Optical Drill Bit Positioning for Accurate Multi-Component Boring
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Solution Overview
Problem
In the aeronautical industry, precise positioning of drill bits for boring components is challenging due to machine tool tolerances and component discrepancies, leading to inaccuracies that complicate assembly when dealing with large components.
Innovation Solution
A method utilizing a machine tool with a control unit and optical sensors to capture images of components, calculate digital representations, superpose design data, evaluate bore positions relative to notable points, and adjust the drill bit for precise alignment based on triangulation, rather than relying on the machine tool's reference frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional machine tool positioning methods are used, then the drilling process is simple to implement, but the positioning precision deteriorates due to machine tool tolerances and component positioning discrepancies
Solution Approach 1:
The patent replaces the traditional mechanical positioning system (based on machine tool reference frames and physical fixtures) with an optical measurement and digital positioning system. Optical sensors capture images of the component, and a control unit processes these images to determine precise bore positions based on the component's actual geometry rather than relying on mechanical positioning accuracy.
Solution Approach 2:
The patent creates a digital representation (copy) of the component's actual geometry through optical scanning. This digital model is then used to calculate precise bore positions and guide the drilling process, replacing the need for precise mechanical positioning with information-based positioning.
2Manufacturing precision
If component positioning is performed with standard tolerances, then the manufacturing process is efficient, but the assembly accuracy deteriorates due to accumulated discrepancies across multiple components
Solution Approach 1:
The patent implements a feedback mechanism where optical sensors measure the actual position and geometry of each component before drilling. The control unit uses this feedback information to calculate adjusted bore positions that compensate for positioning discrepancies, ensuring that components with slight variations can still be assembled accurately.
Solution Approach 2:
The patent dynamically changes the bore position parameters based on the measured actual geometry of each component. Instead of using fixed positions based on nominal dimensions, the system calculates and applies adjusted positions that account for actual component variations, enabling accurate assembly despite tolerance accumulations.
3Manufacturing precision
If multiple components are drilled using traditional methods, then each component can be processed independently, but the overall assembly quality deteriorates due to copied and accumulated positioning errors
Solution Approach 1:
The patent creates digital representations (copies) of multiple components and their assembled configuration. By working with these digital models, the system can calculate precise bore positions for each component relative to the others, ensuring that positioning errors do not accumulate across the assembly while avoiding the need for complex physical measurement and adjustment procedures for each component.
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 ensures precise drilling and alignment of bores on components, improving assembly accuracy by referencing notable points on the components themselves, rather than the machine tool, and allows for precise alignment of multiple components for easier assembly.
Implementation Method 1
a first capturing step, during which the, or each, optical sensor captures at least one image of the first component including the face to be drilled
Data Source
AI summary
A method for assisting with the positioning of a drill bit for boring a component, which includes capturing images of a first component which has notable points, of calculating a digital representation from these images, of superposing the digital representation thus calculated and a digital design representation of the component, of evaluating the distances of the centers of bores to be created with respect to the notable points, and of positioning a drill bit with the aid of a camera and of the evaluated distances. The method continues in the same way for the other components to be assembled.