to achieve Class 1 tolerances, then manufacturing precision is improved, but device complexity and production time increase
Solution Approach 1:
A drill jig is introduced as an intermediary device that attaches to the attachment feature and provides a reference for drilling mounting holes. The drill jig includes a plate with a hole pattern that positions drill bits to create holes at precise locations, eliminating the need for complex match drilling procedures while achieving Class 1 tolerances
Solution Approach 2:
The drill jig pre-establishes the correct hole pattern and positioning before the actual drilling operation. By attaching the drill jig to the attachment feature and using its pre-configured hole pattern, the system performs the positioning action in advance, simplifying the overall manufacturing process and reducing the need for complex fixtures
2Manufacturing precision
If match drilling is used to achieve precise alignment, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The drill jig serves as a mediator that transfers the attachment feature's geometry to the mounting hole pattern. By using the drill jig's pre-configured hole pattern and positioning mechanisms, precise hole alignment is achieved more quickly than through match drilling, thereby improving productivity while maintaining Class 1 tolerances
Solution Approach 2:
The drill jig copies the attachment feature's geometry and uses it to establish the mounting hole pattern. This copying approach allows rapid reproduction of precise hole locations without requiring time-consuming match drilling operations, thus enhancing production throughput
3Manufacturing precision
If large assembly fixtures are used to ensure precise alignment, then manufacturing precision is improved, but device complexity and setup time increase
Solution Approach 1:
The assembly process is segmented into modular steps: first attaching the drill jig to the attachment feature, then using the drill jig's hole pattern for drilling. This segmentation eliminates the need for large, complex assembly fixtures while maintaining precise alignment through the drill jig's integrated positioning features
Solution Approach 2:
The drill jig acts as an intermediary tool that bridges the attachment feature and the mounting holes. It provides the necessary reference geometry and positioning without requiring large assembly fixtures, thereby reducing device complexity and setup time while ensuring precise component alignment
Data Source
AI summary
Drill jigs for positioning mounting holes using metrology processes, and associated systems and methods, disclosed. A representative drill jig system for positioning holes to be made in an object can include a drill jig having a plurality of movable plates. The plates can include: a rotatable plate carrying a hole pattern for positioning the holes to be made; a first translatable plate that is translatable along a first axis; a second translatable plate that is translatable along a second axis that is perpendicular to the first axis; and a base plate carrying one or more attachment elements positioned and configured to grasp the object. In some embodiments, the plates are manually movable via one or more adjusters. In some embodiments, the drill jig includes one or more servos for moving one or more of the plates under computer control, such as in a feedback loop using one or more encoders.