New design of a compact aero-robotic drilling end effector: An experimental analysis

Abstract

This paper presents the development of a normal adjustment cell (NAC) in aero-robotic drilling to improve the quality of vertical drilling, by using an intelligent double-eccentric disk normal adjustment mechanism (2-EDNA), a spherical plain bearing and a floating compress module with sensors. After the surface normal vector is calculated based on the laser sensors’ feedback, the 2-EDNA concept is conceived specifically to address the deviation of the spindle from the surface normal at the drilling point. Following the angle calculation, depending on the actual initial position, two precise eccentric disks (PEDs) with an identical eccentric radius are used to rotate with the appropriate angles using two high-resolution DC servomotors. The two PEDs will carry the spindle to coincide with the surface normal, keeping the vertex of the drill bit still to avoid repeated adjustment and position compensation. A series of experiments was conducted on an aeronautical drilling robot platform with a precise NAC. The effect of normal adjustment on bore diameter, drilling force, burr size, drilling heat, and tool wear was analyzed. The results validate that using the NAC in robotic drilling results in greatly improved vertical drilling quality and is attainable in terms of intelligence and accuracy.