DTS 01 | Drilling and Location Targeting Systems

Next-Generation Aerospace Assembly

DTS is the new innovation aimed to solve the problem in the aerospace assembling. More specifically it focuses on fuselage and ribs connection.

My concept purpose to speed up the workflow and reduce the need for an extremely skilled operator. DTS reduces human error and it enhances accuracy rate in the assembling progress.

The product consists of two major units which are the modular target unit and drill unit. The solution aims to use ultrasonic technology, to detect the location of the hole on the outside of the fuselage. The drilling unit locks on the target part afterward, DTS is automatically drilling the final hole without damaging the surface.

Introduction

The aim of the project is to examine the Aerospace assembly and to discover the problems here, a more healthy and comfortable work environment for the operators and to produce innovative and sustainable solutions for the sector.

Aircraft production is rapidly increasing worldwide and the sector has become unable to meet this demand. Therefore, aircraft manufacturers and suppliers are looking for new solutions on production and assembly, which will accelerate and make more precise the production process.

Research

In order to get in touch with the tools themselves as well as to gather hands-on insights from professionals, we went on a research trip during the first week of the projects. The journey began in Airbus's main production site in Germany, lead us to the harbor city of Hamburg where we got the chance to see the complete process of aerospace assembly.

Then, to examine the products more closely and get detailed information, we headed to Stockholm where the head office of Atlas Copco was located. Here we had the chance to increase our knowledge by experiencing the products.

Our goal was to find a user and expert insights and to identify relevant design opportunities that we can transform into concepts and valuable products for coming material handling generations.
We had the chance to gather information through infield observations, user interviews, factory tours and trying to tools at Stockholm.

Research Video:

https://vimeo.com/319686248

Back to School

Brainstorms

After the field trip, we proceed with a collaborative User Experience workshop. We structured the quotes, wishes and observed insights from the trip on creative boards. Based on the gathered information we used several methods of idea generation to identify and evaluate design opportunities.

Problem Analysis

Back Drilling

Very difficult to drill from inside.

Buried fastener holes occur during the assembly of the rib with pre hole and fuselage with no pre hole. To assemble the rib and skin, back drilling is done from the inside of the fuselage. This transfers the pre hole from the rib to the skin. The process is done manually requires perpendicularity. Time-consuming and requires a highly skilled operator one misaligned hole could result in lost construction time or in the worst case, replacing the part.

Snowman mistake - Double hole

Double holes that can occur during drilling back from the outside (secondary drilling) due to normality deviations or hole mismatch because of jig tolerances after re-connection of the fuselage or if non-transferred pilot holes in the couplings.

Pain points

• Limited space

• Awkward Positions

• Lying on uneven surfaces

• Darkness

• Heavy - Big tools

Challenge

How could we improve the finding of buried fasteners holes and delivery of the pre hole from rib to the skin?

What if we can do the back drilling from the outside?

The main purpose here is to create a new tool that finding the correct position from outside. It should also become modular and smarter to help the operator to find precise locations faster and easier. Thus, the operator can perform easy and error-free drilling from the outside.

Solution | Drilling Targeting Systems

The main idea was only the targeting part is separated from the main body for scanning. After finding the blind hole on the back of the fuselage with the ultrasound technology, it is locked on the surface and then the drilling unit place on the targeting piece and the hole is opened.

Benefits

• Increased accuracy

• Less human errors

• Less time consuming

• Better ergonomics

• Better guidance

• Less Tools

• Less operator

Final Design | DTS 01

The product consists of two major uses ultrasonic technology, to detect the location of the hole on the outside of the fuselage. The drilling unit locks on the target part afterward, DTS is automatically drilling final-hole without damaging the surface.

Drilling unit

The design consists of two main parts targeting and drilling unit. The targeting part is small and lightweight, making it easy for the operator to scan and find the buried hole.

Targeting Unit

Ultrasonic targeting unit passes ultrasonic sound waves into the fuselage and measure the waves that reflect back to the device. This determines the position of the buried hole.

Thanks to the flexible rubber at the bottom of the targeting unit, it provides a more comfortable attachment to the fuselage, which is always slightly curved.

In addition, the modular targeting unit can be pre-locked in many holes separately and only the drilling operation remains. Thus, the workflow can be made faster.

Ergonomics

First of all, since it is heavier than normal drills (about 1.8kg), double handles have been used to increase ergonomics, minimize shaking during drilling and make them drilling more precisely.

The angle and position of the handles are located in the center of gravity and are positioned to guide the user forward. Thus, the most ergonomic grip is provided to the operators.

Technical features

• Display

The process can be monitored continuously via display and can directly interfere when any problem is seen.

• Replaceable battery

• The drill automatically adjusts fine-tuning after locking and finds the exact position of the hole.

• Replaceable drill bit

•Tool change

Through color codes, the mistake rate is even less and the whole process gets more intuitive. It also creates a more efficient way of working.