Remote Match Drilling for Structural Assemblies

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Solution Overview

Problem

Manual match drilling in complex structural assemblies leads to issues such as Foreign Object Debris (FOD), ergonomic problems, limited access, component damage, and instability, resulting in rework and rejection conditions.

Innovation Solution

A method utilizing visual metrology devices to obtain physical characteristics of the environment, which are then used to fabricate components compatible with those characteristics using a CNC machine, allowing for precise drilling of mating holes outside the assembly line, thereby improving accuracy and repeatability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual match drilling is performed in place on structural assemblies, then components can be drilled to fit, but Foreign Object Debris (FOD) is generated and component damage occurs

Engineering Contradiction:

Improvehole alignment precisionVSAvoidForeign Object Debris (FOD)

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The drilling operation is extracted from the assembly environment and performed separately in a controlled machine shop setting. The component is removed from the structural assembly, drilled using precision CNC equipment, and then reinstalled. This separation eliminates FOD generation in the assembly area while maintaining hole alignment precision through digital template guidance.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

A digital template or 3D model of the target hole pattern is created through scanning or CAD data. This digital copy is then used to guide the CNC drilling process, allowing the component to be drilled with precise hole locations without requiring physical match drilling in the assembly environment. The digital template ensures accuracy while avoiding FOD generation.

Inventive Principle:

Principle #26Copying

2Manufacturing precision

If manual match drilling is performed in place, then components can be fitted, but ergonomic problems and limited access occur

Engineering Contradiction:

Improvehole alignment precisionVSAvoidergonomics and access

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The drilling operation is extracted from the difficult-to-reach assembly area and performed in a accessible machine shop environment. Workers can easily access the component on the machine shop floor with proper lighting, tooling, and workspace, eliminating ergonomic problems while maintaining hole alignment precision through digital guidance systems.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The component is prepared in advance by drilling holes in the machine shop before installation. This preliminary action allows workers to perform the drilling operation in an ergonomic setting with full access, and then simply install the pre-drilled component into the assembly, eliminating the need for difficult in-place drilling operations.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If manual match drilling is performed in place, then components can be drilled, but the process is unstable and rework/rejection conditions increase

Engineering Contradiction:

Improvehole alignment precisionVSAvoidprocess stability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

A digital template or 3D model is created as a precise copy of the target hole pattern. This digital copy serves as a stable, repeatable reference for the CNC drilling process, eliminating the variability and instability of manual match drilling. The digital template ensures consistent hole locations across multiple components while maintaining high precision alignment.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The manual mechanical match drilling process is replaced with an automated CNC drilling system guided by digital templates. This substitution eliminates the human error and process instability inherent in manual operations, providing consistent, repeatable, and precise hole drilling while maintaining reliability through automated control and digital guidance.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Manufacturing precision

If manual match drilling is performed in place, then components can be fitted, but additional inspection and protective equipment installation are required

Engineering Contradiction:

Improvehole alignment precisionVSAvoidinspection and protective equipment

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Manual inspection processes are replaced with automated inspection capabilities integrated into the CNC drilling system. The machine can verify hole locations, depths, and dimensions automatically through probes or sensors, eliminating the need for separate manual inspection steps and reducing the complexity of protective equipment requirements while maintaining high precision hole alignment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS9921566B1Advanced remote match drilling process

Publication Date: 2018.03.20 THE BOEING CO

AI summary

Fabricating a component is accomplished by operating a metrology system to obtain physical characteristics for an environment in which the component is to be installed. The physical characteristics for the environment are then transferred to a computer numerical control (CNC) machine and the component is fabricated to be compatible with the physical characteristics of the environment using the CNC machine.