Modular Drill Guide Template for Precise Hole Pattern Transfer
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Solution Overview
Problem
Current methods for transferring hole patterns from an initial part to a replacement part, such as aircraft skin panels, are inefficient, labor-intensive, and require skilled craftsmen due to difficulties in accessibility and precise alignment.
Innovation Solution
A system comprising a fixture template with insert holes and guide inserts having unique orientations, which are removably secured to form a pattern of openings accurately using a tool, such as a drill, by incorporating three-dimensional measurement data to fabricate modular drill guide bushings for precise hole replication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual layout and measurement methods are used to transfer hole patterns, then flexibility and adaptability are maintained, but labor intensity increases and productivity decreases
Solution Approach 1:
The patent uses a template with opening patterns that directly copies the hole pattern from the initial part to the replacement part. The template acts as a physical copy mechanism, transferring the exact spatial arrangement of holes without manual measurement, thereby increasing productivity while reducing operational complexity
Solution Approach 2:
The template serves as an intermediary device between the initial part and replacement part. It mediates the hole pattern transfer process by providing pre-positioned openings that guide tool placement, eliminating the need for skilled craftsmen to perform complex manual layout work
2Measurement precision
If skilled craftsmen perform measurement and layout work, then measurement precision is maintained, but loss of time increases and productivity decreases
Solution Approach 1:
The template is pre-fabricated with opening patterns that correspond to the required hole locations. This preliminary action embeds the measurement precision into the template structure itself, eliminating the need for time-consuming on-site measurements while maintaining high accuracy in hole placement
Solution Approach 2:
The template copies the precise hole pattern geometry from the initial part design into a reusable physical artifact. This copying process transfers accurate spatial relationships directly to the replacement part, achieving high measurement precision without the time investment required for manual measurement and calculation
3Manufacturing precision
If non-removable fixtures are used for hole pattern transfer, then manufacturing precision is maintained, but adaptability decreases and ease of repair worsens
Solution Approach 1:
The template is segmented into multiple components including removable inserts, indexable elements, and modular sections. This segmentation allows the template to maintain precise hole pattern replication while enabling reconfiguration for different hole patterns, different component types, or repair scenarios, thereby achieving both manufacturing precision and adaptability
Solution Approach 2:
The template incorporates dynamic elements such as removable inserts and adjustable components that allow it to change configuration based on the specific task. This dynamic design enables the same template to maintain high manufacturing precision across multiple applications while adapting to different hole patterns and component requirements
Data Source
AI summary
A system and a method include a fixture template configured to be secured to a component. The fixture template includes a plurality of insert holes. A plurality of guide inserts have channels. Each of the channels has an orientation. The orientation of at least two of the plurality of guide inserts differs. Each of the plurality of guide inserts is removably secured within a respective one of the plurality of inserts holes to position and orient the channels in relation to a pattern of openings to be formed in relation to the component. Each of the channels is configured to receive an operative member of a tool that is configured to form the pattern of openings in relation to the component.