Through-Skin Aperture Alignment for Accurate Panel Drilling
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Solution Overview
Problem
Conventional manufacturing processes for drilling holes in complex surfaces, such as airplane or car body panels, are inefficient and labor-intensive, requiring manual manipulation of multiple devices and involving two workers to align and drill accurately.
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 on a surface, allowing for precise location and drilling without manual intervention, integrated with a vacuum pump system for surface engagement and a modular design for robotic integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual manipulation of through-skin sensor and drill bit is used, then alignment precision can be achieved, but labor intensity and process time increase significantly
Solution Approach 1:
The patent combines the through-skin sensor, alignment orifice, and drill bit into a single integrated hand-held device. The sensor detects the target aperture location, the alignment orifice provides mechanical guidance, and the drill bit executes drilling - all in one tool that eliminates the need for separate manual alignment and drilling operations by different workers
Solution Approach 2:
The device performs self-alignment through automated sensor detection of the target aperture. The sensor automatically locates the underlying structure aperture, and the alignment orifice automatically positions itself relative to the detected target, eliminating the need for manual manipulation and expert operation to achieve precise alignment
2Measurement precision
If multiple workers manipulate separate devices, then alignment accuracy can be maintained, but device complexity and coordination requirements increase
Solution Approach 1:
The patent merges the detection function (through-skin sensor), alignment function (alignment orifice), and drilling function (drill bit) into a single integrated device. This eliminates the need for coordination between multiple workers manipulating separate devices, while maintaining alignment accuracy through the integrated design where the alignment orifice is mechanically linked to the sensor detection
3Ease of operation
If manual aperture location and drilling is performed, then flexibility in operation is maintained, but operation time and labor requirements increase
Solution Approach 1:
The device performs automated aperture location using the through-skin sensor to detect the target aperture position. The alignment orifice automatically positions itself relative to the detected aperture, and the drill bit is guided by the alignment orifice - all without requiring manual manipulation or expert operation, thereby reducing operation time while maintaining ease of use
Solution Approach 2:
The patent replaces manual mechanical manipulation with automated sensor-based detection. The through-skin sensor electronically detects the aperture location, replacing the need for manual probing and visual alignment, thereby reducing operation time while maintaining operational simplicity
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
Enables quick and precise location of underlying apertures, reducing manual labor and increasing efficiency in manufacturing processes, facilitating automated systems that reduce downtime and repair costs while ensuring accurate hole placement.
Implementation Method 1
determine the location of an aperture in an underlying structure through electromagnetic, x-ray, ultrasonic or other means
Implementation Method 2
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 alignment assembly includes a first actuator configured to move the alignment orifice in the x-direction in the x-y plane and a second actuator configured to move the alignment orifice in the y-direction in the x-y plane
Implementation Method 3
a processor coupled to the sensor and configured to receive a signal from the sensor indicating the location of the aperture and configured to control the 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
Data Source
AI summary
A 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 processor coupled to the sensor and configured to receive a signal from the sensor indicating the location of the aperture 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.