Pilot-Hole Imaging for Accurate Stackup Drilling Alignment
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Solution Overview
Problem
Current drilling systems fail to completely overlap pilot holes in a stackup, leading to double drilled holes that do not meet manufacturing requirements, requiring manual inspection and increased costs, as they cannot accurately position the drill bit to align with both visible and blind pilot holes.
Innovation Solution
An automated drilling system that uses an imaging system to identify features of both pilot holes and adjust the drilling vector to ensure the hole drilled completely overlaps both pilot holes within selected tolerances, employing a controller to align the drilling device with the identified features and adjust the drilling vector relative to the outer surface of the first part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the drill bit is centered on the exposed end of the tack fastener, then the drilling system can be positioned and drilling can be performed, but the drilled hole may not completely overlap both pilot holes resulting in a double drilled hole
Solution Approach 1:
The imaging system captures images of the tack fastener before drilling occurs, and the controller calculates the optimal drilling vector in advance by identifying features of both pilot holes and determining how to position the drill bit to achieve complete overlap. This preliminary positioning calculation prevents the double drilled hole problem before drilling begins.
Solution Approach 2:
The imaging system provides visual feedback about the tack fastener position and orientation, allowing the controller to adjust the drilling vector based on actual observed features. This feedback loop ensures the drill bit is correctly positioned to overlap both pilot holes despite variations in tack fastener installation.
2Productivity
If automated drilling systems are used, then drilling can be performed efficiently, but the systems are unable to drill holes that completely overlap both pilot holes within selected tolerances
Solution Approach 1:
The patent replaces manual positioning and inspection methods with an automated imaging and control system. The imaging system captures images, the controller processes the images to identify tack fastener features, calculates the optimal drilling vector, and positions the drill bit automatically. This substitution of mechanical/manual operations with automated vision-based control enables both high efficiency and precise hole overlap within selected tolerances.
3Reliability
If operators manually inspect each drilled hole, then double drilled holes can be detected, but the process becomes more time-consuming and labor-intensive
Solution Approach 1:
The system performs preliminary positioning calculations and drill bit alignment before drilling occurs, ensuring the hole will completely overlap both pilot holes. This preventive approach eliminates the need for post-drilling inspection to detect double drilled holes, as the problem is prevented before it occurs.
4Manufacturing precision
If equipment is added to avoid drilling double drilled holes, then hole overlap can be improved, but the equipment becomes more expensive
Solution Approach 1:
The imaging system serves multiple functions: it captures images of the tack fastener, identifies features of both pilot holes, determines the optimal drilling vector, and guides drill bit positioning. This multi-functional system achieves precise hole overlap without requiring separate specialized equipment for each function, reducing overall system complexity and cost.
Data Source
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AI summary
A method and apparatus for drilling a hole through a first part (110) and a second part (112). An image of a first pilot hole (114) in the first part is generated using an imaging system (132). A first feature related to the first pilot hole in the first part is identified based on the image. A second feature related to a second pilot hole (116) in the second part is identified based on the image. A drilling vector (154) for drilling the hole through the first part and the second part is identified based on the first feature and the second feature.