Tool Alignment Device for Precise Drilling Angles
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Solution Overview
Problem
Existing tool alignment devices for drilling, milling, and countersinking operations fail to ensure precise alignment and consistent depth due to limitations in aligning the machining tool relative to the workpiece surface, particularly at angles other than right angles, leading to uneven bore or countersink depths.
Innovation Solution
A tool alignment device with a signaling mechanism and guide device that allows for mechanical contact with the workpiece surface to output alignment signals and maintain a defined machining angle, featuring a main part with a through hole and a guide device connecting the stop sleeve, enabling precise alignment and axial displacement of the stop within the device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a stop device with a freely rotatable stop sleeve is used, then the tool can be easily attached to different tool shanks, but the alignment precision of the machining tool to the workpiece surface is limited
Solution Approach 1:
The device is divided into functionally independent segments: the stop device (with stop sleeve and bearing) handles adaptability to different tool shanks, while the separate alignment device (with alignment element and signaling device) handles alignment precision. This segmentation allows each component to optimize its specific function without compromising the other.
Solution Approach 2:
The alignment element acts as an intermediary between the stop device and the workpiece surface. It mechanically contacts the workpiece surface and transmits alignment information to the signaling device, enabling precise alignment without affecting the stop sleeve's rotatability or the adaptability to different tool shanks.
2Ease of operation
If the stop sleeve is freely rotatable about the tool shank, then the tool head can be exchanged as necessary, but the machining tool cannot be aligned exactly to the surface of the workpiece at angles other than right angles
Solution Approach 1:
The system separates the ease of operation function (tool head exchange via rotatable stop sleeve) from the alignment precision function (alignment element with signaling device). The alignment element provides reference surfaces at defined angles (e.g., 90 degrees) that remain stable regardless of stop sleeve rotation, enabling precise angular alignment while maintaining easy tool head exchange capability.
Solution Approach 2:
The stop sleeve is designed to be dynamically rotatable during operation for easy tool head exchange, while the alignment element provides static reference surfaces at defined angles. The signaling device dynamically indicates when the desired alignment is achieved, combining dynamic flexibility with static precision references.
3Manufacturing precision
If known alignment devices are directly connected to the tool shank, then the alignment can be performed, but the inner surface of the alignment device contacts the tool shank which interferes with the stop device functionality
Solution Approach 1:
The alignment element serves as an intermediary component that connects the stop device to the workpiece surface without requiring direct contact between the alignment device and tool shank. The alignment element mechanically engages with the stop device (via the stop sleeve or bearing) and extends to contact the workpiece surface, providing alignment functionality while avoiding interference with the stop device's rotatable connection to the tool shank.
Solution Approach 2:
The alignment element extends the alignment function from the tool shank dimension to the workpiece surface dimension. Instead of aligning directly at the tool shank level, the alignment element reaches out to contact the workpiece surface, providing alignment in a different spatial dimension that does not interfere with the stop device's rotational degree of freedom around the tool shank.
Data Source
AI summary
A tool alignment device for mounting on a tool having a stop, especially on a drilling and/or countersinking tool having a single-piece tool shaft and a stop, for alignment of a drill hole and/or countersink to be introduced or for alignment of a finishing step in relation to a normal to the surface of a workpiece, comprising a main part and a through hole. Upon mechanical contact between the tool alignment device and the surface of the workpiece, a signaling device is actuated and emits alignment signal(s) during alignment in an alignment direction, and the stop of the tool can be accommodated in the main part, which comprises a guide device which establishes a connection between a stop sleeve of the stop and the tool alignment device such that the stop can be aligned in the alignment direction. Also, a drilling, milling and/or countersinking tool having a stop.