Limited Access Drilling

A powerful and rugged 1-inch diameter drilling machine includes independently controlled drill and feed motors. Electrostatic motor technology is employed for creating high torque in a compact size. Commercial ion implantation techniques are used to create highly charged regions on disk rotors. The controller is an attached module that employs a variable frequency control algorithm. The algorithm provides fine grained control and updates every 5 microseconds. Automated drilling is supported, including the ability to sense and prevent jamming of the drill bit. The control algorithm adapts the speed and feed rate for different drill diameters and different materials such as aluminum, titanium, and composite. The tool will be rugged, reliable, low-maintenance, easy to use in tight spaces, well-powered, automatically controlled, safe, and operable using hands-free operation. It will have a faster cycle time than current methods because the controller will enable it to operate at maximum feed rates, while avoiding problems like delamination and jamming. It will be capable of making multiple drilling passes automatically, for example if accumulated shavings create a problem. Other problems such as tool breakage, poor hole quality, re-work, delamination, burrs, and operator fatigue should be avoided.