Through-Skin Sensor Assembly for Hidden Aperture Drill Alignment
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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 operation of multiple devices, leading to tedious and labor-intensive procedures.
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 manipulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual alignment and operation of through-skin sensor and drill bit are used, then ease of operation is maintained, but productivity is reduced and labor intensity increases
Solution Approach 1:
The patent combines the through-skin sensor and drill bit into a single integrated tool. The sensor assembly and drill bit are co-located on the same handheld device, eliminating the need for separate manual operations. The alignment orifice in the sensor housing automatically co-locates with the detected aperture, and the drill bit is positioned through this orifice, merging detection and drilling functions into one tool that improves productivity while maintaining ease of operation.
Solution Approach 2:
The sensor automatically detects the aperture location and the alignment orifice self-aligns with the detected target without requiring manual manipulation. The system performs its own alignment function through the sensor detecting the aperture and the actuators moving the alignment orifice into co-location, eliminating the need for a worker to manually maneuver the sensor until aligned.
2Ease of operation
If one or two workers manipulate multiple devices manually, then ease of operation is maintained, but loss of time increases due to tedious procedures
Solution Approach 1:
The sensor automatically detects the aperture location and the alignment orifice self-aligns with the detected target without requiring manual manipulation. The system performs its own alignment function through the sensor detecting the aperture and the actuators moving the alignment orifice into co-location, eliminating the time-consuming manual maneuvering process.
Solution Approach 2:
The patent replaces manual mechanical alignment with an automated sensing and actuation system. The sensor detects the aperture location and electronic actuators move the alignment orifice into position, substituting the manual mechanical manipulation process with an automated electromechanical system that reduces alignment time significantly.
3Productivity
If automated sensor and actuation system is implemented, then productivity is improved and manual labor is reduced, but device complexity increases
Solution Approach 1:
The patent combines the through-skin sensor, alignment orifice, actuators, and drill bit into a single integrated handheld tool. This merging of multiple functions into one device improves productivity by eliminating the need for separate tools and workers, while the integrated design manages the inherent complexity within a unified system rather than requiring coordination between multiple separate devices.
4Manufacturing precision
If automated aperture location and co-location is used, then manufacturing precision is improved, but device complexity increases due to additional actuators and sensors
Solution Approach 1:
The patent replaces manual mechanical alignment with an automated sensing and actuation system. The sensor detects the aperture location and electronic actuators move the alignment orifice into position, substituting the manual mechanical manipulation process with an automated electromechanical system that enhances precision while managing complexity through integration.
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 while enhancing precision.
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
An automated manufacturing system that includes a self-contained through-skin sensor for determining the location of an underlying aperture in a support structure suited to mount a skin or surface. In an embodiment, the 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 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 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.