Through-Skin Aperture Sensor With Self-Aligning Drill Positioning
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Solution Overview
Problem
Conventional manufacturing processes for drilling holes in complex structures, such as airplane or car body panels, are inefficient as they require manual alignment and manipulation of sensors and drill bits, necessitating multiple workers and being tedious and time-consuming.
Innovation Solution
A hand-held through-skin sensor with an automated aperture-locating mechanism, equipped with a sensor array and actuators, that can detect and align with underlying apertures using electromagnetic or ultrasonic means, allowing for precise location and drilling of holes without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual alignment and manipulation of sensors and drill bits is used, then the process can be completed with simple equipment, but the productivity is low and the process is time-consuming
Solution Approach 1:
The patent combines the sensor, actuators, and control system into an integrated automated assembly system. The sensor detects aperture locations, actuators automatically position the drill bit, and the control system coordinates these functions, eliminating the need for separate manual operations and significantly improving manufacturing efficiency.
Solution Approach 2:
The automated system performs self-alignment and self-positioning functions. The sensor automatically detects aperture locations, the actuators automatically adjust the drill bit position based on sensor feedback, and the system autonomously completes the drilling operation without requiring manual intervention, thereby increasing productivity.
2Measurement precision
If multiple workers are used to manipulate sensor and drill bit, then the measurement precision can be maintained, but the device complexity and operational complexity increase
Solution Approach 1:
The patent replaces manual mechanical manipulation with an automated control system. The sensor electronically detects aperture positions with high precision, and the control system automatically translates this data into actuator commands for precise drill bit positioning, eliminating manual alignment operations while maintaining or improving measurement precision.
Solution Approach 2:
The system implements a feedback loop where the sensor continuously monitors aperture location, the control system processes this information, and the actuators adjust the drill bit position accordingly. This closed-loop feedback mechanism ensures high positioning precision while automating the operation, improving both measurement accuracy and ease of operation.
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
The system enables quick and precise alignment of drill bits with underlying apertures, reducing manual labor and increasing efficiency in manufacturing processes, thereby reducing downtime and repair costs by integrating into modular and automated manufacturing systems.
Implementation Method 1
The sensor is disposed in a housing and configured to determine a location of an aperture disposed in an adjacent surface through electromagnetic, x-ray, ultrasonic or other means
Data Source
AI summary
A self-contained hand-held through-skin (HHTS) sensor for determining the location of an underlying aperture in a support structure suited to mount a skin or surface. In an embodiment, the HHTS sensor includes a sensor disposed in a housing and configured to determine a location of an aperture disposed in an adjacent surface through electromagnetic, x-ray, ultrasonic or other means. The HHTS sensor further includes an alignment assembly having an alignment orifice disposed in the housing and configured to be maneuvered in an x-y plane within the housing. The HHTS sensor also includes a vacuum pump system, a local battery and a processor coupled to the sensor and configured to control first and second actuators to maneuver the alignment orifice within the x-y plane to be co-axially located with the aperture in response to the sensor signal.