Patent Abstract:
A portable power drill having an automatic drilling cycle for feeding a rotating tool bit to a workpiece to effect the desired operation. The drill uses a rotary gerotor pump to pump hydraulic fluid used in its system, and pressurized air to operate the hydraulic pump. The drill has a clamping assembly which clamps the unit on a workpiece before the drill bit is advanced toward the workpiece. The drill also has an integral drill spindle-planet carrier area which adds to its operability and reliability.

Full Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   This invention relates to portable power tools and more specifically, to powered drilling apparatus of the type that executes an automatic drilling cycle consisting of: (1) clamping the drilling apparatus to the workpiece and, in most instances, to a template or jig that positions the drill spindle relative to the workpiece; (2) advancing or feeding a rotating tool bit (e.g., twist drill, countersink, or combined twist drill-countersink) to effect the desired machining operations; (3) withdrawing the tool bit from the machined opening and (4) releasing the clamping mechanism that secures the drilling apparatus to the workpiece. 
   2. Description of the Prior Art 
   Pneumatically operated, self-colleting, power feed drill motors of the above-mentioned type are presently utilized in the manufacture of various structural assemblies, being of particular importance in the drilling and countersinking of precision holes during the fabrication, maintenance, and repair of airframe assemblies, including conventional transport aircraft and space vehicles. As known to those skilled in the art, such drill motors are generally clamped to the workpiece by means of a collet foot or base assembly that extends from the forward portion of the drill motor. An expansible collet that is alternatively located at a fixed position in the base assembly or mounted therein so as to be an adjustable distance from the position at which a twist drill (or other tool bit) is to contact the workpiece is operated by a mandrel that extends through the collet. The mandrel is in turn operated by an axially translatable drawbar that is connected to the piston of a pneumatic cylinder so that the collet expands and contracts as the drawbar is moved respectively away from and toward the base assembly. 
   In the most commonly employed manufacturing method, a thin metal template having openings that define the desired hole pattern is placed against a workpiece such as, for example, aircraft skin panels that are temporarily held in position against structural members of an aircraft wing, fuselage, or other such assembly or subassembly. The drill motor is then positioned so that the base assembly abuts the template with the collet extending through an opening in the template and through a previously-drilled hole in the workpiece. A shoulder or boss that circumferentially surrounds an opening through which the drill or tool bit will emerge is positioned within a second opening of the template. The power tool is then activated by squeezing a conventional trigger control on a pistol-grip type handle that extends from the drill motor and the pneumatic cylinder retracts the drawbar and mandrel so that the collet expands in the opening of the workpiece. This action insures that the base assembly remains against the workpiece and clamps the drill motor in the proper position. A pneumatic motor is automatically activated to drive the drill spindle via reduction gears and a second pneumatic cylinder drives the spindle so as to feed the rotating tool bit into the workpiece. During this portion of the sequence, a hydraulic control circuit maintains the feed rate at or within desired limits. When the outward extension of the spindle reaches a preset limit or stop position, the sequence is reversed to retract the tool bit and then move the mandrel away from the base assembly to allow the collet to contract so that the drill motor can be repositioned in a different opening of the template. 
   Although satisfactory in some situations, prior art drill motors of the above-described type exhibit several disadvantages and drawbacks. First, such drill motors are relatively large and heavy and because of such size and weight often cannot be utilized in limited quarters. Secondly, drill motors of the above-described type have remained a rather specialized tool with a single type of drill motor accommodating only a rather limited range of drilling depths, drill diameters, drilling speed and feed rate. Moreover, although an expansible collet that replaces the above-discussed base assembly adapts some prior art drill motors for use with precision drill jigs, prior art devices have not been adaptable to other manufacturing situations. 
   Another drawback and disadvantage of the prior art apparatus is that hydraulic pressure for the hydraulic control system has generally been provided by a gear-type pump that is driven by the same pneumatic motor that drives the drill spindle as well as the system feed and clamp cylinders. Because of this, the clamp-up force and feed thrust provided by prior art drill motors have not been as great as possible. Moreover, the gear-type pump of such a prior art unit is constantly driven throughout the entire period of time that the drill motor is actuated. Thus, both the pump and the pneumatically-driven motor are subject to substantial wear and maintenance. Moreover, driving the gear pump during the period in which the workpiece is being drilled or machined in another manner can unnecessarily limit the torque produced by the drill motor. This can be especially important when a drill breaks through the workpiece, since stalling is then more likely to occur. In some cases, if the drill motor stalls, hydraulic power may terminate and allow the drill motor to unclamp from the workpiece. Such unclamping can assert bending loads that break the drill bit and/or damage the hole that has been machined in the workpiece. 
   Additionally, the hydraulic control circuits utilized in the prior art drill motors to automatically sequence the tool through the steps of “clamp-up,” drill thrust, drill retraction and unclamping, are relatively complex and are not as reliable as is often desired. In some cases, the requirements of the pneumatic drill motor reduce the clamp-up and thrust forces to a degree that results in hole elongation, drill breakage, or other damage. Prior art drill motors have limited hole-making accuracy because the forward and rear drill spindle support bearings are not rigidly attached in an essentially one-piece housing with the result that the rear bearing slides relative to the front bearing while the machine is drilling. This sliding requires mechanical clearance, which when combined with the resistance developed by the hydraulic feed control mechanism which is not in line with the feed force, causes the rear spindle bearings to move off-axis from the centerline of the hole to be drilled. In addition, the forward spindle bearing is a plain bearing which needs clearance to prevent seizure of the drill spindle. This clearance also limits the potential accuracy of the drilled hole, and allows fine drilling chips into the clearance between the spindle and plain bearing. The chips cause accelerated wear, reducing hole accuracy and increasing tool maintenance. 
   One United States patent which attempted to address the shortcomings of the prior art discussed above is U.S. Pat. No. 4,594,030 issued to Weigel. This particular embodiment had advantage over the drills in the prior art, but had difficulties due to its design. One of the major drawbacks of Weigel was that hydraulic pump design problems arose with its piston-type shuttle pump resulting in air leaking in the oil used in that pump, resulting in air bubbles in the hydraulic system causing failure ultimately. Means to bleed air from the system were lacking. Further, the drill used a plain spindle bearing which had difficulty with its ability to be lubricated. Given the allowed clearance for the disclosed bearing, it was impossible to get a proper oil film on it to facilitate lubrication. If more clearance in the drive system was built in to allow the bearings to be coated with oil, thereby preventing excess heat and eventually failure, accuracy of the drilled hole was sacrificed. This one defect rendered the unit of that patent problematic during operation. 
   Other problems with Weigel included its clamping system wherein the unit is clamped to the workpiece prior to drilling. The many linkages involved resulted in binding problems which were significant. The linkage was not strong enough in the high clamp forces created by the hydraulic clamp cylinder which assured a tight clamping to the workpiece. The links in the Weigel system tended to flex and eventually jam. Other shortcomings of the system of the Weigel patent also existed including the force required to operate the drill trigger, and the fact that the collet of the clamping system pulled only with a center pin, resulting in less strength and rigidity in that system than what was desired. 
   Accordingly, it is an object of this invention to provide a drill for drilling precise and accurate holes on a workpiece, such as an airplane fuselage, which functions efficiently, smoothly, and consistently. 
   Another object of the present invention is to provide a drill that is adaptable to a large number of drill bit sizes and drilling requirements specified in the aircraft industry. 
   Yet another object of the present invention is to provide a drill apparatus that can be used to drill holes in applications that require accuracy. 
   SUMMARY OF THE INVENTION 
   These and other objects of the present invention will be accomplished by the drill apparatus as described in the following summary and disclosure. In the main embodiment, the drill is a pneumatic-hydraulic drill which has a main housing. The main housing has an opening running longitudinally therethrough from what can be considered the front end of the drill (the end closest to the workpiece during operation) to the rear end of the drill. The drill apparatus has as one of its component assemblies used during its operation a hydraulically activated feed cylinder. The feed cylinder is external to the main housing of the drill unit and is located adjacent to the rear end of the housing mentioned above. In its simplest terms, the feed cylinder has a forward and rearward end in which the forward end is adjacent to the rear end of the main housing with a central bore running through the feed cylinder. The central bore of the feed cylinder is substantially parallel to the opening within the main housing. The feed cylinder also has an outer piston having an axial bore that extends forward from the piston partially disposed within it. The outer piston can move axially within the central bore of the feed cylinder and main housing. The feed cylinder also includes in it a stationary inner piston having a bore disposed in the bore of the outer cylinder. 
   The drill apparatus according to the present invention also has a pneumatically activated motor. This pneumatically activated motor is configured to fit within the opening aforementioned in the main housing. The pneumatically activated motor has a forward end (the end closest to the workpiece) and a rear end. The rear end of the pneumatically activated motor is attached to the forward end of the bore of the outer piston. As mentioned above, the bore of the outer piston is in fluid communication with the pneumatically activated motor. The communication between the bore of the outer piston and the pneumatically activated motor allows pressurized air to be supplied to the pneumatically activated motor during operation of the drill. The pressurized air will allow the pneumatically activated motor to eventually turn the drill spindle of the drill apparatus allowing a drill bit to drill a hole in the workpiece. As the pneumatically activated motor is connected to the bore of the outer piston, the pneumatically activated motor can be moved along a longitudinal axis through its center. If the outer piston is in a retracted position, the pneumatically activated motor will be in a rearmost position. When the outer piston is in an extended position, the pneumatically activated motor will be in a forward position with the main housing. 
   To supply pressurized hydraulic fluid to the hydraulic circuit of the drill apparatus, a pneumatically operated rotary gerotor pump is provided. The rotary gerotor pump differs in a significant way from a conventional piston-type shuttle pump in its operation and ultimately in the results it produces an efficient operation of the drill apparatus. The rotary gerotor pump is actuated by an air motor connected thereto which when activated pressurizes hydraulic fluid with the hydraulic circuit of the apparatus. The hydraulic fluid is delivered to the feed cylinder of the apparatus which drives the retraction and extension of the outer piston. 
   To allow operation of the drill of the present invention with all of its requirements and versatility, a valve system is used to control the operation of the drill. The valve system of the drill uses a number of valves responding to pneumatic or hydraulic pressure which controls the clamping operation and the drilling operation of the drill apparatus. To supply air from a source of pressurized air, such as a compressor, to the proper parts of the drill apparatus, a circuit is provided. The circuit supplies pressurized air to the bore of the outer piston. The circuit also provides pressurized air to the rotary gerotor pump and to the valve system mentioned above. This circuit for supplying air from a source of pressurized air also includes a sub-circuit for supply air to the rotary gerotor pump. The drill also has a second circuit which serves to supply pressurized hydraulic fluid to the feed cylinder and to the valve system of the drill apparatus. 
   The rotary gerotor pump of the present invention has a gerotor assembly which replaced the prior art hydraulic pump internal assembly so as to prevent pressurized air from the air motor of the pump from leaking into the hydraulic fluid used by the rotary gerotor pump. To that end and more specifically, the gerotor assembly of the rotary gerotor pump of the present invention has a first gear with external gear teeth and a second gerotor gear having internal teeth which cooperate with the teeth of the first gear. With this setup and suitable seals, as will become more apparent from the detailed description of the rotary gerotor pump and its cross-sectional figure, the problem of pressurized air leaking into the pump and contaminating the hydraulic fluid of the pump with air bubbles is obviated. The rotary gerotor hydraulic pump of the present invention also conveniently allows for a reservoir of hydraulic fluid being in the circuit of hydraulic fluid. The reservoir is located outside the main housing of the apparatus, preferably for convenient venting to remove any air bubbles which may appear in the hydraulic fluid used in the drill. The rotary gerotor pump of the present invention also provides for a filter which is used to prevent circulation of foreign particles in the hydraulic system thus preventing wear and malfunction within the drilling apparatus. 
   The operation of the drill is initiated by an operator pulling a trigger conveniently situated on the drill. To make this operation somewhat easier for the operator, in a preferred embodiment of the apparatus, a pilot valve is provided which is responsive to the operator&#39;s finger movement. The pull of the trigger of the apparatus opens the pilot valve which in turn operates a pulse valve. The force required on the trigger to operate the pilot valve is significantly less than the force required to pull the trigger without a pilot valve. The operator, therefore, is less susceptible to tiring, especially after extended use of the drill as the force required by the operator&#39;s trigger finger during operation of the drill is diminished. 
   One other aspect of the circuit supplying pressurized air to the drill deserves mention, as it is an improvement over the prior art. In the apparatus of the present invention, an automatic cycle mode is provided. Essentially, the circuit for providing pressurized air to the drill during operation is such that when automatic mode is activated, the trigger is held depressed until the hole is completely drilled. Upon completion of the drilling of the desired hole, the drill bit is retracted from the hole by movement of the feed cylinder. At this point the drill unit turns itself off stopping turning of the drill bit. The drill, however, remains clamped to the workpiece. The net result is that the amount of air wasted on turning the drill bit when it is retracted from the hole is eliminated. This savings of pressurized air becomes significant as the amount of usage of the drill increases in its normal application. 
   Another sub-assembly of the drill apparatus is the drill spindle assembly. The drill spindle assembly includes a drill spindle extending from the opening in the main housing at the front end of the main housing (the end closest to the workpiece). The drill spindle has a front end and a rear end with the rear end connected to the pneumatically actuated motor discussed somewhat previously. The drill bit for actual drilling of the hole in the workpiece will extend from the front end of the drill spindle and preferably is threaded into the drill spindle. The drill spindle is able to accommodate a wide selection of drill bits depending on the application and its specific requirements. In a preferred embodiment of the drill spindle, the rear end of the drill spindle is integral with a planet gear carrier. In prior art applications, it can be mentioned that a joint occurred at this interface which resulted in problems with the operation of the drill, especially regarding precision and accuracy of the drilled hole. As will be described in further detail in a later section of the disclosure, a planet carrier is integral with the spindle resulting in elimination of a joint therebetween. 
   The clamping assembly of the present invention serves to securely clamp the drill to the workpiece so as to permit accurate drilling of the desired holes. The clamp assembly has a front end (the front end being the end nearer the workpiece) and a rear end further from the workpiece. The clamp assembly includes a hydraulically activated clamp cylinder which is connected to the rear end of the clamping assembly. The hydraulically activated clamp cylinder is axially aligned with the clamp assembly as a whole. The clamp cylinder has a bore, and the clamp cylinder has a front end and rear end. The clamp cylinder also includes a piston and a collet puller disposed within the bore of the clamp cylinder. The piston and collet puller are configured for movement axially within the bore of the clamp cylinder. The clamp assembly also includes a collet having an axial bore and collapsible outer diameter with a pilot disposed in the axial bore. The pilot is fixed to the collet puller of the clamp cylinder and moves axially in response to movement of the collet puller and piston of the clamp cylinder. To clamp the drill unit on the workpiece, the collet with tapered pilot therein is placed through a given pre-drilled hole. When the pilot is fully forward within the collet, the trigger is activated. The collet with pilot therein is larger in diameter than the pre-drilled hole. The drill is in a stable clamped position on the workpiece prior to drilling of a new hole when the piston and collet puller are moved rearward with the collet and pilot therein acting as a single tension member. It should also be mentioned that the clamping assembly includes a clamp foot. The clamp foot abuts the workpiece and is mounted on the drill. The collet fits through an aperture in the foot. The clamp foot serves to support and stabilize the drill and in its preferred embodiment is generally symmetrical. Also in the preferred embodiment, the clamp foot is configured to allow movement of the collet relative to the clamp foot. 
   The valving of the drill unit also includes a four-way, two-position hydraulic valve that is positioned between the hydraulic pump and the feed and clamp cylinders. The hydraulic valve is actuatable between a first position wherein pressurized hydraulic fluid is supplied to the retract chamber of the feed cylinder causing the piston to retract, and a second position wherein pressurized hydraulic fluid is applied to the extend chamber of the feed cylinder causing the piston to extend. A spring pilot biases the hydraulic valve in its first position and an air actuated pilot moves the hydraulic valve from its first to its second position when pressurized air is supplied to the pilot. The air actuated pilot is in fluid communication with a retract valve that is mounted in the forward end of the casing. The retract valve initiates the actuation of valves to cause the motor to retract and also operates as a mechanical stop to limit the forward travel of the motor. 
   A pulse valve is positioned between the pilot valve actuated by the trigger of the drill, and the portion of the pneumatic circuit consisting of the retract valve and the pilot of the hydraulic valve. The pulse valve is actuatable between a first position wherein the retract valve and pilot are in fluid communication with the pilot valve and a second position wherein the retract valve and pilot are isolated from the pilot valve. The pulse valve transmits a pulse of pressurized air to the retract valve and the pilot of four-way hydraulic valve when the pulse valve is in its first position. A first pilot moves the pulse valve into the first position when the pilot valve is first actuated, and a second pilot moves the pulse valve into its second position a set time interval after the pilot valve has been actuated. 
   The drill unit also includes a sequence valve that is positioned between the hydraulic valve and the extend chamber of the feed cylinder. The sequence valve is actuatable between a first position wherein the hydraulic valve is not in fluid communication with the extend chamber and a second position wherein the hydraulic valve is placed in fluid communication with the extend chamber. The sequence valve includes a hydraulic pilot that moves the sequence valve into its second position when the hydraulic pressure reaches a predetermined percentage of the final value. This results in a time delay that insures that the drill unit is clamped to the workpiece before the feed cylinder begins to advance the motor and tool bit toward the workpiece. 
   In the preferred embodiment, the pulse valve and a portion of the pneumatic circuitry is housed within a pneumatic module that is mounted to the casing. A hydraulic logic module that also mounts to the casing contains the hydraulic valves and a portion of the drill unit hydraulic circuitry. 
   When the drill unit is to be used in a drilling operation, it is attached to a source of pressurized air. Upon supplying pressurized air to the drill unit, the hydraulic pump operates to establish the necessary hydraulic pressure to activate the feed and clamp cylinders. The collet of the drill unit is inserted into a hole that has been previously drilled in the workpiece, and the foot of the clamp unit is held against the workpiece or a template attached to the workpiece. When the tool bit of the drill unit is aligned with the location at which a hole is to be drilled, the trigger valve is actuated and pressurized air is supplied to the air motor causing it to rotate the tool bit. Actuation of the trigger valve also allows pressurized air to pass through the pulse valve and pressurize the retract valve and the pilot of the hydraulic valve, thereby moving the hydraulic valve into its second position which allows hydraulic fluid to pressurize the clamp and feed cylinders. After pressurization of the retract valve and the pilot, the pulse valve shifts into its second position, isolating the retract valve and pilot from the rest of the pneumatic circuit. 
   When the hydraulic valve is shifted into its second position, pressurized hydraulic fluid is directed to the clamp cylinder causing the collet to clamp to the inner surface of the hole into which it was inserted. Pressurized hydraulic fluid is simultaneously directed to the sequence valve. The sequence valve is actuated by its hydraulic pilot when a predetermined pressure is reached due to stalling of the clamp assembly on the workpiece and allows hydraulic fluid to flow to the extend chamber of the feed cylinder. When the pressurized hydraulic fluid enters the extend chamber, the piston of the feed cylinder is urged forwardly, thereby advancing the motor and rotating the tool bit toward the workpiece. Once a hole has been formed in the workpiece, the motor contacts the retract valve. The retract valve is actuated to release pressurized air to the atmosphere, thereby releasing the pressurized air held in the circuit formed by the retract valve and the pilot of the hydraulic valve. When the pressure at the pilot is released, the hydraulic valve is moved back into its first position by the spring pilot to start the retract portion of the drilling cycle. 
   With the hydraulic valve in it first position, pressurized hydraulic fluid is directed to the retract chamber of the feed cylinder and the extend chamber of the clamp cylinder. The pressurized hydraulic fluid filling the retract chamber of the feed cylinder causes the feed cylinder to retract the motor and tool bit away from the workpiece. The pressurized hydraulic fluid supplied to the pilot-operated check valve of the clamp circuitry causes the collet to unclamp and allows the drill unit to be withdrawn from the workpiece, thus completing a drilling cycle. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a drill in accordance with the present invention looking down upon the drill and from the right side. 
       FIG. 2  is a perspective view of a drill in accordance with the present invention looking up at the drill from the right side from a position rear of the drill. 
       FIG. 3  is a perspective view of a drill in accordance with the present invention looking up at the drill from the left side and from a position forward of the drill. 
       FIG. 4  is a cross-sectional view of the drill of the present invention showing the drill assembly of the apparatus. 
       FIG. 5  is a cross-sectional view of the drill spindle assembly of the present invention. 
       FIG. 6  is a cross-sectional view of the clamp assembly of the present invention. 
       FIG. 7  is a cross-sectional view of the rotary gerotor hydraulic pump of the present invention. 
       FIG. 8  is a schematic diagram of the pneumatic-hydraulic circuit of the present invention. 
       FIG. 9  is an isometric view of the drill spindle-planet carrier area of the present invention showing the integral assembly from two angles. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Referring now to the drawings, and especially to  FIGS. 1 ,  2 , and  3  initially, the general configuration of a drill apparatus can be described. One of the main components of the drill of the present invention is a drill spindle assembly generally designated as reference numeral  100 . The drill spindle assembly  100  has a main housing  105 , and nosepiece  103  extending from the forward end of the main housing  105 . The details of the nosepiece  103  and of the drill spindle  100  will be described later in the disclosure, the present discussion identifying only the general configuration of the drill. In any case, the drill nosepiece  103  holds a drill bit  101  which extends from the forward end of the drill nosepiece  103 . The drill bit  101  is used to perform work on a hole in the workpiece (not shown in  FIGS. 1 ,  2 , and  3 ). The main housing  105  contains an air motor  107  (best seen in  FIG. 4 ) which serves to rotate the drill bit  101  during operation of the apparatus. A feed assembly generally designated as  800  has as a component feed cylinder  801 . Feed cylinder  801  controls movement of the drill spindle assembly  100  to and from the workpiece in an axial direction. The feed cylinder  801  extends from the rearward end of main housing  105  of the drill spindle assembly  100 . In fluid communication with the feed cylinder  801  is a hydraulic pump  300 , and more specifically, a pneumatically operated rotary gerotor pump which delivers pressurized hydraulic fluid to feed cylinder  801  during operation of the apparatus. A valve system which will be described later in the disclosure and a circuit for providing pressurized air to the various components and assemblies of the drill will be described in further detail later in the disclosure. The hydraulic pump  300  has a reservoir  301  which holds a suitable quantity of hydraulic fluid for use in the hydraulic circuitry of the drill including the feed assembly  800  and hydraulic valve system which will be further described in a later section of the disclosure. The hydraulic pump is also connected to an air motor  303  which is located forward of the hydraulic pump  300  and serves to operate the hydraulic pump  300  taking pressurized air from a source not shown. The hydraulic pump  300  of the drill also is connected with hydraulic hoses  907 A and  907 B to a clamp assembly  200  located on the side of the drill to the right of the drill spindle  100  when the drill is being operated. Clamp assembly  200  has as its purpose to clamp the drill to a workpiece thereby allowing more precise drilling operations on any hole to be made in the workpiece. To that end, clamp assembly has a clamp cylinder  209  which has a clamp cylinder base  207  fixed thereto. A collet  203  extends from the forward end of the clamp cylinder base  207 . Collet  203  has a pilot  205  disposed in an axial opening of the collet  203 . The pilot  205  is adapted for axial movement within the collet  203  in response to hydraulic fluid from the hydraulic pump  300 . The pilot  205  has a retracted position within the collet  203  whereby the collet can be fit within a pre-existing hole in the workpiece prior to clamping the drill to the workpiece. The pilot  205  also has an extended position within the collet  203  whereby the hydraulic pressure holds the clamp assembly and therefore the drill apparatus to the workpiece. Another part of the clamp assembly  200 , preferably, is a clamp foot  201 . Clamp foot  201  is slidably attached to clamp cylinder base  207  at its forward end and has an opening therethrough which collet  203  is disposed in during operation of the drill. Clamp foot  201  also is attached to the nosepiece  103  of drill spindle  100  at its forward portion and has a suitable opening at the left end of the clamp foot  201  to receive the drill bit  101 . The clamp foot  201  also has a tail pad  211  at its left end (the end nearer the clamp assembly  200 ) to keep the drill spindle square with the workpiece when drilling, compensating for the thickness of tooling used to locate holes. 
   The drill apparatus has a main bracket designated as  905  which essentially holds the assemblies of the drill together. The main bracket  905  holds the drill spindle substantially circumferentially around the main housing  105 , and also receives the forward end of air motor  303  of the hydraulic pump  300 . It also holds a pneumatic block  700  of the drill apparatus. Hydraulic block  600  is adjacent to pneumatic block  700  and contains hydraulic valving and circuitry relating to routing and distribution of hydraulic fluid through the assemblies of the drill apparatus during operation. Pneumatic block  700  contains pneumatic valving and circuitry relating to the routing of pressurized air to the various assemblies of the drill during operation. Handle  901 , which is located underneath the apparatus, and is the point of grip for the operator of the drill apparatus. It should also be pointed out that a drill lubrication system  500  is mounted on the left side of the main housing using main bracket  905 . The drill lubrication system  500  serves to create a mist of air and lubricant that is pumped through the drill bit  101  to lubricate the drill bit and blow chips out of the hole during drilling, greatly increasing hole accuracy. 
   Referring now to  FIG. 4  which shows a cross-section through several assemblies of the drill, more detail as to the configuration of the drill can be presented.  FIG. 4  shows the main housing  105  of the drill containing a main air motor  107 . It is the function of the main air motor  107  disposed in main housing  105  to rotate the drill bit  101  for drilling a hole in a workpiece. The main air motor responds to pressurized air routed to it during operation to perform this function. The main air motor  107  is connected at its rearward end to an outer feed piston  807  at least partially disposed within feed cylinder  801 . Outer feed piston  807  has disposed within it an inner feed piston  805  extending from its rearward end. Outer feed piston  807  has an axial bore  806  and slides over inner feed piston  805  which has an axial bore  804  itself. Outer feed piston  807  has an axial bore  806  and “telescopes” over inner feed piston  805  which has an axial bore  804  itself. The axial bores  804  and  806  within pistons  805  and  807  respectively serve as a conduit which feeds pressurized air to main air motor  107  during operation of the drill. The outer feed piston  807  pushes drill spindle assembly  100  forward and rearward in response to the hydraulic circuit of the drill. Feed cylinder  801  has a central bore  802  which houses inner feed piston  805  and outer feed piston  807 . Feed cylinder  801  has an end cap  803  which seals the rearward end of feed cylinder  801 . The forward end of outer piston  807  is threadably connected to a motor retainer  809  which is located on the rearward end of the main air motor  107 . The motor retainer  809  supports air motor  107  within housing  105 . A feed rate body  811  is provided on hydraulic block  600  which regulates the speed of movement of drill assembly  100  using a feed control restrictor  813 . Feed rate body  811  has a feed rate screw (not shown) which is disposed in an inner passage of feed rate body  811 . The feed rate screw is threaded and can vary the rate of hydraulic fluid flowing from the feed rate body  811  by changing the length of a triangular passage formed by the screw and body. The rate of movement of the drill assembly  100  toward and away from the workpiece can thereby be controlled by adjusting the feed screw. It can be mentioned that prior art drills used a needle valve which proved to malfunction as the passages for fluid transmission were too small and tended to clog easily. Further detail as to the cooperation of these enumerated parts will follow in subsequent disclosure including the operation of the feed cylinder  801  in moving the main air motor  107  in an axial direction within the housing  105 . 
   The drill spindle assembly  100  is connected to the forward end of the main air motor  107  via a planetary gear train and extends forwardly from the main housing. As shown in  FIG. 4 , that assembly has a drill spindle  113  which holds a drill bit  101 . The drill bit  101  extends from the forward end of the drill spindle  113  and is threaded to the drill spindle  113 . The drill spindle  113  sits on bearings designated collectively as  111  ( FIG. 4 ) within the nosepiece  103  and the main housing  105 . The drill bit  101  and part of the drill spindle  113  extend through the left section of the clamp foot  201  during operation of the drill. The drill spindle assembly also includes wear rings  115 A and  115 B disposed in the main housing  105  which abut the inner circumference of the main housing  105 . A motor carrier  109  is provided which supports the main air motor  107  within the main housing  105  as it is moved axially by hydraulic pressure through the feed cylinder  801 . The motor carrier  109  contacts the inner surface of wear rings  115 A and  115 B. 
   At the rear end of the main housing  105 , a manifold block  917  is provided. The manifold block connects air and oil passages from a hydraulic block  601  and pneumatic block  701 . These two blocks  601  and  701  provide valving and circuits which route hydraulic fluid and pressurized air through the apparatus and to the drill spindle assembly  100  during operation which will be described later in the disclosure using the schematic diagram of  FIG. 8 . The pneumatic block  701  is located forward of hydraulic block  601  and directly above handle  901  of the drill. The pneumatic block  701  is connected to the main bracket  905  of the drill. A trigger  903  is provided on the forward side of handle  901  which initiates operation of the drill when it is connected to a source of pressurized air. An auto cycle engage button  915  is located on the rear side of the handle  901  and when depressed initiates an automatic cycle that holds trigger  903  depressed until a hole in the workpiece is completely drilled. Upon completion of the drilling of the hole, the drill bit  101  is retracted from the hole just drilled. The rotation of the drill bit  101  stops but the drill remains clamped to the workpiece. The net result is that large amounts of pressurized air are saved as the drill spindle is not rotating needlessly after drilling a hole and prior to unclamping the drill. 
   Drill Spindle Assembly 
   Referring now to  FIG. 5 , the drill spindle assembly can be described in detail. In that figure, a nosepiece  103  is shown extending from main housing  105  of the drill spindle assembly at the forward end of the main housing  105 . The nosepiece  103  is secured to the main housing  105  with a V-band  913 A. Disposed partially within the nosepiece  103  and partially within the main housing  105  is a drill spindle  113 . Drill spindle  113  has a drill shank locating hole  133  tapped in its forward end. The drill shank locating hole  133  has a tapered portion  135  and a threaded portion  137  to accommodate and threadably fix drill bit  101  to the drill spindle  113 . A coolant hole  139  axially runs through the drill spindle filler  123  and communicates with shank locating hole  133 . The coolant hole  139  receives coolant from the coolant system assembly  500  ( FIG. 1 ) mounted on the main housing  105 . The drill spindle  113  is situated within the nosepiece  103  on angular contact bearings  111 A and  111 B. These bearings  111 A and  111 B are separated slightly by a bearing spacer  129 . The bearings  111 A and  111 B also have a cavity  128  which holds a preload spring  131 . A bearing retainer  127  is located rearward of bearing  111 A and holds the bearings  111 A, B in place within the nosepiece  103 . The bearing retainer  127  abuts a muffler  117  which is disposed in the main housing  105 . The rearward end of the drill spindle  113 , the portion which is disposed within the main housing  105 , contains a planet gear assembly  121 . Spindle  113  has a planet carrier area  141  which contains four gear axles designated as  143  running through the planet gear assembly  121 . The configuration allows for an integral drill spindle  113  and planet carrier  141  which eliminates any joint between the planet carrier  141  and spindle  113  which increases the accuracy of the spindle  113 . On the forward side of the planet gear assembly  121 , an angular contact bearing  111 C is situated and on the rearward side an identical bearing, designated as  111 D, is located. The bearing  111 D abuts an air motor bearing spacer  119  which is disposed in the front end of the main air motor  107 . The planet gear assembly  121  and drill spindle  113  are extended out forwardly from the main air motor  107 . A preload spring  131 A abuts the inner race of bearing  111 C and gear axle body  141 . 
   A ring gear  125  is provided which is located adjacent the planet gear  121  at the circumference.  FIG. 5  also shows a wear ring  115 A between the main air motor  107  and housing  105  which forms a bearing surface between the air motor  107  and housing  105 . The wear ring  115 A is necessary due to the relative axial movement of an air motor carrier  109  relative to the main housing  105 . A fluid inducer body  911  is provided forward of the bearing  111 C and the main air motor  107 . A fluid inducer seal  919  is located circumferentially adjacent to the rearward position of drill spindle  113 . Fluid inducer  911  allows coolant and air from coolant system assembly into the rotating drill spindle  101  during operation of the drill. Inner fluid inducer  919  performs a sealing function and is preferably made of a composition of Teflon, graphite, and carbon fiber. Inner fluid inducer rides against the drill spindle  101 , floating in two O-rings which allow it to move with any spindle irregularity without pushing on drill spindle  101  itself. The material chosen for the inner fluid inducer  919  has a high degree of chemical resistance, low swelling capability, high wear resistance, and good anti-seize properties to maintain a close fit to drill spindle  101  during operation even at high speeds for the most efficient cooling of the drill point. 
   Clamp Assembly 
   Referring now to  FIG. 6 , the clamp assembly of the present invention can be described. Clamp assembly, generally designated as  200  in  FIG. 6 , has a clamp cylinder  209  fit to a base  207  located at its forward end. Clamp cylinder has a push chamber  225  which is that space within clamp cylinder  209  located rearward of a clamp piston  221 . Clamp cylinder  209  also has a pull chamber  223  located forward of clamp piston  221 . These chambers  223  and  225  vary in volume depending on movement of piston  221  in response to hydraulic fluid from the hydraulic circuit of the drill. Hydraulic fluid can be directed into either chamber  223  or  225 . Attached to clamp piston  221  is a collet puller  219 . Collet puller  219  is a rod which holds a collet  203  at its forward end while being connected to clamp piston  221  at its rearward end. Collet  203  is partially disposed within collet puller  219  and extends from the forward end of collet puller  219 . Collet  203  has axial slots which allow its outer diameter to be collapsible. A tapered pilot  205  is disposed within the collet  203  and has a pilot flange  227  which fits the pilot  205  within the collet puller  219  independently of the collet  203 . A collet guide  215  is also provided in the clamp assembly  200  which serves as a guide for alignment of the collet  203  and to create friction resisting collet axial movement. The collet guide abuts the forward end of the clamp cylinder base  207 . The clamp assembly  200  is also provided with a clamp foot  201  which in operation of the drill rests on the work-piece  213  to be drilled. The collet  203  and pilot  205  extend through a suitable opening in the clamp foot and into a pre drilled hole in the workpiece  213 . The clamp cylinder base  207  and collet guide  215  fit within a recess area  218  of the clamp foot  201  and are held fast during operation of the clamp assembly. A collet push flange  217  is provided on the collet  203  which contacts the fixed collet guide  215  during pushing of the collet  203  serving as a limit to its forward axial movement as shown in  FIG. 6  which depicts an unclamped position of the clamp assembly  200 . To initially fit the collet  203  in a hole in the workpiece, the pilot  205  is at a forward limit with collet  203 . The collet  203  can be collapsed slightly to fit into the hole in the workpiece until the flange portion  204  of the collet  203  extends out of the hole. The unclamped position of clamping assembly  200  is shown in  FIG. 6 . To clamp the clamp assembly  200  to the workpiece  213 , hydraulic fluid is directed to the pull chamber  223  which forces clamp piston  221  rearward. Collet puller  219  and pilot  205  are forced rearward. Collet  203  is not moved until collet puller face  250  contacts collet puller flange  251 . Pilot  205  thereby moves axially relative to the collet  203 , forcing the outer diameter of the collet  203  to expand. This expansion causes the outer diameter of collet flange  204  to be larger than the hole in the workpiece. As collet puller  219  continues to pull, puller face  250  contacts collet pull flange  251 . Collet  203  and pilot  205  are pulled simultaneously. The collet  203  and pilot  205  both act as a tension member during pulling adding an increase in strength and rigidity compared to prior art designs which only pull with the pilot. 
   Rotary Gerotor Hydraulic Pump Assembly 
   Referring now to  FIG. 7 , the rotary gerotor hydraulic pump assembly generally designed as  300  can be described. The hydraulic pump assembly  300  has a fluid reservoir  301  at its rearward end (orientation best seen in  FIG. 1 ) which is joined thereto through a join plate  307 . Fluid reservoir  301  holds a quantity of hydraulic fluid which is used in the hydraulic circuit of the drill apparatus. Fluid reservoir  301  has a snorkel  311  which serves as a feed conduit from the fluid reservoir  301  to the rotary gerotor pump  302 . Fluid reservoir  301  has an oil return area  317  which receives hydraulic fluid returning from the hydraulic circuit of the drill apparatus. A reservoir fill port  315  is also provided which opens to the oil return area and is used when hydraulic fluid is to be added to the fluid reservoir  301 . All hydraulic fluid added to the fluid reservoir  301  or returning from the hydraulic circuit of the drill apparatus is filtered through filter  309 . The filtering of small particles of debris from the hydraulic circuit of the drill apparatus has an obvious beneficial effect on the operation and reliability of the drill. It can be mentioned that prior art drills had problems with debris prematurely wearing and clogging the hydraulic circuit of the drill apparatus. Fluid reservoir has a chamber  319  where the hydraulic fluid is stored and air is separated from the hydraulic fluid. It is well know that in prior art drills air bubbles not yet bled from the system contaminate the hydraulic fluid used in the hydraulic circuit of the drill. The storage and separation chamber allows air bubbles to separate from the hydraulic fluid before being recycled to the hydraulic circuit of the drill. To that end a bleed port is provided in the rearward end of the reservoir  301  which allows bleeding of any air separated from the hydraulic fluid in the chamber  319 . Reservoir  301  has a volume changer  305  disposed therein. 
   At the forward end of the rotary gerotor pump  302 , an air motor  303  is provided and is attached thereto through a pump to motor adapter  339 . The air motor  303  receives pressured air from the air circuit of the drill apparatus and powers rotary gerotor pump  302  during operation of the drill. Air motor  303  has an end fitting  341  which closes off its forward end. Air motor  303  is connected to a drive shaft  333  which is disposed in the rotary gerotor pump  302 . Rotary gerotor pump  302  receives the drive shaft  333  within an outer housing  331 . The outer housing  331  holds a gear assembly with an outer gerotor  329  and an inner gerotor  327  which are keyed to the drive shaft  333  with a key  325 . In this setup, the air motor  303  when operating turns drive shaft  333  which in turn rotates inner gerotor  327  and outer gerotor  329 . Hydraulic fluid from reservoir  301  is drawn through snorkel  311  into pump  302  and circulated through the hydraulic circuit of the drill apparatus. Drive shaft  333  disposed within the housing  331  of the rotary gerotor pump  302  is supported by bearing  321  at its rearward end. Bearing  321  is held in place by a bearing carrier  323  abutting housing  331 . Seal  337  is provided around drive shaft  333  to prevent the mixing of pressurized air from air motor  303  and hydraulic fluid from rotary gerotor pump  302 . Also, to support the drive shaft  333  at its forward end, within the adapter  339  a ball bearing  335  is provided which performs that function efficiently. This above described hydraulic pump assembly  300  has significant advantage over the prior art. With this hydraulic pump assembly, the problem of air leaking into the hydraulic fluid of the hydraulic circuit in the drill apparatus through the pump has been abated. The use of the rotary gerotor pump as the hydraulic pump in the drill, as opposed to a conventional piston-type shuttle pump, avoids one of the major problems present in prior art drills of this type, namely, the unwanted leaking of air into the hydraulic fluid of the drill. 
   Pneumatic-Hydraulic Circuit 
   Referring now to  FIG. 8 , in conjunction with the other figures, a schematic of the pneumatic-hydraulic circuit of the drill is presented.  FIG. 8  shows trigger  903  connected to a source of air, preferably 90 psi. Trigger  903  is connected to a pilot valve  703 . Pilot valve  703  supplies air to main air motor  107  and hydraulic pump assembly  300 . The pilot valve  703  is in turn connected to pulse valve  711 . This above described sub-circuit allows the drill bit  101  to turn in response to the activation of air motor  107 . The pressurized air circuit runs through the inner feed cylinder  805  to the air motor  107 . A reversing button  707  is provided, which when depressed allows the drill to retract from the workpiece and causes the clamp circuit to unclamp. Opening of pilot valve  703  allows pressurized air to momentarily reach a four-way valve  607  within the hydraulic block  600 . The four-way valve  607  controls the hydraulic fluid from pump assembly  300 . Upon activation of four-way valve  607 , hydraulic fluid is pumped through sequence valve  605  and clamp cylinder  209 . 
   A pilot check valve  603  is provided upstream of the clamp cylinder  209 . Feed control restrictor  813  is shown downstream of hydraulic fluid fed out of feed cylinder  801  to control the rate at which the drilling assembly is moved axially to a workpiece. As part of the hydraulic circuit and pump assembly, reservoir  301  is shown having a bleed port  313  and a fill port  315 . Also, as part of the schematic diagram, auto cycle engage button  915  is shown which, if activated, starts an automatic cycle mode that will hold the trigger  903  depressed until a hole is completely drilled. When the drill bit  101  is retracted from the hole, the auto cycle button allows the clamp assembly to keep the drill clamped to the workpiece with the drill bit not rotating thereby avoiding the unnecessary waste of pressurized air after the hole is drilled. 
   Operation of the Pneumatic-Hydraulic Circuit 
   The valve system of the drill unit as shown in  FIG. 8  includes a four-way, two-position hydraulic valve  607  that is positioned between the hydraulic pump assembly  300  and the feed cylinder  801  and clamp cylinder  209 . The four-way hydraulic valve  607  is actuatable between a first position wherein pressurized hydraulic fluid is supplied to the retract chamber of the feed cylinder  801  causing the outer piston  807  to retract, and a second position wherein pressurized hydraulic fluid is applied to the extend chamber of the feed cylinder causing the outer piston  807  to extend. A spring pilot biases the hydraulic valve  607  in its first position and an air actuated pilot moves the hydraulic valve  607  from its first to its second position when pressurized air is supplied to the air actuated pilot. The air actuated pilot is in fluid communication with a retract valve  921  that is mounted in the forward end of the housing  105 . The retract valve  921  initiates the actuation of valves to cause the air motor  107  to retract and also operates as a mechanical stop to limit the forward travel of the motor. 
   A pulse valve  711  is positioned between the pilot valve  703  and the portion of the pneumatic circuit consisting of the retract valve  921  and the pilot of the hydraulic valve  607 . The pulse valve  711  is actuatable between a first position wherein the retract valve  921  and pilot of valve  607  are in fluid communication with the pilot valve  703 , and a second position wherein the retract valve  921  and pilot of valve  607  are isolated from the pilot valve  703 . The pulse valve  711  transmits a pulse of pressurized air to the retract valve  921  and the pilot of valve  607  when the pulse valve is in its first position. A first pilot moves the pulse valve into the first position when the trigger valve is first actuated, and a second pilot moves the pulse valve  711  into its second position a set time interval after the pilot valve  703  has been actuated. 
   The drill unit also includes a sequence valve  605  that is positioned between the hydraulic valve  607  and the extend chamber of the feed cylinder  801 . The sequence valve  605  is actuatable between a first position wherein the hydraulic valve  607  is not in fluid communication with the extend chamber and a second position wherein the hydraulic valve  607  is placed in fluid communication with the extend chamber. The sequence valve  605  includes a hydraulic pilot (not shown) that moves the sequence valve  605  into its second position when the hydraulic pressure reaches a predetermined percentage of the final value. This results in a time delay that insures that the drill unit is clamped to the workpiece before the feed cylinder  801  begins to advance the motor  107  and drill bit  101  toward the workpiece. 
   In the preferred embodiment, the pulse valve and a portion of the pneumatic circuitry is housed within the pneumatic module or block  701  that is mounted to the drill. The hydraulic logic module or block  601  that also mounts to the drill contains the hydraulic valves and a portion of the drill unit hydraulic circuitry. 
   When the drill unit is to be used in a drilling operation, it is attached to a source of pressurized air. Upon supplying pressurized air to the drill unit, the hydraulic pump  301  operates to establish the necessary hydraulic pressure to activate the feed cylinder  801  and clamp cylinder  209 . The collet  203  of the drill unit is inserted into a hole that has been previously drilled in the workpiece, and the foot  201  of the clamp assembly  200  is held against the workpiece or a template attached to the workpiece. When the drill bit  101  of the drill unit is aligned with the location at which a hole is to be drilled, the trigger  903  is actuated and pressurized air is supplied to the air motor  107  causing it to rotate the drill bit. Actuation of the trigger  903  also allows pressurized air to pass through the pulse valve  711  and pressurize the retract valve  921  and the pilot of the hydraulic valve  607 , thereby moving the hydraulic valve  607  into its second position which allows hydraulic fluid to pressurize the clamp and feed cylinders,  209  and  801  respectively. After pressurization of the retract valve  921  and the pilot of hydraulic valve  607 , the pulse valve  711  shifts into its second position, isolating the retract valve  921  and pilot of hydraulic valve  607  from the rest of the pneumatic circuit. 
   When the hydraulic valve  607  is shifted into its second position, pressurized hydraulic fluid is directed to the clamp cylinder  209  causing the collet  203  to clamp to the inner surface of the hole into which it was inserted. Pressurized hydraulic fluid is simultaneously directed to the sequence valve  605 . The sequence valve  605  is actuated by its hydraulic pilot (not shown) when a predetermined pressure is reached due to stalling of the clamp mechanism against the workpiece and allows hydraulic fluid to flow to the extend chamber of the feed cylinder  801 . When the pressurized hydraulic fluid enters the extend chamber, the outer piston  807  of the feed cylinder  801  is urged forwardly, thereby advancing the air motor  107  and rotating the drill bit  101  toward the workpiece. Once a hole has been formed in the workpiece, the air motor  107  contacts the retract valve  921 . The retract valve  921  is actuated to release pressurized air to the atmosphere, thereby releasing the pressurized air held in the circuit formed by the retract valve  921  and the pilot of the hydraulic valve  607 . When the pressure at the pilot of hydraulic valve  607  is released, the hydraulic valve  607  is moved back into its first position by the spring pilot to start the retract portion of the drilling cycle. 
   With the hydraulic valve in it first position, pressurized hydraulic fluid is directed to the retract chamber of the feed cylinder  801  and the extend chamber of the clamp cylinder  209 . The pressurized hydraulic fluid filling the retract chamber of the feed cylinder causes the feed cylinder  801  to retract the air motor  107  and drill bit  101  away from the workpiece. The pressurized hydraulic fluid supplied to the pilot-operated check valve  603  of the clamp circuitry causes the collet  203  to unclamp and allows the drill unit to be withdrawn from the workpiece, thus completing a drilling cycle.

Technology Classification (CPC): 8