Robotic Countersinking of Curved Aircraft Panels Without Bespoke Fixtures
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Solution Overview
Problem
Current methods for countersinking predrilled holes in aircraft panels, whether manual or using machine tools, face challenges such as panel deflection, high costs for bespoke fixtures, and repetitive strain injuries for operators, while also requiring large workspaces and expensive machinery.
Innovation Solution
A method and apparatus utilizing a drilling apparatus with a pressure foot and cutting tool, guided by digital models of the panel and pressure foot, which aligns the cutting tool with the hole and moves it to the correct depth, while a second robot applies pressure to prevent panel deflection, using sensors and light detection for precise alignment and movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual countersinking by human operators is used, then flexibility and adaptability are maintained, but operator strain and workspace requirements increase
Solution Approach 1:
The system uses automated robots equipped with sensors and digital models to perform countersinking operations independently, eliminating the need for human operators to manually handle each panel. The robot autonomously positions the cutting tool, applies appropriate pressure, and completes the countersinking process based on digital panel geometry data.
Solution Approach 2:
The patent replaces manual mechanical operations with an automated robotic system that uses sensors, digital models, and controlled mechanical pressure to perform countersinking. This substitution eliminates repetitive strain on operators while maintaining precision through digital guidance.
2Stability of the object's composition
If machine tools with secure fixtures are used, then panel stability is improved, but equipment cost and fixture complexity increase
Solution Approach 1:
The system uses a movable robotic arm that can dynamically adjust its position and apply variable pressure to the panel during countersinking. The pressure foot can adapt its contact force based on real-time sensor feedback and digital model data, providing stability without requiring rigid fixed fixtures.
Solution Approach 2:
The patent uses digital models (virtual copies) of the panel geometry to guide the robotic positioning and pressure application. Instead of physical fixtures matching the panel shape, the system creates a digital representation and uses it to calculate optimal pressure points and tool paths, eliminating the need for complex physical fixtures.
3Manufacturing precision
If bespoke fixtures are used for each panel shape, then alignment precision is improved, but manufacturing cost and setup time increase
Solution Approach 1:
The robotic system is designed to handle multiple panel shapes and sizes using a single universal robot equipped with sensors and digital modeling capabilities. The robot can adapt to different panel geometries by loading appropriate digital models and adjusting its pressure application strategy, eliminating the need for dedicated fixtures for each panel type.
Solution Approach 2:
The system changes operational parameters (pressure magnitude, tool position, approach angle) based on the specific panel geometry described in digital models. By dynamically adjusting these parameters rather than using fixed fixtures, the system achieves precise alignment for different panel shapes without requiring custom-made fixtures for each configuration.
Data Source
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AI summary
Drilling apparatus and method, the apparatus comprising: a first robot (10); a first member (30) (e.g. a pressure foot) and a drilling tool (38) both coupled to the first robot (10); a second robot (12); and a second member (52) coupled to the second robot (12); wherein the apparatus is arranged to press the members (30, 52) against opposite sides of a part to be drilled (2, 100) (e.g. an aircraft panel) so as to hold the part (2, 100) and prevent deflection of at least a portion of the part (2, 100); and the first member (30) and the drilling tool (38) are arranged such that the drilling tool (38) may drill into the portion of the part (2, 100) of which deflection is opposed from the side of the part (2, 100) pressed against by the first member (30). The robots (10, 12) may be robotic arms. The application also relates to a method and apparatus of countersinking a hole formed in a curved and in particular a concave aircraft panel using such a drilling apparatus.