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<p>In osteosynthesis, the correct determination of drill channel lengths with deviations less than 0.5&#xa0;mm is crucial for selecting the screws used to fix the implant to the bone. Since the length is still determined manually, which is prone to handling or reading errors, an alternative measurement solution is demanded. Therefore, an indirect approach for accurate drill channel length measurements during drilling is presented by evaluating different in-process sensor signals from inside the drilling machine using a sensor data and knowledge fusion. The sensor signals are in particular used to detect the drill contact and the drill breakthrough event, and the axial movement of the drill, in order to finally determine the drill channel length. Experimental results for a composite reference material and for pig bones show the method’s feasibility, precision and accuracy. The achieved length measurement uncertainty is 0.12&#xa0;mm for the reference material and 0.25&#xa0;mm for bone, which meets the conditions of the screw length choice. In addition, the spring deformation of the axial coupling and the temporal offset between contact and breakthrough detection are identified as major uncertainty contributions, which show future optimization potential. Thus, the presented methodology of sensitive machining seems promising to meet the requirements for osteosynthesis.</p>

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Drill channel length measurements by means of sensitive machining and sensor data and knowledge fusion

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年7月14日

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  • Adriano Boaron,
  • Dirk Stöbener,
  • Andreas Fischer

摘要

In osteosynthesis, the correct determination of drill channel lengths with deviations less than 0.5 mm is crucial for selecting the screws used to fix the implant to the bone. Since the length is still determined manually, which is prone to handling or reading errors, an alternative measurement solution is demanded. Therefore, an indirect approach for accurate drill channel length measurements during drilling is presented by evaluating different in-process sensor signals from inside the drilling machine using a sensor data and knowledge fusion. The sensor signals are in particular used to detect the drill contact and the drill breakthrough event, and the axial movement of the drill, in order to finally determine the drill channel length. Experimental results for a composite reference material and for pig bones show the method’s feasibility, precision and accuracy. The achieved length measurement uncertainty is 0.12 mm for the reference material and 0.25 mm for bone, which meets the conditions of the screw length choice. In addition, the spring deformation of the axial coupling and the temporal offset between contact and breakthrough detection are identified as major uncertainty contributions, which show future optimization potential. Thus, the presented methodology of sensitive machining seems promising to meet the requirements for osteosynthesis.