Adaptive PCA-Based Normal Estimation for Automatic Drilling System of Large-Curvature Aerospace Components

Abstract

AI-integrated robotics in Industry 5.0 demands advanced manufacturing systems capable of autonomously interpreting complex geometries and dynamically adjusting machining strategies in real time—particularly when dealing with aerospace components featuring large-curvature surfaces. Large-curvature aerospace components present significant challenges for precision drilling due to surface-normal deviations caused by curvature, roughness, and thin-wall deformation. This study presents a robotic drilling system that integrates adaptive PCA-based surface normal estimation with in-process pre-drilling correction and post-drilling verification. This system integrates a 660 nm wavelength linear laser projector and a 1.3-megapixel industrial camera arranged at a fixed 30° angle, which project and capture structured-light fringes. Based on triangulation, high-resolution point clouds are reconstructed for precise surface analysis. By adaptively selecting localized point-cloud regions during machining, the proposed algorithm converts raw measurements into precise normal vectors, thereby achieving an accurate solution of the normal direction of the surface of large curvature parts. Experimental validation on a 400 mm-diameter cylinder shows that using point clouds within a 100 mm radius yields deviations within an acceptable range of theoretical normals, demonstrating both high precision and reliability. Moreover, experiments on cylindrical aerospace-grade specimens demonstrate normal direction accuracy ≤ 0.2° and hole position error ≤ 0.25 mm, maintained across varying curvature radii and roughness levels. The research will make up for the shortcomings of existing manual drilling methods, improve the accuracy of hole-making positions, and meet the high fatigue service needs of aerospace and other industries. This system is significant in promoting the development of industrial automation and improving the productivity of enterprises by improving drilling precision and repeatability, enabling reliable assembly of high-curvature aerospace structures within stringent tolerance requirements.