Automated fastener system and method having automated washer installation, and method of using conductive washer

Abstract

To provide an automated fastener system having automated washer installation.SOLUTION: The automated fastener system includes an automated washer feed system holding and dispensing one or more washers, and providing a selected washer for the automated washer installation. The automated fastener system further includes: an automated fastener holder assembly holding and dispensing one or more fasteners, and providing a selected fastener for the automated washer installation; an automated shuttle assembly; an automated inspection system; an automated delivery system; an automated installation system; and a control system. The automated washer installation is performed at one or more of: before inspection of the selected fastener; after inspection of the selected fastener; or after delivery of the selected fastener and the selected washer by the automated delivery system to the automated installation system.SELECTED DRAWING: Figure 2A

Description

[Technical Field]

[0001] The present disclosure relates generally to automatic fastener systems and methods, and more particularly to automatic fastener systems and methods having automatic washer attachment of a washer, such as a conductive washer, with a fastener to obtain a fastener and washer assembly for attachment to a structure, such as an aircraft structure. [Background technology]

[0002] Fasteners, such as bolts, rivets, screws, blind fasteners, pins, and bushings, are typically used to join two or more structural members together to assemble a structure. With the increase in automated assembly and manufacturing processes, such fasteners may be automatically installed in structures, such as aircraft structures, spacecraft structures, rotorcraft structures, watercraft structures, and other vehicles and structures, to join the structural members together. Typically, a washer may be coupled to the fastener, for example, installed under the fastener head of the fastener or under the nut or collar as a grip or fastener length adjustment. However, known systems and methods for installing a washer under the fastener head of the fastener or under the nut or collar involve manual installation. Such manual installation can be time-consuming and labor-intensive, resulting in increased manufacturing time and costs.

[0003] Additionally, metal fasteners are used to join composite structures together, such as in the manufacture of aircraft, spacecraft, rotorcraft, ships, and other vehicles and structures. Such composite structures are typically made of composite materials including a matrix material, such as a resin, reinforced with a fibrous material, such as carbon fiber. Resins, in contrast to fibrous materials, are generally not electrically conductive. Good electrical contact between a composite aircraft wing, fuselage, or other aircraft structure and the metal fasteners used to fasten such structures together is important to provide electrical conductivity and static dissipation, such as in the event of a lightning strike or other electromagnetic effect (EME) and electrical event, to dissipate and conduct current energy from the lightning strike through the surface of the composite structure to the ground. For example, a composite wing structure requires an electrical path to distribute the large currents caused by a lightning strike. If there is poor electrical contact between a metal fastener and such a composite aircraft structure, such as a composite wing skin or panel, the current energy from a lightning strike cannot dissipate and may remain in the vicinity of the struck fastener and may be conducted to the undercarriage and possibly to fuel tanks within the wing, where unwanted discharges or sparks may occur as a result of hot plasma particles released from the joint due to electrical arching and / or decomposition of the material system, leading to a potential ignition source.

[0004] Known systems and methods exist for preventing or mitigating discharges and effects from lightning strikes in aircraft composite structures, such as wing fuel tanks and other aircraft composite structures. Such known systems and methods include distributing electrical current through a fastener-to-hole fit, where the fastener material engages with the composite fibers in the hole bore to direct the current through the connection and distribute it within the primary structure. For example, interference-fit fasteners, in which the fastener shank contacts the hole bore, and countersunk fasteners, in which the countersunk fastener head contacts the hole bore, may be used. However, such interference-fit fasteners may be used with sleeves, which can result in increased parts and labor. Furthermore, such countersunk fastener heads may not be sufficiently conductive to transfer sufficient loads. Furthermore, clearance-fit fasteners, which have a gap between the fastener shank and the hole bore, may not conduct electrical current well due to no or minimal contact between the clearance-fit fastener shank and the composite fibers in the hole bore.

[0005] Additionally, known systems and methods may require specialized fastener materials having multiple components, which may result in increased manufacturing costs and production problems.

[0006] Additionally, known systems and methods may require the application of an electrically insulating coating or sealant and the use of fastener cap seals to cover metal fasteners within aircraft composite wing fuel tanks to contain electrical discharges within the fastener joints and direct them away from the fuel tank or other aircraft composite structure. However, such known electrically insulating coatings or sealants and fastener seal caps can be time-consuming and labor-intensive to apply or install and inspect on aircraft composite wing sections and fuel tanks or other aircraft structures, resulting in increased manufacturing and inspection time and increased labor costs. Furthermore, such known electrically insulating coatings or sealants can be heavy, and such known fastener seal caps can be numerous, both of which can add weight to the aircraft, resulting in reduced performance and increased fuel consumption, which in turn can result in increased fuel costs.

[0007] Therefore, there is a need in the art for improved fastener systems and methods that are automated, provide automatic washer installation of washers, such as conductive washers, onto metal fasteners that can be used in electromagnetic effect (EME) applications, do not require special fastener materials having multiple parts, minimize or eliminate the use of electrically insulating coatings or sealants and fastener cap seals, save weight, and offer advantages over known fastener systems and methods. Summary of the Invention [Problem to be solved by the invention]

[0008] Exemplary implementations of the present disclosure provide improved automatic fastener systems and methods with automatic washer installation. As discussed in the detailed description below, versions of the improved automatic fastener systems and methods can offer significant advantages over known systems and methods. [Means for solving the problem]

[0009] In one version of the present disclosure, an automatic fastener system with automatic washer installation is provided. The automatic fastener system includes an automatic washer supply system that holds and dispenses one or more washers and provides a selected washer for automatic washer installation. The automatic fastener system further includes an automatic fastener holder assembly that holds and dispenses one or more fasteners and provides the selected fastener for automatic washer installation. In automatic washer installation, a selected fastener is inserted into a selected washer to obtain a fastener and washer assembly, whereby the selected washer contacts and is positioned below the fastener head of the selected fastener.

[0010] The automated fastener system further includes an automated shuttle assembly having one or more shuttle cups, wherein a selected shuttle cup receives and carries one of a selected washer from the automated washer supply system, a selected fastener from the automated fastener holder assembly, or a fastener and washer assembly.

[0011] The automated fastener system further comprises an automated inspection system having two or more inspection gripper fingers that pick up, inspect, and release one of the selected fasteners or fastener and washer assemblies. The automated fastener system further comprises an automated transport system having a transport device that transports one or more of the selected fasteners, selected washers, or fastener and washer assemblies. The automated fastener system further comprises an automated installation system having an end effector with two or more end effector gripper fingers that pick up one or more of the selected fasteners, selected washers, or fastener and washer assemblies from the transport device and further install the fastener and washer assemblies into a structure.

[0012] The automated fastener system further includes a control system including at least a controller, one or more power sources, and a computer system. The control system is configured to control the automated fastener system and the automated washer installation. The automated washer installation is performed one or more of before the automated inspection system inspects the selected fasteners, after the automated inspection system inspects the selected fasteners, or after the automated transport system transports the selected fasteners and the selected washer to the automated installation system.

[0013] In another version of the present disclosure, a method for using a conductive washer to distribute electrical current within an aircraft structure is provided. The method includes installing an aircraft fastener and conductive washer assembly within the aircraft structure. The aircraft structure includes one or more of a wing, fuselage, or tail of the aircraft. The aircraft fastener and conductive washer assembly includes a conductive washer made of a conductive material or having a conductive coating. The aircraft fastener is made of one of a metal material or a metal alloy material, and the conductive washer contacts and is positioned below a fastener head of the aircraft fastener.

[0014] The method further includes distributing electrical current from the lightning strike applied to the aircraft structure through the aircraft fastener and conductive washer assembly to the aircraft structure, the conductive washer transferring the electrical current from the fastener head of the aircraft fastener to the aircraft structure.

[0015] In another version of the present disclosure, an automated method for performing automated washer installation in an automated fastener system is provided. The automated method includes providing an automated fastener system.

[0016] The automatic fastener system includes an automatic washer supply system that holds and dispenses one or more washers and provides a selected washer for automatic washer installation. The automatic fastener system further includes an automatic fastener holder assembly that holds and dispenses one or more fasteners and provides a selected fastener for automatic washer installation. In automatic washer installation, a selected fastener is inserted into a selected washer to obtain a fastener and washer assembly, whereby the selected washer contacts and is positioned beneath the fastener head of the selected fastener.

[0017] The automated fastener system further includes an automated shuttle assembly having one or more shuttle cups, wherein a selected shuttle cup receives and carries one of a selected washer from the automated washer supply system, a selected fastener from the automated fastener holder assembly, or a fastener and washer assembly.

[0018] The automated fastener system further includes an automated inspection system having two or more inspection gripper fingers that pick up, inspect, and release one of the selected fastener or fastener and washer assembly. The automated fastener system further includes an automated transport system having a transport device that transports one or more of the selected fastener, the selected washer, or the fastener and washer assembly.

[0019] The automated fastener system further includes an automated installation system having an end effector with two or more end effector gripper fingers that pick up one or more of a selected fastener, a selected washer, or a fastener and washer assembly from the transport device. The automated fastener system further includes a control system including at least a controller, one or more power sources, and a computer system. The control system is configured to control the automated fastener system and the automated washer installation.

[0020] The automated method further includes performing automated washer installation one or more of before inspection of the selected fasteners by the automated inspection system, after inspection of the selected fasteners by the automated inspection system, or after transfer of the selected fasteners and the selected washer by the automated transfer system to the automated installation system. The automated method further includes installing the fastener and washer assembly into the structure using the automated installation system.

[0021] The discussed features, functions, and advantages can be achieved independently in various versions of the present disclosure or may be combined in yet other versions, further details of which can be understood with reference to the following description and drawings.

[0022] The present disclosure can be better understood by reference to the following detailed description in conjunction with the accompanying drawings, which show preferred exemplary versions, but which are not necessarily drawn to scale, and which are examples and are not meant to be limitations on the specification or claims. [Brief explanation of the drawings]

[0023] [Figure 1] FIG. 1 is a block diagram of an exemplary automated fastener system of the present disclosure. [Figure 2A] FIG. 1 is a front perspective view of an exemplary fastener and washer assembly that may be used in versions of the automated fastener system of the present disclosure, with the fastener and washer assembly in an exploded position. [Figure 2B] FIG. 2B is a front perspective view of the fastener and washer assembly of FIG. 2A, with the fastener and washer assembly in a partially assembled position. [Figure 2C] FIG. 2C is a front partial cross-sectional view of the fastener and washer assembly of FIG. 2B showing a clearance fit washer positioned under the fastener head of the fastener. [Figure 2D] FIG. 10 is a partial cross-sectional front view of another version of a fastener and washer assembly showing an interference fit washer positioned under the fastener head of the fastener. [Figure 3A] FIG. 2D is a front partial cross-sectional view of the fastener and washer assembly of FIG. 2C in a partially assembled and partially installed position within a structure, the fastener being a clearance fit fastener. [Figure 3B] FIG. 3B is a front partial cross-sectional view of the fastener and washer assembly of FIG. 3A, with the fastener and washer assembly in an assembled and installed position within a structure. [Figure 3C] FIG. 10 is a front partial cross-sectional view of another version of a fastener and washer assembly in an assembled and installed position within a structure, where the fastener is an interference fit fastener. [Figure 4A] FIG. 10 is a front perspective view of another exemplary fastener and washer assembly that may be used in versions of the automated fastener system of the present disclosure, with the fastener and washer assembly in an exploded position, the fastener being a protruding head fastener and the washer being a chamfered washer. [Figure 4B] FIG. 4B is a front perspective view of the fastener and washer assembly of FIG. 4A, with the fastener and washer assembly in an assembled position. [Figure 5A] FIG. 1 is a front cross-sectional view of a symmetrical chamfered washer. [Figure 5B] FIG. 1 is a front cross-sectional view of an asymmetrical chamfered washer. [Figure 6A] FIG. 4B is a front partial cross-sectional view of the fastener and washer assembly of FIG. 4A in an exploded position prior to installation on a structure, the fastener being a clearance fit fastener and the washer being a chamfered washer. [Figure 6B] FIG. 6B is a front partial cross-sectional view of the fastener and washer assembly of FIG. 6A, with the fastener and washer assembly in an assembled position and installed within a structure. [Figure 6C] FIG. 10 is a partial cross-sectional front view of another version of a fastener and washer assembly in an assembled position and installed within a structure, where the fastener is an interference fit fastener and the washer is a chamfered washer. [Figure 7]FIG. 10 is a schematic diagram of a process flow using a version of an exemplary automated fastener system of the present disclosure showing automated washer installation prior to fastener inspection. [Figure 8] FIG. 10 is a schematic diagram of a process flow using another version of an exemplary automated fastener system of the present disclosure showing automated washer installation after fastener inspection. [Figure 9] FIG. 10 is a schematic diagram of a process flow using another version of an exemplary automated fastener system of the present disclosure showing automated washer installation in the automated installation system. [Figure 10] FIG. 1 is a front perspective view of an exemplary version of an automated fastener holder assembly for holding fasteners, showing an exemplary version of an automated shuttle assembly positioned below the automated fastener holder assembly. [Figure 11] FIG. 10 is a front perspective view of an exemplary version of an automated inspection system that may be used in one version of the automated fastener system and automated method of the present disclosure, showing an inspection gripper finger holding a selected fastener above a partial cross-sectional view of an automated shuttle assembly holding a selected washer. [Figure 12A] FIG. 10 is a top front perspective view of an exemplary version of a shuttle cup of an automated shuttle assembly that may be used in one version of the automated fastener system and automated method of the present disclosure. [Figure 12B] FIG. 10 is a top front perspective view of another exemplary version of a shuttle cup of an automated shuttle assembly that may be used in one version of the automated fastener system and automated method of the present disclosure. [Figure 13] FIG. 1 is a top front perspective view of an exemplary version of a transport device of an automated transport system used in one version of the automated fastener system and automated method of the present disclosure, showing a fastener and washer assembly held within the transport device. [Figure 14A]FIG. 10 is a side perspective view of a version of an automated installation system that may be used in one version of the automated fastener system and automated method of the present disclosure, showing a robotic system having an end effector coupled to end effector gripper fingers that hold a fastener and washer assembly. [Figure 14B] FIG. 10 is a side perspective view of another version of an automated installation system that may be used in one version of the automated fastener system and automated method of the present disclosure, showing a gantry system having an end effector coupled to end effector gripper fingers that hold a fastener and washer assembly. [Figure 15] FIG. 2 is a block diagram of an exemplary version of a computer system used in one version of the automated fastener system and automated method of the present disclosure. [Figure 16A] FIG. 1 is a flow diagram of an exemplary version of the automated method of the present disclosure. [Figure 16B] FIG. 10 is a flow diagram of another exemplary version of the automated method of the present disclosure. [Figure 17] 1 is a perspective view of an aircraft incorporating an aircraft structure having fastener and washer assemblies of a type that can be installed by versions of the automated fastener system and method of the present disclosure; FIG. [Figure 18] FIG. 1 is a flow diagram of an exemplary aircraft manufacturing and service method. [Figure 19] FIG. 1 is an exemplary block diagram of an aircraft. DETAILED DESCRIPTION OF THE INVENTION

[0024] The figures shown in this disclosure represent various aspects of the presented versions, and only the differences are discussed in detail.

[0025] The disclosed versions will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, of the disclosed versions are shown. Indeed, several different versions may be provided and should not be construed as limited to the versions set forth herein. Rather, these versions are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.

[0026] This specification includes references to "one version" or "a version." Instances of the phrase "one version" or "a version" do not necessarily refer to the same version. Particular features, structures, or characteristics may be combined in any suitable manner not inconsistent with the present disclosure. All features disclosed in this specification, including the claims, abstract, and drawings, and all steps of any disclosed method or process, may be combined in any combination, except combinations in which at least some of such features and / or steps are mutually exclusive. Each feature disclosed in this specification, including the claims, abstract, and drawings, may be replaced with an alternative feature serving the same, equivalent, or similar purpose, unless otherwise specified.

[0027] As used herein, "comprising" is an open-ended term and, when used in the claims, the term does not exclude additional structures or steps.

[0028] As used herein, "configured to" means that various parts or components may be described or claimed as being "configured to" perform one or more tasks. In this context, "configured to" is used to suggest structure by indicating that a part or component includes structure that performs those one or more tasks during operation. Thus, a part or component may be said to be configured to perform a task even when the specified part or component is not currently operating (e.g., not on).

[0029] As used herein, the terms "first," "second," etc. are used as labels for the nouns they precede and do not imply any type of ordering (e.g., spatial, temporal, logical, etc.).

[0030] As used herein, singular listed elements or steps preceded by the word "a" or "an" should be understood to not necessarily exclude a plurality of elements or steps. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. Also, as used herein, the term "combination of" includes combinations having at least one of the associated listed items, and the combination may further include additional items, such as unlisted items.

[0031] As used herein, the phrase "at least one of," when used in conjunction with a list of items, means that one or more different combinations of the listed items may be used, and that only one of each item in the list may be required. In other words, "at least one of" means that any combination of items, and that some items may be used from the list, but not necessarily all items from the list are required. An item may be a particular object, thing, or category.

[0032] Referring now to FIG. 1 , FIG. 1 is a block diagram of an exemplary automated fastening system 10 having an automated washer installation (AWI) 12, such as an automated washer installation (AWI) capability 12a, to obtain a fastener and washer assembly (ASSY.) 14, e.g., an aircraft fastener and conductive washer assembly (ASSY.) 14a. The blocks in FIG. 1 represent elements, and the lines connecting the various blocks do not imply any particular dependency relationships among the elements. Furthermore, the connecting lines shown in the various figures included herein are intended to represent exemplary functional relationships and / or physical couplings between the various elements, although it should be noted that other alternative or additional functional relationships or physical connections may exist in the versions disclosed herein. When implemented in the exemplary example, one or more of these blocks may be combined, divided, or combined and divided into different blocks. Furthermore, the illustration of the automated fastening system 10 in FIG. 1 does not imply physical or architectural limitations to the manner in which the exemplary example may be implemented. Other components in addition to or in place of the illustrated components may be used. Some components may be unnecessary.

[0033] As shown in FIG. 1 , the fastener and washer assembly 14 resulting from the automatic washer installation 12 of the automatic fastener system 10 includes a washer 16, such as selected washer 16a, for example, an aircraft washer (AW) 18, such as selected aircraft washer (AW) 18a. The washer 16 is configured to be coupled to a fastener 26 (see FIG. 1 ) to obtain the fastener and washer assembly 14 (see FIG. 1 ). Preferably, the washer 16, such as aircraft washer 18, is made of a conductive (CON.) material (MAT.) 54 (see FIG. 1 ) or has a conductive (CON.) coating (COAT.) 53 (see FIG. 1 ), or is a conductive washer (CW) 20 (see FIG. 1 ), such as selected conductive washer (CW) 20a (see FIG. 1 ) made of a conductive material 54 and having a conductive coating 53. Washer 16, such as aircraft washer 18, may include a countersunk washer 22 (see FIGS. 2A-2B), a clearance fit washer 23 (see FIG. 2C), an interference fit washer 24 (see FIG. 2D), a chamfered washer 25 (see FIGS. 4A-4B, 5A-5B), or another suitable type of washer. Chamfered washer 25 may include a symmetrical chamfered washer 25a (see FIG. 5A) or an asymmetrical chamfered washer 25b (see FIG. 5B). Washers 16 are discussed in further detail below with respect to FIGS. 2A-6C.

[0034] 1, the fastener and washer assembly 14 resulting from the automatic washer installation 12 of the automatic fastener system 10 includes a fastener 26, such as a selected fastener 26a, for example, an aircraft fastener (AF) 28, such as a selected aircraft fastener (AF) 28a. The fastener 26, such as aircraft fastener 28, may include a countersunk fastener 30 (see FIGS. 2A-2D), a protruding head fastener 32 (see FIGS. 4A-4B), a clearance fit fastener 34 (see FIGS. 3B, 6B), an interference fit fastener 36 (see FIGS. 3C, 6C), a trans. fit fastener (FAST.) 37 (see FIG. 1), or another suitable type of fastener.

[0035] In automated washer installation 12, a fastener 26, such as a selected fastener 26a, is inserted into a washer 16, such as a selected washer 16a, so that the washer 16, such as the selected washer 16a, contacts and is positioned beneath a fastener head 160 of the fastener 26, such as the selected fastener 26a, to obtain a fastener and washer assembly 14. The fastener 26 is inserted through and coupled to or attached to the selected washer 16 to form the fastener and washer assembly 14 prior to installation 38 (see FIG. 1) within a structure (STRUC.) 40 (see FIG. 1, FIG. 17), such as an aircraft structure (STRUC.) 42 (see FIG. 1, FIG. 17). A nut, collar, or another suitable device may be added to the fastener 26 or to the washer 16 to tighten the washer 16 onto the fastener 26. Fastener 26 may also include another suitable fastener, and washer 16 may also include another suitable washer for attachment 38 in another suitable structure, such as a spacecraft structure, a rotorcraft structure, an unmanned aerial vehicle structure, a watercraft structure, an automobile structure, a truck structure, a train structure, a building structure, or other suitable structure.

[0036] A structure 40 (see FIGS. 1, 3A, 17), such as an aircraft structure 42 (see FIGS. 1, 17), may be made of a composite material, such as a carbon fiber reinforced plastic (CFRP) material having composite (COMP.) fibers 43 (see FIG. 1). Composite structures, such as CFRP structures, are typically made of a composite material that includes a matrix material, such as a resin, reinforced with a fibrous material, such as composite fibers 43, e.g., carbon fibers. Resins, in contrast to fibrous materials, such as composite fibers 43, are generally not electrically conductive. The fastener and washer assembly 14 disclosed herein provides a simple and effective system and method that allows electrical current 144 (see FIG. 17 ) or energy to be transferred through the metal material 56 and / or metal alloy material 58 of the fastener 26, such as a metal fastener, through the metal material 56 and / or metal alloy material 58 of the conductive washer 20, such as a washer 16, such as a copper washer, to the composite fibers 43 of the composite material of the structure 40, such as the aircraft structure 42, such as the composite aircraft structure 42a (see FIG. 17 ), and into the structure 40 itself, such as the aircraft structure 42, regardless of the fit of the fastener 26 with the hole 126 (see FIG. 3A ) within the structure 40, such as the aircraft structure 42, such as the composite aircraft structure 42a.

[0037] One or more fasteners 26, such as one or more aircraft fasteners 28, are used to join together multiple pieces of a structure 40, such as an aircraft structure 42. As shown in FIG. 1 , one of the one or more washers 16 selected for use in the automatic fastener system 10, including for the automatic washer installation 12, includes a selected washer 16a, and one of the one or more fasteners 26 selected for use in the automatic fastener system 10, including for the automatic washer installation 12, includes a selected fastener 26a.

[0038] As shown in FIG. 1, each of the one or more fasteners 26, such as the one or more aircraft fasteners 28, includes one of a bolt 44, such as a countersunk bolt 44a (see FIGS. 2A-2D) or a raised head bolt 44b (see FIGS. 4A-4B), a rivet 45, a screw 46, a blind fastener 47, a pin 48, a bushing 50, or another suitable fastener.

[0039] 1, each of the one or more washers 16, such as the one or more aircraft washers 18, is made from a base washer material (MAT.) 52, e.g., a conductive material 54. As further shown in FIG. 1, each of the one or more fasteners 26, such as the one or more aircraft fasteners 28, is made from a base fastener material (MAT.) 55. As shown in FIG. 1, the base washer material 52 and the base fastener material 55 may comprise a metallic material 56, including copper (CU) 56a, aluminum (AL) 56b, nickel (NI) 56c, steel 56d, titanium (TI) 56e, silver (AG) 56f, zinc (Zn) 56g, gold (AU) 56h, or another suitable metallic material. Base washer material 52 and base fastener material 55 may further include a metal alloy material (MAT.) 58, including copper alloy 58a, nickel-chromium alloy 58b, brass 58c, bronze 58d, titanium (TI) alloy 58e, aluminum (AL) alloy 58f, nickel (NI) alloy 58g, steel alloy 58h, silver (AG) alloy 58i, zinc (ZN) alloy 58j, gold (AU) alloy 58k, or another suitable metal alloy. In other versions of washer 16 and fastener 26, base washer material 52 and base fastener material 55 may include another suitable material.

[0040] In one version, each of the one or more washers 16, such as the one or more aircraft washers 18, may be coated with a conductive coating 53 (see FIG. 1), a painted coating, or another suitable coating. Preferably, the coating is a conductive coating 53 made of a conductive material 54 that can conduct electricity and distribute current 144 (see FIG. 17), or energy, such as from a lightning strike 294 (see FIG. 17) or other electromagnetic effect (EME) and electrical event. In another version, each of the one or more washers 16, such as the one or more aircraft washers 18, is uncoated or has one or more uncoated portions.

[0041] In one version, each of the one or more fasteners 26, such as the one or more aircraft fasteners 28, is coated with a coating, such as a dry film lubricant coating, a painted coating, or another suitable coating. Preferably, the coating is a conductive coating capable of conducting electricity. In another version, each of the one or more fasteners 26, such as the one or more aircraft fasteners 28, is uncoated, or has one or more uncoated portions.

[0042] As shown in FIG. 1 , automated fastener system 10 includes an automated washer feed system 60 configured to hold and dispense one or more washers 16, such as one or more aircraft washers 18, and to hold, dispense, and provide selected washers 16a, such as selected aircraft washers 18a, for automated washer installation 12. Automatic washer feed system 60 includes a feed device 62 (see FIG. 7), such as a tube feeder 64 (see FIG. 7 ), a channel feeder, a conveyor belt, or other suitable feed device, to move or transport one or more washers 16 at a time from tube feeder 64 or other feed device. Preferably, automatic washer feed system 60 further includes a trigger gate 65 (see FIGS. 7-9 ) to allow only one washer 16 at a time to be dispensed, dropped, or transferred from feed device 62.

[0043] 9, an automated washer feeding system 60 includes a holder 66, such as a selected holder 66a, e.g., cup holder 66b, and a selected washer 16a, such as a selected aircraft washer 18a, is dispensed, dropped, or transferred from a feeding device 62, such as a tube feeder 64, into the selected holder 66a, e.g., cup holder 66b. In another version, as shown in FIG. 7, a selected washer 16a, such as a selected aircraft washer 18a, is dispensed, dropped, or transferred from a feeding device 62, such as a tube feeder 64, into a shuttle cup 68, such as a selected shuttle cup 68a, of an automated shuttle assembly 70.

[0044] As further shown in FIG. 1, the automatic washer supply system 60 may include a washer orientation (ORIENT.) system (SYS.) 72 (see also FIG. 7) configured to orient and position one of the countersunk washers 22 (see FIG. 7) or the asymmetrical chamfered washers 25b (see FIG. 5B) for dispensing, dropping, transferring, and inserting into a selected holder 66a, e.g., a holder 66, such as cup holder 66b, or a selected shuttle cup 68, such as shuttle cup 68a.

[0045] In one version, the washer orientation system 72 includes an orientation (ORIENT.) device 74 (see FIGS. 1 and 7) for orienting and holding each washer 16, e.g., each countersunk washer 22 (see FIG. 7), in a properly oriented position 75 (see FIG. 7) so that a top end 76 (see FIGS. 2A and 7) of the countersunk washer 22 faces upward in the proper orientation and a bottom end 78 (see FIGS. 2A and 7) of the countersunk washer 22 faces downward. In one version, the orientation device 74 may include a tubular carrier that holds the washer 16 in the proper orientation or position and drops or pushes the washer 16 out of the tubular carrier. In another version, the orientation device 74 may include a bowl feeder that separates the washer 16 and, if necessary, rotates the washer 16 into the properly oriented position 75 to accurately orient the washer 16. Washer orientation system 72 may further include one or more sensors or other components to ensure that countersunk washer 22 or asymmetrical chamfer washer 25b is transferred and inserted in the correct orientation and position into a selected holder 66a, e.g., a holder 66, such as cup holder 66b, or into a selected shuttle cup 68, such as shuttle cup 68a. Automated washer supply system 60, including washer orientation system 72, is controlled by control system 130 (see FIGS. 1, 7-9).

[0046] As further shown in FIG. 1 , automatic washer dispensing system 60 may include a washer type determination system 80 (see also FIGS. 7-9 ) to view the geometric shape 82 of washer 16 and determine the type of washer 16 based on the geometric shape 82, for example, whether washer 16 is a countersunk washer 22 type or a chamfered washer 25 type. Washer type determination system 80 may include a vision system 84 (see FIGS. 1 , 7-9 ) to view the geometric shape 82 of washer 16 to determine whether washer 16 is a countersunk washer 22 type or a chamfered washer 25 type. Vision system 84 may include a camera, a camera and laser line scanner, a multi-laser line scanner, a radio frequency identification (RFID) scanner, or another optical or camera-based system to view the geometric shape 82 (see FIG. 1 ) of washer 16 passing through automatic washer dispensing system 60 to determine the type of washer 16. The washer type determination system 80 (see also FIGS. 7-9) may further include one or more sensors 85 (see FIG. 1, FIGS. 7-9), connectors, or other components known in the art of vision systems, such as those listed above. In another version, the washer type determination system 80 may be integrated into a vision system 84 that may be used to inspect or view the fastener and washer assembly 14 after the automatic washer installation 12. The automatic washer supply system 60, including the washer type determination system 80, is controlled by a control system 130 (see FIGS. 1, 7-9).

[0047] 1 , the automatic washer supply system 60 may include a washer material verification system 86 (see also FIGS. 7-9 ), such as an inspection module, to determine and verify washer color 87 and / or determine and verify what base washer material 52 of a washer 16, such as a selected washer 16a, is made of. For example, the washer material verification system 86 may verify washer color 87 by using a vision system 84a (see FIG. 1 ), such as a camera, a camera and laser line scanner, a multi-laser line scanner, a radio frequency identification (RFID) scanner, or another optical or camera-based system, to view the washer color 87 of a washer 16 passing through the automatic washer supply system 60 to determine and verify what base washer material 52 of the washer 16 is made of based on the washer color 87. If the base washer material 52 cannot be determined based on the washer color 87, as an alternative to the vision system 84, the washer material verification system 86 may include a conductivity measurement system 88 (see FIGS. 1, 7-9) to perform an electrical conductivity (CONDUCT.) measurement 89 of a washer 16, such as the selected washer 16a, compare it to a predetermined conductivity value range for a predetermined base washer material, and determine the base washer material 52 based on the conductivity measurement 89 obtained by the conductivity measurement system 88. The washer material verification system 86 may be used to detect different base washer materials 52 of a washer 16, such as the selected washer 16a, to prevent an incorrect washer 16, such as the incorrectly selected washer 16a, from being used in the automated fastener system 10 and installed on a structure 40, such as the aircraft structure 42.

[0048] In one version, the conductivity measurement system 88 may include one or more eddy current conductivity probe assemblies having one or more eddy current conductivity probes with one or more coils coupled to electrical wires, and may include one or more sensors coupled to the one or more eddy current conductivity probes via electrical wires. The eddy current conductivity probe may include a contact probe for contacting the surface of the washer 16, such as an eddy current conductivity surface probe, an eddy current conductivity pencil probe, an eddy current conductivity encircling probe, or another suitable type of eddy current conductivity probe known in the art. Generally, an eddy current conductivity probe includes a coil of conductive wire through which an alternating current flows to generate an oscillating magnetic field. When the eddy current conductivity probe and its magnetic field are brought close to a conductive material, such as the metallic material 56 (see FIG. 1) of the washer 16 (see FIG. 1), a circular flow of electrons, known as eddy currents, begins to move through the metallic material 56. The eddy currents flowing through the metallic material 56 also generate their own magnetic field, which interacts with the coil and its magnetic field via mutual inductance. The eddy current conductivity probe is used to measure the conductivity of a washer 16, such as an aircraft washer 18. In one version, the eddy current conductivity probe assembly is coupled to the automated washer feed system 60. In another version, the eddy current conductivity probe assembly is coupled to or integral with one of one or more shuttle cups 68, an inspection center shaft 95a (see FIG. 11), two or more inspection gripper fingers 96a (see FIG. 11), an end effector center shaft 95b (see FIGS. 14A-14B), or two or more end effector gripper fingers 96b (see FIGS. 14A-14B). Each eddy current conductivity probe assembly contacts a selected washer 16a to obtain a conductivity measurement 89 of the selected washer 16a. In another version, the conductivity measurement 89 of a washer 16, such as the selected washer 16a, is obtained using another suitable conductivity measurement device. The automated washer supply system 60, including the washer material verification system 86, is controlled by a control system 130 (see FIGS. 1, 7-9).

[0049] As shown in FIG. 1 , the automated fastener system 10 further includes an automated fastener holder assembly 90 configured to hold and dispense one or more fasteners 26, such as one or more aircraft fasteners 28, and to hold, dispense, and provide selected fasteners 26a, such as selected aircraft fasteners 28a, for the automated washer installation 12. In one version, the automated fastener holder assembly 90 includes one or more fastener holders 92 (see FIGS. 1 , 7 , 8 , 10 ), such as in the form of one or more vertical tube holders 92a. In other versions, the one or more fastener holders 92 may comprise cassettes, chutes, hangers, or other suitable fastener holder structures. The fastener holders 92 may accommodate fasteners 26 of different size diameters; for example, one fastener holder 92 may hold fasteners 26 of one diameter size, and another fastener holder 92 may hold fasteners 26 of another diameter size. The fastener holder 92 may receive fasteners 26, such as aircraft fasteners 28, from a fastener feeder device (not shown), such as a bowl feeder or another suitable fastener feeder device, located upstream from the automated fastener holder assembly 90 of the automated fastener system 10. The automated fastener holder assembly 90 is controlled by a control system 130 (see FIGS. 1, 7-9).

[0050] As further shown in FIG. 1 , the automated fastener system 10 further includes an automated shuttle assembly 70 having one or more shuttle cups 68. A selected shuttle cup 68a of the one or more shuttle cups 68 receives a selected fastener 26a of one or more fasteners 26 from the automated fastener holder assembly 90, and the selected shuttle cup 68a carries the selected fastener 26a in the selected shuttle cup 68a. The selected shuttle cup 68a is configured to receive and receives the selected fastener 26a from a fastener holder 92 of the automated fastener holder assembly 90; for example, the selected fastener 26a may drop from the fastener holder 92 into the selected shuttle cup 68a positioned below the fastener holder 92. The selected fastener 26a is selected based on its kind or type, its diameter, and its length. The selected shuttle cup 68a partially or fully supports and retains the selected fastener 26a within the selected shuttle cup 68a, and in one version, the selected shuttle cup 68a does not have a retention mechanism, such as a clamp or other type of retention mechanism, to retain the selected fastener 26a within the selected shuttle cup 68a. The shuttle cups 68 are discussed in further detail below with respect to Figures 7-9 and 12A-12B.

[0051] The automated shuttle assembly 70 has one or more shuttle cups 68. A selected shuttle cup 68a receives and carries one of a selected washer 16a from the automated washer supply system 60, a selected fastener 26a from the automated fastener holder assembly 90, or a fastener and washer assembly 14. The automated shuttle assembly 70 is controlled by a control system 130 (see FIGS. 1, 7-9).

[0052] 1 , the automated fastener system 10 includes an automated inspection system (SYS.) 94. The selected shuttle cup 68a transports the selected fastener 26a from the automated fastener holder assembly 90 to the automated inspection system 94 via an automated transport mechanism (not shown) of the automated shuttle assembly 70; for example, the automated transport mechanism may include a rail or track system, or a suspended rail or track system, along which the selected shuttle cup 68a automatically moves back and forth between the automated fastener holder assembly 90 and the automated inspection system 94. The automated transport mechanism may also include another suitable transport system for automatically moving the shuttle cup 68 between the automated fastener holder assembly 90 and the automated inspection system 94.

[0053] The automated inspection system 94 has a central shaft 95 (see FIG. 11), such as an inspection central shaft 95a (see FIG. 11), and two or more gripper fingers 96 (see FIG. 11), such as two or more INSPECT. gripper fingers 96a (see FIGS. 1 and 11). The two or more inspection gripper fingers 96a are configured to pick up, inspect, and release one of the selected fasteners 26a or fastener and washer assemblies 14. The inspection gripper fingers 96a, such as in the form of a claw, are configured to automatically pick up the selected fasteners 26a or fastener and washer assemblies 14, automatically grip and inspect the selected fasteners 26a or fastener and washer assemblies 14, and automatically release the selected fasteners 26a or fastener and washer assemblies 14.

[0054] In one version, as shown in FIG. 1 , the automated inspection system 94 includes a vision system 84b (also see FIG. 11 ) having a camera 97 (see FIG. 11 ) and a laser scanner 98 (also see FIG. 11 ) for inspecting the selected fastener 26a or fastener and washer assembly 14. The vision system 84b may further include one or more of a camera and laser line scanner, a multi-laser line scanner, a radio frequency identification (RFID) scanner, or another optical or camera-based system for inspecting the selected fastener 26a or fastener and washer assembly 14. The automated inspection system 94 may also include additional components suitable for inspecting the selected fastener 26a. The automated inspection system 94 (see FIG. 11 ) is controlled by a control system 130 (see FIGS. 1 , 7-9 , and 11 ).

[0055] 1, the automated fastener system 10 includes an automated transport system 100 having a transport device 102 configured to transport and convey one or more of the selected fasteners 26a, selected washers 16a, or fastener and washer assemblies 14 away from the automated inspection system 94. In one version, the transport device 102 includes a transport shuttle 104 (see FIGS. 1, 13), such as a receptacle cup 106 (see FIG. 13), or another suitable transport container device. The transport shuttle 104 is designed to enclose one or more of the selected fasteners 26a, selected washers 16a, or fastener and washer assemblies 14. 1, the automated transfer system 100 further includes a transfer tube, such as a vacuum tube 108a, a pressure tube 108b, or another suitable transfer tube 108, for transporting or carrying a transfer device 102, such as a transfer shuttle 104, carrying one or more of the selected fastener 26a, the selected washer 16a, or the fastener and washer assembly 14. The transfer device 102, such as the transfer shuttle 104, is described in further detail below with respect to FIG. 13. The automated transfer system 100 (see FIGS. 1, 7-9, 13) is controlled by a control system 130 (see FIGS. 1, 7-9).

[0056] As further shown in FIG. 1, the automated fastener system 10 includes an automated installation system 110. The automated installation system 110 includes an end effector 112 having two or more gripper fingers 96 (see FIGS. 14A-14B), such as two or more end effector gripper fingers 96b (see FIGS. 14A-14B), configured to pick up one or more of a selected fastener 26a, a selected washer 16a, or a fastener and washer assembly 14 from a transport device 102 (see FIGS. 1, 7-9) and further configured to install the fastener and washer assembly 14 within an aircraft structure 42 (see FIGS. 1, 17), a structure 40 (see FIGS. 1, 17), such as a composite aircraft structure 42a (see FIG. 17), or another suitable structure. As shown in FIGS. 14A-14B, the end effector 112 is also coupled to a central shaft 95, such as an end effector central shaft 95b.

[0057] In one version, as shown in Figure 14A, the automated mounting system 110 further includes an end effector 112 coupled to a robotic system 114 having a robot 115. The robotic system 114 is discussed in more detail below with respect to Figure 14A. In another version, as shown in Figure 14B, the automated mounting system 110 further includes an end effector 112 coupled to a gantry system 116 having a gantry 118. The gantry system 116 is discussed in more detail below with respect to Figure 14B.

[0058] As shown in FIG. 1 , in one version, the automated installation system 110 may further include an alignment assembly 120 coupled to the end effector 112 of the automated installation system 110. The location of the alignment assembly 120 depends on the type of end effector 112 used with the automated installation system 110. As shown in FIG. 1 , the alignment assembly 120 includes one or more linear actuators 122 and alignment guides 124 to move one or more of the fastener and washer assembly 14, the selected fastener 26 a, or the selected washer 16 a to and from different positions within the automated installation system 110, such as home, pickup, and installation 38. The end effector gripper fingers 96 b of the end effector 112 grasp one of the fastener and washer assembly 14, the selected fastener 26 a, or the selected washer 16 a from a transport device 102, such as a transport shuttle 104. 9, the selected washer 16a and the selected fastener 26a are assembled by the automated washer installation 12, and the end effector gripper fingers 96b partially or completely install the fastener and washer assembly 14 into a hole 126 (see FIGS. 3B, 6B), such as a hole bore, in the structure 40 (see FIGS. 3B, 6B). If the automated washer installation 12 is performed prior to the transfer of the fastener and washer assembly 14 to the automated installation system 110, the end effector gripper fingers 96b grasp the fastener and washer assembly 14 from the transfer shuttle 104 and partially or completely install the fastener and washer assembly 14 into a hole 126 (see FIGS. 3B, 6B), such as a hole bore, in the structure 40 (see FIGS. 3B, 6B).

[0059] The method of installation 38 depends on the type of fastener 26, such as fastener 26a, selected and the fitment of the selected fastener 26, such as fastener 26a, within a hole 126, such as a hole bore. Alignment assembly 120 is configured to align and maintain an aligned position (POS.) 128 (see FIG. 1) of fastener and washer assembly 14 with a hole 126 within a structure 40 (see FIG. 1), such as an aircraft structure 42 (see FIG. 1), until the selected fastener 26a is partially inserted through the hole 126 within the structure 40 and partially installed within the structure 40. Alignment assembly 120 (see FIG. 1) is controlled by control system 130 (see FIGS. 1, 7-9).

[0060] 1, the automated fastener system 10 includes a control system 130 including at least a controller 132, one or more power sources 134, and a computer system 136. The control system 130 is configured to control the automated fastener system 10, including the automated washer installation 12. As shown in FIG. 1, the computer system 136 includes at least a computer 138 and a computer software program 140 that implements control logic 142. For example, in the washer material verification system 86, the control logic 142 implemented by the computer software program 140 uses the conductivity measurement 89 of the selected washer 16a, such as the selected aircraft washer 18a, to compare it to a predetermined conductivity value range for a predetermined base washer material to obtain a base washer material determination for the selected washer 16a, such as the selected aircraft washer 18a. Control logic 142 compares conductivity measurement 89 to a predetermined conductivity value range for a given base washer material to obtain a base washer material determination, which is based on the difference in value between the actual measured conductivity measurement 89 and the predetermined conductivity value range. As used herein, "predetermined conductivity value range" means a standard or known conductivity value range for a known base washer material as measured by an eddy current conductivity probe or another suitable conductivity measurement device. Computer system 136 is described in further detail below with respect to FIG. 15.

[0061] In the automated fastener system 10, the automated washer installation 12 is performed at one or more of the following times: before the inspection of the selected fastener 26a by the automated inspection system 94, after the inspection of the selected fastener 26a by the automated inspection system 94, such as before transfer to the automated transport system 100 and automated installation system 110, or after transfer of the selected fastener 26a and selected washer 16a by the automated transport system 100 to the automated installation system 110. When the aircraft structure 42 (see FIGS. 1, 17) is attached to a wing 284 (see FIG. 17) or a fuselage 282 (see FIG. 17) or a tail 288 (see FIG. 17) of an aircraft 280a (see FIG. 17), the fastener and washer assembly 14 (see FIG. 1), such as the aircraft fastener and conductive washer assembly 14a (see FIG. 1), is configured to distribute current 144 (see FIG. 17) or energy from a lightning strike 294 (see FIG. 17) applied to the aircraft structure 42 through the fastener and washer assembly 14, such as the aircraft fastener and conductive washer assembly 14a, in a current path 144a (see FIG. 17) to the aircraft structure 42.

[0062] In another version of the present disclosure, an automatic fastener system 10 (see FIG. 1) is provided having an automatic washer attachment 12 (see FIG. 1). The automatic fastener system 10 includes an automatic washer supply system 60 (see FIGS. 1, 7-9) that holds and dispenses one or more conductive washers 20 (see FIGS. 1, 7-9) and provides a selected conductive washer 20a (see FIGS. 1, 7-9) for the automatic washer attachment 12. The one or more conductive washers 20 are preferably one of a countersunk washer 22 (see FIGS. 1, 2A) and a chamfered washer 25 (see FIGS. 1, 4A).

[0063] The automatic fastener system 10 further includes an automatic fastener holder assembly 90 (see FIGS. 1, 10) that holds and dispenses one or more aircraft fasteners 28 (see FIGS. 1, 10) and provides a selected aircraft fastener 28a (see FIGS. 1, 10) for the automatic washer installation 12. Each of the one or more aircraft fasteners 28 may include one or more of a countersink fastener 30 (see FIG. 2A), a protruding head fastener 32 (see FIG. 4A), a clearance fit fastener 34 (see FIG. 3B), an interference fit fastener 36 (see FIG. 3C), an intermediate fit fastener 37 (see FIG. 1), or another suitable fastener.

[0064] In the automatic washer installation 12, to obtain an aircraft fastener and conductive washer assembly 14a (see FIG. 1), a selected aircraft fastener 28a is inserted into a selected conductive washer 20a such that the selected conductive washer 20a contacts and is positioned below the fastener head 160 (see FIG. 2B) of the selected aircraft fastener 28a.

[0065] The automatic fastener system 10 further includes an automatic shuttle assembly 70 (see FIGS. 1, 7-9, 10A-10B) having one or more shuttle cups 68 (see FIGS. 1, 7-9, 10A-10B), wherein a selected shuttle cup 68a (see FIGS. 1, 7-9) receives and carries one of a selected conductive washer 20a from the automatic washer supply system 60, a selected aircraft fastener 28a from the automatic fastener holder assembly 90, or an aircraft fastener and conductive washer assembly 14a.

[0066] The automated fastener system 10 further includes an automated inspection system 94 (see FIGS. 1, 7-9, 11) having two or more inspection gripper fingers 96a (see FIGS. 1, 11) configured to pick up, inspect, and release a selected aircraft fastener 28a or one of the aircraft fastener and conductive washer assemblies 14a.

[0067] The automated fastener system 10 further includes an automated transport system 100 (see FIGS. 1, 13) having a transport device 102 (see FIGS. 1, 13) configured to transport one or more of the selected aircraft fasteners 28a, the selected conductive washers 20a, or the aircraft fastener and conductive washer assemblies 14a.

[0068] The automated fastener system 10 further includes an automated installation system 110 (see FIGS. 1, 7-9, 14A-14B) having an end effector 112 (see FIGS. 1, 14A-14B) with two or more end effector gripper fingers 96b (see FIGS. 1, 14A-14B) configured to pick up one or more of the selected aircraft fasteners 28a, the selected conductive washers 20a, or the aircraft fastener and conductive washer assemblies 14a from the transport device 102, and further configured to install the aircraft fastener and conductive washer assemblies 14a within the aircraft structure 42 (see FIGS. 1, 17).

[0069] The automated fastener system 10 further includes a control system 130 (see FIGS. 1, 7-9) that includes at least a controller 132 (see FIGS. 1, 7-9), one or more power sources 134 (see FIGS. 1, 7-9, 15), and a computer system 136 (see FIGS. 1, 7-9, 15). The control system 130 is configured to control the automated fastener system 10 and the automated washer installation 12.

[0070] The automated washer installation 12 is performed at one or more of: before the automated inspection system 94 inspects the selected aircraft fasteners 28a; after the automated inspection system 94 inspects the selected aircraft fasteners 28a, such as before transfer to the automated transport system 100 and automated installation system 110; or after the automated transport system 100 transfers the selected aircraft fasteners 28a and selected conductive washers 20a to the automated installation system 110.

[0071] When the aircraft structure 42 (see FIGS. 1, 17) is attached to a wing 284 (see FIG. 17) or a fuselage 282 (see FIG. 17) or a tail 288 (see FIG. 17) of an aircraft 280a (see FIG. 17), the fastener and washer assembly 14 (see FIG. 1), such as the aircraft fastener and conductive washer assembly 14a (see FIG. 1), is configured to distribute current 144 (see FIG. 17) or energy from a lightning strike 294 (see FIG. 17) applied to the aircraft structure 42 through the fastener and washer assembly 14, such as the aircraft fastener and conductive washer assembly 14a, in a current path 144a (see FIG. 17) to the aircraft structure 42.

[0072] Referring now to FIG. 2A, FIG. 2A is a front perspective view of an exemplary fastener and washer assembly 14 that may be used in versions of the automated fastener system 10 (see FIG. 1) and automated method 270 (see FIG. 16B) of the present disclosure, with the fastener and washer assembly 14 in a disassembled position 145a.

[0073] 2A is a countersunk washer 22. A washer 16, such as a countersunk washer 22, may or may not include a conductive washer 20 (see FIG. 1).

[0074] As shown in FIG. 2A, washer 16 has a top end 76, a bottom end 78, and a washer body 146 formed between top end 76 and bottom end 78. As shown in FIG. 2A, top end 76 has a top end outer diameter 148a, and bottom end 78 has a bottom end outer diameter 148b, where top end outer diameter 148a has a length that is greater than the length of bottom end outer diameter 148b. Washer body 146 has a frustoconical shape 150 (see FIG. 2A) and a thickness 152 (see FIG. 2A), which is preferably uniform thickness 152a.

[0075] As further shown in FIG. 2A , the washer body 146 has washer sides 154 that are angled or sloped inward and downward from the top end 76 to the bottom end 78. The washer sides 154 underlie a portion that is located below the top end 76. In one version, the washer sides 154 have one or more washer side portions that can be contacted by one or more eddy current conductivity probes or another conductivity measuring device of a washer material verification system 86 (see FIG. 1 ) to obtain a conductivity measurement 89 (see FIG. 1 ) of the washer 16, such as a countersunk fastener 30. As further shown in FIG. 2A , the washer 16 has a through opening 155 formed through the washer body 146 from the top end 76 to the bottom end 78. The top end 76 of the through opening 155 is sized larger than the bottom end 78 of the through opening 155. As shown in FIG. 2A , the washer 16 has an interior 156 and an exterior 158.

[0076] The fastener 26 shown in Figure 2A is a countersunk fastener 30 in the form of a bolt 44, such as countersunk bolt 44a. As shown in Figure 2A, the fastener 26 has a fastener head 160, such as countersunk fastener head 160a, having a top end 162, a bottom end 164, and a side surface 166 that is angled or sloped inward and downward from top end 162 to bottom end 164. Side surface 166 is below a portion of the fastener head 160 that is disposed below top end 162.

[0077] 2A, the upper end 162 of the fastener head 160 has an alignment portion 168, or alignment mark or point, formed on a surface of the upper end 162. The alignment portion 168 is configured to align with a central shaft end 95c (see FIG. 11) of a central shaft 95 (see FIG. 11), such as the end of an inspection central shaft 95a (see FIG. 11) of the automated inspection system 94 (see FIG. 11), and also with a central shaft end 95c of a central shaft 95 (see FIG. 14A), such as the end of an end effector central shaft 95b (see FIG. 14A) of the automated installation system 110 (see FIG. 14A).

[0078] As further shown in Figure 2A, the top end 162 of fastener head 160 has a fastener head top end outer diameter 170a, and the bottom end 164 of fastener head 160 has a fastener head bottom end outer diameter 170b. As shown in Figure 2A, the top end outer diameter 148a of the top end 76 of washer 16 has a length that is greater than the length of fastener head top end outer diameter 170a, and the bottom end outer diameter 148b of the bottom end 78 of washer 16 has a length that is greater than the length of fastener head bottom end outer diameter 170b, thereby allowing fastener head 160 to seat and fit within interior 156 of washer 16 (see Figures 2A-2B).

[0079] 2A, fastener 26 includes a fastener shank 172 having a first end 174, a second end 175, and a shank body 176 disposed between first end 174 and second end 175. As shown in FIG. 2A, first end 174 of fastener shank 172 is integral with bottom end 164 of fastener head 160.

[0080] As further shown in FIG. 2A, fastener 26 has a back end 178 having a first end 180, a second end 182, and a thread body 184 disposed between first end 180 and second end 182. As shown in FIG. 2A, first end 180 of back end 178 is integral with second end 175 of fastener shank 172. Thread body 184 has a plurality of threads 185 (see FIG. 2A). Back end 178 further has a pintail 186 (see FIG. 2A) at second end 182.

[0081] 2B, which is a front perspective view of the fastener and washer assembly 14 of FIG. 2A, in which the fastener and washer assembly 14 is in a partially assembled position 145b, with a fastener shank 172 and rear end 178 of a fastener, such as a countersunk fastener 30 in the form of a bolt 44, such as countersunk bolt 44a, inserted through a through opening 155 in a washer 16, such as countersunk washer 22, such that the fastener head 160 is partially within an interior 156 of the washer 16. In one version, as shown in FIG. 2B, the fastener and washer assembly 14 includes a countersunk fastener and countersunk washer assembly 14b.

[0082] 2B shows a washer 16, such as countersunk washer 22, having a top end 76, a bottom end 78, and a washer body 146 formed between the top end 76 and the bottom end 78 and having a washer side surface 154. An interior washer side surface 154a (see FIG. 2B) of an interior 156 (see FIG. 2B) of the washer 16 is adjacent or adjacent to an exterior side surface 166a of the fastener head 160.

[0083] 2B, a top end 162 of a fastener head 160, such as countersunk fastener head 160a, is positioned slightly above the top end 76 of a washer 16, and a bottom end 164 of the fastener head 160 is positioned slightly above the bottom end 78 of a washer 16, such as countersunk washer 22. As shown in FIG. 3B, when the fastener and washer assembly 14 is in the assembled position 145c, the top end 162 of the fastener head 160, such as countersunk fastener head 160a, is preferably positioned flush 188 with the top end 76 of a washer 16, such as countersunk washer 22.

[0084] In automated washer installation 12 (see FIGS. 1, 7-9), to obtain fastener and washer assembly 14 (see FIG. 1), a selected fastener 26a (see FIGS. 1, 7-9) is inserted into a selected washer 16a (see FIGS. 1, 7-9) so that the selected washer 16a contacts and is positioned below a fastener head 160 of the selected fastener 26a, such as a countersunk fastener head 160a, below a top end 162 and a bottom end 164 of the fastener head 160.

[0085] As shown in FIG. 2B , when a washer 16, such as countersunk washer 22, includes a clearance fit washer 23, a clearance 190 exists in the interior 156 of the clearance fit washer 23 between the fastener shank 172 and the bottom end 78 of the clearance fit washer 23.

[0086] 2C, which is a front partial cross-sectional view of the fastener and washer assembly 14 of FIG. 2B in a partially assembled position 145b showing a washer 16, such as countersunk washer 22 in the form of clearance fit washer 23, positioned under a fastener head 160, such as countersunk fastener head 160a, of a fastener 26, such as countersunk fastener 30. As shown in FIG. 2C, fastener 26 may include a clearance fit fastener 34 (also see FIG. 3B). As shown in FIG. 2C, in one version, clearance fit washer 23 has a gap 190 in interior 156 of clearance fit washer 23 between fastener shank portion 172a of fastener shank 172 and bottom end 78 of clearance fit washer 23. The clearance fit washer 23 may be used with a clearance fit fastener 34 (see FIGS. 2C, 3B), an interference fit fastener 36 (see FIG. 3C), an intermediate fit fastener 37 (see FIG. 1), or another suitable fastener.

[0087] Referring now to FIG. 2D, FIG. 2D is a partial cross-sectional front view of another version of fastener and washer assembly 14 in a partially assembled position 145b showing a washer 16, such as countersunk washer 22 in the form of an interference fit washer 24, positioned under a fastener head 160, such as countersunk fastener head 160a, of a fastener 26, such as countersunk fastener 30.

[0088] As shown in FIG. 2D , the fastener 26 may include an interference fit fastener 36 (also see FIG. 3C ). As shown in FIG. 2D , in one version, the interference fit washer 24 has an interior 156 in which there is no clearance between the fastener shank portion 172 a of the fastener shank 172 and the bottom end 78 of the interference fit washer 24. The interference fit washer 24 may be used with a clearance fit fastener 34, an interference fit fastener 36, a transition fit fastener 37 (see FIG. 1 ), or another suitable fastener. The interference fit between the interference fit washer 24 and the interference fit fastener 36 is also referred to as a press fit or friction fit.

[0089] 3A, which is a front partial cross-sectional view of the fastener and washer assembly 14 of FIG. 2C in a partially assembled position 145b and a partially installed position 194a within a hole 126 in the structure 40, with a fastener 26, such as a countersink fastener 30, being a clearance fit fastener 34. In this version, as shown in FIG. 3A, the hole 126 includes a shank bore portion 126a in which a fastener shank 172 is disposed within a fastener head bore portion 126b in which a fastener head 160 is disposed. FIG. 3A shows the fastener and washer assembly 14 in the partially installed position 194a, with the fastener shank 172 and back end 178 of the fastener 26 inserted through a hole 126, such as a bore hole formed through the structure 40.

[0090] Figure 3A further shows a gap 190a between fastener shank 172 and an interior wall 192 of structure 40 when fastener shank 172 is inserted into hole 126 in structure 40. Figure 3A also shows washer side surface 154 of washer 16, such as countersunk washer 22, e.g., interference fit washer 24, and angled countersunk portion 195 configured to press against and align therewith. Figure 3A shows fastener head 160, such as countersunk fastener head 160a, positioned above washer 16.

[0091] 3B, which is a front partial cross-sectional view of the fastener and washer assembly 14 of FIG. 3A, where the fastener and washer assembly 14 is in an assembled position 145c and an installed position 194b within the structure 40, and the fastener 26, such as countersunk fastener 30, is a clearance fit fastener 34. As shown in FIG. 3B, when the fastener and washer assembly 14 is in the assembled position 145c and installed position 194b, the upper end 162 of the fastener head 160, such as countersunk fastener head 160a, is positioned flush with the upper end 76 of the washer 16, such as the countersunk washer 22, e.g., the interference fit washer 24, in position 188. FIG. 3B further shows the washer side 154 of the washer 16 contacting and seated against the angled countersunk portion 195 of the structure 40 and inserted into the fastener head bore portion 126b.

[0092] 3B further illustrates a gap 190a between the fastener shank 172 and the interior wall 192 of the structure 40 when the fastener and washer assembly 14 is inserted into the hole 126 of the structure 40 in the installed position 194b. As shown in FIG. 3B, the hole diameter 127 of the hole 126, such as shank hole portion 126a, has a length that is greater than the length of the fastener shank diameter 172b of the fastener shank 172. Thus, in a clearance fit fastener 34, the size of the hole 126, such as shank hole portion 126a, is greater than the size of the fastener shank 172, which is smaller than the size of the hole 126, such as shank hole portion 126a.

[0093] Referring now to FIG. 3C, FIG. 3C is a front partial cross-sectional view of another version of fastener and washer assembly 14 in assembled position 145c and installed position 194b within structure 40, where fastener 26, such as countersunk fastener 30, is an interference fit fastener 36.

[0094] As shown in FIG. 3C, when the fastener and washer assembly 14 is in the assembled position 145c and the installed position 194b, the top end 162 of the fastener head 160, such as countersunk fastener head 160a, is positioned flush with the top end 76 of the washer 16, such as the countersunk washer 22, e.g., interference fit washer 24. FIG. 3C further shows the washer side 154 of the washer 16 contacting and seating against the angled countersunk portion 195 of the structure 40 and inserted into the fastener head hole portion 126b.

[0095] As shown in FIG. 3C , when the fastener and washer assembly 14 is inserted into the hole 126 of the structure 40 in the installed position 194b, no gap exists between the fastener shank 172 and the inner wall 192 of the structure 40. When the interference fit fastener 36 is installed in the hole 126, the fastener shank diameter 172b (see FIG. 3C ) of the fastener shank 172 has a length and size that is slightly larger than the hole diameter 127 (see FIG. 3C ) of the hole 126, such as the shank hole portion 126a, because the fastener shank 172 of the interference fit fastener 36 is press-fit or friction-fit into the hole 126, such as the shank hole portion 126a. Thus, in an interference fit fastener 36, the size of the bore 126, such as shank bore portion 126a, is smaller than the size of the fastener shank 172, which is larger than the size of the bore 126, such as shank bore portion 126a, and the interference fit fastener 36 is press-fit or friction-fit into the bore 126. Transition fit fasteners 37 (see FIG. 1 ) may provide either a clearance fit or an interference fit, depending on individual tolerances, with the tolerance zones of the bore 126 and fastener shank overlapping between a clearance fit and an interference fit.

[0096] Referring now to FIG. 4A , FIG. 4A is a front perspective view of another exemplary fastener and washer assembly 14 that may be used in versions of the automated fastener system 10 (see FIG. 1 ) and automated method 270 (see FIG. 16B ) of the present disclosure, where the fastener and washer assembly 14 is in an exploded position 145 a and the fastener 26 is a protruding head fastener 32.

[0097] 4A is a chamfered washer 25. A washer 16, such as chamfered washer 25, may or may not include conductive washer 20 (see FIG. 1).

[0098] As shown in FIG. 4A, washer 16 has a top end 76a, a bottom end 78a, and a washer body 146a formed between top end 76a and bottom end 78a. As shown in FIG. 4A, washer 16, such as chamfered washer 25, has an outer diameter 196 and a thickness 198, such as uniform thickness 198a, around the circumference of chamfered washer 25. As shown in FIG. 4A, washer body 146a has a through opening 155a formed through an interior 156a of washer body 146a, and washer body 146a has an exterior 158a. As shown in FIG. 5A, in symmetrically chamfered washer 25a, through opening 155a at top end 76a is the same size as through opening 155a at bottom end 78a. As shown in Figure 5B, in asymmetric chamfered washer 25b, the size of through opening 155a at top end 76a is larger than the size of through opening 155a at bottom end 78a. Washer body 146a has a disk shape 200, as shown in Figure 4A.

[0099] 4A, washer body 146a has a washer side 154b that is straight or substantially straight and extends between top end 76a and bottom end 78a. Washer side 154, in one version, has one or more washer side portions that can be contacted by one or more eddy current conductivity probes or another conductivity measuring device of washer material verification system 86 (see FIG. 1) to obtain conductivity measurements 89 (see FIG. 1) of washer 16, such as chamfered washer 25.

[0100] The fastener 26 shown in FIG. 4A is a protruding-head fastener 32 in the form of a bolt 44, such as protruding-head bolt 44b. As shown in FIG. 4A, the fastener 26 has a fastener head 160, such as protruding fastener head 160b, having a top end 162a, a bottom end 164a, and a linear or substantially linear side 166b extending between the top end 162a and the bottom end 164a. The protruding fastener head 160b has a disk shape 200a. As further shown in FIG. 4A, the top end 162a of the protruding fastener head 160b has a protruding fastener head outer diameter 170c. As shown in FIG. 4A, the outer diameter 196 of the chamfered washer 25 has a length greater than the length of the protruding fastener head outer diameter 170c.

[0101] 4A, the upper end 162a of the protruding fastener head 160b has an alignment portion 168a, or alignment mark or point, formed on the surface of the upper end 162a. The alignment portion 168a is configured to align with a central shaft end 95c (see FIG. 11) of a central shaft 95 (see FIG. 11), such as the end of an inspection central shaft 95a (see FIG. 11) of the automated inspection system 94 (see FIG. 11), and also with a central shaft end 95c of a central shaft 95 (see FIG. 14A), such as the end of an end effector central shaft 95b (see FIG. 14A) of the automated installation system 110 (see FIG. 14A).

[0102] As further shown in FIG. 4A, the protruding-head fastener 32 includes a fastener shank 172c having a first end 174a, a second end 175a, and a shank body 176a disposed between the first end 174a and the second end 175a. As shown in FIG. 4A, the first end 174a of the fastener shank 172c is integral with a portion of the bottom end 164a of the protruding fastener head 160b. The protruding-head fastener 32 may include a fillet (not shown) including a rounded corner at the junction between the first end 174a of the fastener shank 172c and a portion of the bottom end 164a of the protruding fastener head 160b, where the first end 174a of the fastener shank 172c and the bottom end 164a of the protruding fastener head 160b are integral.

[0103] As further shown in FIG. 4A, the protruding-head fastener 32 has a rear end 178a having a first end 180a, a second end 182, and a thread body 184 disposed between the first end 180a and the second end 182. As shown in FIG. 2A, the first end 180 of the rear end 178 is integral with the second end 175a of the fastener shank 172. The thread body 184a has a plurality of threads 185a (see FIG. 4A). The rear end 178 further has a pintail 186a (see FIG. 4A) at the second end 182a.

[0104] 4B, which is a front perspective view of the fastener and washer assembly 14 of FIG. 4A, in which the fastener and washer assembly 14 is in an assembled position 145c with the fastener shank 172c and rear end 178a of a fastener 26, such as a protruding-head fastener 32 in the form of a bolt 44, such as protruding-head bolt 44b, inserted through the through opening 155a of the washer 16, such as chamfered washer 25, so that the bottom end 164a of the fastener head 160, such as protruding fastener head 160b, is adjacent to a portion of the top end 76a of the chamfered washer 25. In one version, as shown in FIG. 4B, the fastener and washer assembly 14 includes a protruding-head fastener and chamfered washer assembly 14c.

[0105] When the fastener and washer assembly 14 is in the assembled position 145c, a portion of the fastener shank 172c abuts the through-opening wall 155b (see FIG. 4A). FIG. 4B shows a washer 16, such as chamfered washer 25, having a top end 76a, a bottom end 78a, and a washer body 146a formed between the top end 76a and the bottom end 78a and having a washer side surface 154b.

[0106] As shown in FIG. 4B, the protruding fastener heads 160b are positioned above the chamfered washers 25 in a stacked configuration 202. In automated washer installation 12 (see FIGS. 1, 7-9), to obtain a fastener and washer assembly 14 (see FIG. 1), a selected fastener 26a (see FIGS. 1, 7-9), such as protruding-head fastener 32, is inserted into a selected washer 16a (see FIGS. 1, 7-9), such as chamfered washer 25, so that the selected washer 16a, such as chamfered washer 25, contacts and is positioned below the fastener head 160, such as protruding fastener head 160b, of the selected fastener 26a, below the top and bottom ends 162a, 164a of the protruding fastener head 160b.

[0107] Referring now to FIG. 5A, FIG. 5A is a front cross-sectional view of a chamfered washer 25, such as symmetrically chamfered washer 25a. As shown in FIG. 5A, symmetrically chamfered washer 25a has chamfers 204 near top end 76a and near bottom end 78a. As further shown in FIG. 5A, symmetrically chamfered washer 25a has fillet relief portion 205 configured to provide space for a fillet that may be formed at the junction between first end 174a of fastener shank 172c and a portion of bottom end 164a of protruding fastener head 160b of protruding-head fastener 32. The fillet is a rounded corner or radius formed under protruding fastener head 160b at the junction with first end 174a of fastener shank 172c. Fillet relief portions 205 may be formed on top end 76a and bottom end 78a of symmetrically chamfered washer 25a, so that symmetrically chamfered washer 25a does not need to be oriented by washer orientation system 72 (see FIG. 1) of automatic washer supply system 60 (see FIG. 1).

[0108] As further shown in Figure 5A, the size 206a of the through opening 155a at the top end 76a is the same as the size 206b of the through opening 155a at the bottom end 78a. As further shown in Figure 5A, the through opening 155a of the symmetrically chamfered washer 25a has a central protruding portion 207, where the size of the through opening 155a is narrower than the size 206a of the through opening 155a at the top end 76a and the size 206b of the through opening 155a at the bottom end 78a.

[0109] Referring now to FIG. 5B, FIG. 5B is a front cross-sectional view of a chamfered washer 25, such as asymmetrical chamfered washer 25b. As shown in FIG. 5B, asymmetrical chamfered washer 25b has a chamfer 204 only near top end 76a. As further shown in FIG. 5B, asymmetrical chamfered washer 25b has a fillet relief 205 only at top end 76a, configured to provide space for a fillet that may be formed at the junction between first end 174a of fastener shank 172c and a portion of bottom end 164a of protruding fastener head 160b of protruding-head fastener 32. Asymmetrical chamfered washer 25b must be oriented by washer orientation system 72 (see FIG. 1) of automated washer supply system 60 (see FIG. 1) to ensure it is in the correct orientation and position prior to automated washer installation 12.

[0110] As further shown in Figure 5B, asymmetrical chamfered washer 25b does not have a central protruding portion 207 (see Figure 5A), and the through openings 155a are of uniform internal size below the chamfer 204. As further shown in Figure 5B, the size 206a of the through openings 155a at the top end 76a is larger than the size 206b of the through openings 155a at the bottom end 78a.

[0111] 6A, which is a front partial cross-sectional view of the fastener and washer assembly 14 of FIG. 4A in a partially assembled position 145b within a hole 126 of a structure 40 and in a partially installed position 194a, where the fastener 26, such as the protruding head fastener 32, is a clearance fit fastener 34 and the washer 16 is a chamfered washer 25. FIG. 6A shows the fastener and washer assembly 14 in the partially installed position 194a, with the fastener shank 172c and the rear end 178a of the protruding head fastener 32 inserted through the hole 126 formed through the structure 40.

[0112] FIG. 6A further illustrates a gap 190b between fastener shank 172c and an interior wall 192 of structure 40 when fastener shank 172c is inserted into hole 126 in structure 40. FIG. 6A further illustrates structure top 40a configured to contact bottom end 78a of chamfered washer 25. FIG. 6A illustrates fastener head 160, such as protruding fastener head 160b, positioned above chamfered washer 25 and chamfered washer 25 positioned below protruding fastener head 160b. FIG. 6A further illustrates top end 76a of washer 16, such as chamfered washer 25, and illustrates bottom end 164a of fastener head 160, such as protruding fastener head 160b.

[0113] Referring now to FIG. 6B, FIG. 6B is a front partial cross-sectional view of the fastener and washer assembly 14 of FIG. 6A, where the fastener and washer assembly 14 is in an assembled position 145c, in an installed position 194b, within and protruding from structure 40, fastener 26, such as protruding head fastener 32, is a clearance fit fastener 34, and washer 16 is a chamfered washer 25.

[0114] As shown in FIG. 6B, when fastener and washer assembly 14 is in assembled position 145c and installed position 194b, fastener head 160, such as protruding fastener head 160b, is positioned above chamfered washer 25 in stacked configuration 202. FIG. 6B shows bottom end 164a (see also FIG. 6A) of fastener head 160, such as protruding fastener head 160b, in contact with and pressed against top end 76a (see also FIG. 6A) of washer 16, such as chamfered washer 25, and bottom end 78a (see also FIG. 6A) of chamfered washer 25 in contact with and pressed against structural top 40a (see also FIG. 6A) of structure 40. With the protruding head fastener 32 installed at the installed position 194b within the structure 40, the protruding fastener head 160b and chamfered washer 25 of the fastener and washer assembly 14 protrude above the upper end of the structure 40, with the bottom end 78a of the chamfered washer 25 contacting the upper structural portion 40a at the upper end of the structure 40.

[0115] FIG. 6B further illustrates a gap 190b between the fastener shank 172c and the interior wall 192 of the structure 40 when the fastener and washer assembly 14 is inserted into the hole 126 of the structure 40 in the installed position 194b. As shown in FIG. 6B, the hole 126 through the structure 40 is of a constant or uniform width and has a constant or uniform hole diameter 127a throughout the hole 126. As shown in FIG. 6B, the hole diameter 127a of the hole 126 has a length that is greater than the length of the fastener shank diameter 172d of the fastener shank 172c. Thus, in a clearance fit fastener 34, the size of the hole 126 is larger than the size of the fastener shank 172c, and the size of the fastener shank 172c is smaller than the size of the hole 126.

[0116] Referring now to FIG. 6C, FIG. 6C is a front partial cross-sectional view of another version of fastener and washer assembly 14 in assembled position 145c and installed position 194b within structure 40, where fastener 26, such as protruding head fastener 32, is an interference fit fastener 36 and washer 16 is a chamfered washer 25.

[0117] As shown in FIG. 6C , when fastener and washer assembly 14 is in assembled position 145c and installed position 194b, fastener head 160, such as protruding fastener head 160b, is positioned above chamfered washer 25 in stacked configuration 202. FIG. 6C further shows bottom end 164a of fastener head 160, such as protruding fastener head 160b, in contact with and pressed against top end 76a of washer 16, such as chamfered washer 25, and bottom end 78a of chamfered washer 25 in contact with and pressed against structural top 40a of structure 40. With the protruding head fastener 32 installed at the installed position 194b within the structure 40, the protruding fastener head 160b and chamfered washer 25 of the fastener and washer assembly 14 protrude above the upper end of the structure 40, with the bottom end 78a of the chamfered washer 25 contacting the upper structural portion 40a at the upper end of the structure 40.

[0118] As shown in FIG. 6C , when the fastener and washer assembly 14 is inserted into the hole 126 of the structure 40 in the installed position 194b, no gap exists between the fastener shank 172c and the inner wall 192 of the structure 40. With the interference fit fastener 36 installed in the hole 126, the fastener shank diameter 172d (see FIG. 6C ) of the fastener shank 172c has a length that is slightly larger than the hole diameter 127a (see FIG. 6C ) of the hole 126, because the fastener shank 172c of the interference fit fastener 36 is press-fit or friction-fit into the hole 126. Thus, in the interference fit fastener 36, the size of the hole 126 is smaller than the size of the fastener shank 172c, and the size of the fastener shank 172 is larger than the size of the hole 126, so that the interference fit fastener 36 is press-fit or friction-fit into the hole 126.

[0119] Referring now to FIG. 7 , FIG. 7 is a schematic diagram of a process flow 208, such as a first process flow 208a, using an exemplary version of the automated fastener system 10 of the present disclosure, illustrating automated washer installation 12 of a fastener 26, such as an aircraft fastener 28, prior to inspection using an automated inspection system 94.

[0120] FIG. 7 illustrates an automatic washer supply system 60 of the automated fastener system 10 that holds and dispenses washers 16, such as aircraft washers 18. In one version, each washer 16, such as each aircraft washer 18 shown in FIG. 7, is a countersunk washer 22 and a conductive washer 20. In other versions, the washer 16 may comprise a chamfered washer 25 (see FIG. 4A) and / or may not be conductive. As shown in FIG. 7, a selected aircraft washer 18a, e.g., a selected washer 16a, such as a selected conductive washer 20a, is pushed through a supply device 62, such as a tube feeder 64, by a washer pushing action 209a and dropped or released from the automated washer supply system 60 into an interior through-opening 210 of a shuttle cup 68, such as a selected shuttle cup 68a of the automated shuttle assembly 70, by a washer releasing action 209b. Alternatively, tube feeder 64 may be vertical and gravity may be used to dispense washers 16, such as selected washer 16a, and retention fingers may be used to hold and release each washer 16, such as each selected washer 16a. Automated washer feeding system 60 includes a trigger gate 65 to allow only one selected washer 16a at a time to be dispensed, dropped, or transferred from feeding device 62 to a shuttle cup 68, such as selected shuttle cup 68a.

[0121] As further shown in FIG. 7 , automated washer feeding system 60 includes a washer orientation system 72 for orienting and placing countersunk washers 22 in a properly oriented position 75 as they are conveyed along feeding device 62, such as tube feeder 64, for dispensing, dropping, transferring, and inserting into shuttle cup 68, such as selected shuttle cup 68 a. As discussed above, in one version, orienting device 74 (see FIG. 1 ) may include a tubular carrier that holds washer 16 in the proper orientation or position and drops or pushes washer 16 out of the tubular carrier. In another version, orienting device 74 (see FIG. 1 ) may include a bowl feeder that separates washer 16 and, if necessary, rotates washer 16 into properly oriented position 75 to accurately orient washer 16. Washer orientation system 72 may further include one or more sensors or other components to ensure that countersunk washer 22 or asymmetrical chamfer washer 25b (see FIG. 5B) is transported and inserted in the correct orientation and position within shuttle cup 68, such as selected shuttle cup 68a. As shown in FIG. 7, washer orientation system 72 is coupled to automated washer supply system 60 by connector 211a.

[0122] As further shown in FIG. 7 , the automatic washer dispensing system 60 includes a washer type determination system 80 for viewing the geometric shape 82 (see FIG. 1 ) of the washer 16 and determining the type of the washer 16 based on the geometric shape 82, for example, determining whether the washer 16 is a countersunk washer 22 type or a chamfered washer 25 type. As shown in FIG. 7 , the washer type determination system 80 includes a vision system 84 for viewing the geometric shape 82 of the washer 16. The vision system 84 includes a camera, a camera and laser line scanner, a multi-laser line scanner, a radio frequency identification (RFID) scanner, or another optical or camera-based system for viewing the geometric shape 82 (see FIG. 1 ) of the washer 16 passing through the automatic washer dispensing system 60 to determine the type of the washer 16. As shown in FIG. 7 , the washer type determination system 80 includes a sensor 85. The washer type determination system 80 may further include connectors or other components known in the art of vision systems.

[0123] As further shown in FIG. 7 , the automatic washer dispensing system 60 includes a washer material verification system 86, such as an inspection module, to determine and verify the washer color 87 (see FIG. 1 ) and / or determine and verify the base washer material 52 (see FIG. 1 ) of a washer 16, such as a selected washer 16a. As shown in FIG. 7 , the washer material verification system 86 includes a vision system 84a, such as a camera, a camera and laser line scanner, a multi-laser line scanner, a radio frequency identification (RFID) scanner, or another optical or camera-based system, to view the washer color 87 of the washer 16 passing through the automatic washer dispensing system 60 and to determine and verify the base washer material 52 of the washer 16 based on the washer color 87. As shown in FIG. 7 , the washer material verification system 86 further includes a conductivity measurement system 88 for use when the base washer material 52 cannot be determined based on the washer color 87. As discussed above, the conductivity measurement system 88 measures a conductivity measurement value 89 (see FIG. 1 ) of a selected washer 16, such as the washer 16a, compares it to a predetermined conductivity value range for a given base washer material, and determines the base washer material 52 (see FIG. 1 ) based on the conductivity measurement value 89 obtained by the conductivity measurement system 88. In one version, as discussed above, the conductivity measurement system 88 includes one or more eddy current conductivity probe assemblies having one or more eddy current conductivity probes with one or more coils coupled to electrical wires, and one or more sensors coupled to the one or more eddy current conductivity probes via electrical wires. As shown in FIG. 7 , the washer type determination system 80 and the washer material verification system 86 are coupled to the automated washer supply system 60 via one or more connectors 211b. The automated washer supply system 60, including the washer orientation system 72, the washer type determination system 80, and the washer material verification system 86, is controlled by the control system 130 (see FIG. 7 ).

[0124] As shown in FIG. 7 , a selected aircraft washer 18 a, e.g., a selected washer 16 a, such as selected conductive washer 20 a, is released or transported into a shuttle cup 68, such as selected shuttle cup 68 a, by a washer transport 213. The shuttle cup 68 is part of an automated shuttle assembly 70 of the automated fastener system 10. As further shown in FIG. 7 , a selected aircraft washer 18 a, e.g., a selected washer 16 a, such as selected conductive washer 20 a, is transported and carried in the shuttle cup 68, such as selected shuttle cup 68 a, by a washer transport 214 to the automated fastener holder assembly 90 for automated washer installation 12. As shown in FIG. 7 , the shuttle cup 68, such as selected shuttle cup 68 a, incorporates a shuttle cup sensor 68 b within the shuttle cup 68 to sense or detect the presence of the selected aircraft washer 18 a, e.g., the selected washer 16 a, such as selected conductive washer 20 a, within the shuttle cup 68. A shuttle cup 68, such as a selected shuttle cup 68a, may be moved by an automated transport mechanism (not shown) of the automated shuttle assembly 70, which may, for example, comprise a rail or track system along which the selected shuttle cup 68a automatically moves back and forth between the automated washer supply system 60 and the automated fastener holder assembly 90. The automated transport mechanism may also comprise another suitable transport system for automatically moving the selected shuttle cup 68a between the automated washer supply system 60 and the automated fastener holder assembly 90.

[0125] As shown in FIG. 7 , the automatic fastener holder assembly 90 of the automatic fastener system 10 holds and dispenses one or more fasteners 26, such as one or more aircraft fasteners 28, and provides a selected fastener 26a, such as a selected aircraft fastener 28a, for the automatic washer installation 12. As shown in FIG. 7 , the fastener 26, such as the aircraft fastener 28, includes a countersunk fastener 30. However, the fastener 26, such as the aircraft fastener 28, may also include a protruding head fastener 32, or another suitable type of fastener. As shown in FIG. 7 , the automatic fastener holder assembly 90 includes a fastener holder 92, such as a vertical tube holder 92a.

[0126] In the automatic washer installation 12, a selected aircraft fastener 28a, e.g., a selected fastener 26a, such as countersunk fastener 30, is dispensed or transferred into the interior through-opening 210 of a shuttle cup 68, such as a selected shuttle cup 68a, and into the through-opening 155 of a selected aircraft washer 18a, e.g., a selected washer 16a, such as countersunk washer 22, seated in the selected shuttle cup 68a. In the automatic washer installation 12, the selected aircraft fastener 28a, e.g., a selected fastener 26a, such as countersunk fastener 30, is assembled with the selected aircraft washer 18a, e.g., a selected washer 16a, such as countersunk washer 22, to form a fastener and washer assembly 14 (see FIG. 7), such as an aircraft fastener and conductive washer assembly 14a (see FIG. 7), or in this version, a countersunk fastener and countersunk washer assembly 14b (see FIG. 7).

[0127] 7, in this version, after the automated washer installation 12 and fastener and washer assembly 14 are obtained, the fastener and washer assembly 14 may, in one version, be picked up and gripped by gripper fingers 96, such as inspection gripper fingers 96a, of the automated inspection system 94 of the automated fastener system 10, and a selected aircraft fastener 28a, e.g., a selected fastener 26a, such as a countersunk fastener 30, is inspected by the automated inspection system 94. The inspection gripper fingers 96a open and close with an opening and closing action 215 (see FIG. 7), including a closing action 215a (see FIG. 7), to grip and release the fastener and washer assembly 14, or only the selected fastener 26a.

[0128] 7, after a selected aircraft fastener 28a, such as a selected fastener 26a, e.g., a countersunk fastener 30, undergoes inspection by the automated inspection system 94, the fastener and washer assembly 14 is transferred from the automated inspection system 94 to an automated transport system 100 of the automated fastener system 10. The automated transport system 100 includes a transport device 102 (see FIG. 13), such as a transport shuttle 104 (see FIG. 13), for transporting the fastener and washer assembly 14.

[0129] 7, the fastener and washer assembly 14 is transported via the automated transport system 100 to the automated installation system 110 of the automated fastener system 10. The automated installation system 110 may include a robotic system 114 (see FIG. 14A) in one version, or a gantry system 116 (see FIG. 14B) in another version.

[0130] 7, automated washer supply system 60, automated shuttle assembly 70, automated fastener holder assembly 90, automated inspection system 94, automated transport system 100, and automated installation system 110 are controlled and operated via control system 130, which are connected by control system connections 212. Control system connections 212 may include wired connections 212a (see FIGS. 7 and 8) or wireless connections 212b (see FIG. 9). As shown in FIG. 7, control system 130 includes controller 132, one or more power sources 134, and computer system 136.

[0131] Referring now to FIG. 8 , FIG. 8 is a schematic diagram of a process flow 208, such as a second process flow 208b, using another exemplary version of the automated fastener system 10 of the present disclosure, illustrating automated washer installation 12 after inspection of fasteners 26, such as aircraft fasteners 28, by an automated inspection system 94 and before transfer to, for example, an automated transport system 100 and an automated installation system 110.

[0132] As shown in FIG. 8 , in this version, a selected aircraft fastener 28a, e.g., a selected fastener 26a, such as a countersunk fastener 30, is transferred from an automated fastener holder assembly 90 of the automated fastening system 10 to an automated shuttle assembly 70 of the automated fastening system 10. As shown in FIG. 8 , the automated fastener holder assembly 90 holds and dispenses one or more fasteners 26, such as one or more aircraft fasteners 28, and provides the selected aircraft fastener 28a, e.g., a selected fastener 26a, such as a countersunk fastener 30, into a shuttle cup 68, such as a selected shuttle cup 68a, of the automated shuttle assembly 70. As shown in FIG. 8 , the fastener 26, such as the aircraft fastener 28, includes a countersunk fastener 30. However, the fastener 26, such as the aircraft fastener 28, may also include a protruding head fastener 32, or another suitable type of fastener. As shown in FIG. 8 , the automated fastener holder assembly 90 includes a fastener holder 92, such as a vertical tube holder 92a.

[0133] As shown in FIG. 8 , a selected aircraft fastener 28a, e.g., a selected fastener 26a, such as a countersink fastener 30, is automatically dispensed or transferred from the automated fastener holder assembly 90 into the interior through-opening 210 of a shuttle cup 68, such as a selected shuttle cup 68a, by a fastener transfer 216 action. While the shuttle cup 68 does not show a shuttle cup sensor 68b (see FIG. 7 ), in one version, the shuttle cup 68 may include the shuttle cup sensor 68b. The shuttle cup 68, such as the selected shuttle cup 68a, may be moved by an automated transport mechanism (not shown) of the automated shuttle assembly 70; for example, the automated transport mechanism may comprise a rail or track system along which the selected shuttle cup 68a automatically moves back and forth between the automated fastener holder assembly 90 and the automated inspection system 94. The automated transport mechanism may also comprise another suitable transport system for automatically moving the selected shuttle cup 68a between the automated washer supply system 60 and the automated fastener holder assembly 90.

[0134] As further shown in FIG. 8 , after a selected aircraft fastener 28a, e.g., a selected fastener 26a, such as a countersunk fastener 30, is transferred into the interior through-opening 210 of a shuttle cup 68, such as a selected shuttle cup 68a, and seated within the shuttle cup 68, the selected aircraft fastener 28a, e.g., a selected fastener 26a, such as a countersunk fastener 30, is transported from the automated fastener holder assembly 90 to the automated inspection system 94.

[0135] 8, in the automated inspection system 94, a selected aircraft fastener 28a, e.g., a selected fastener 26a, such as countersunk fastener 30, is picked up from an internal through-opening 210 of a shuttle cup 68, such as a selected shuttle cup 68a, and gripped by a gripper finger 96, such as inspection gripper finger 96a, of the automated inspection system 94 of the automated fastener system 10, and the selected aircraft fastener 28a, e.g., a selected fastener 26a, such as countersunk fastener 30, is subjected to inspection by the automated inspection system 94. The inspection gripper finger 96a opens and closes with an opening and closing action 215 (see FIG. 8), including a closing action 215a (see FIG. 8), to grip and release the fastener and washer assembly 14, or just the selected fastener 26a.

[0136] As further shown in FIG. 8 , during inspection by automated inspection system 94 of selected aircraft fastener 28 a, e.g., selected fastener 26 a, such as countersunk fastener 30, shuttle cup 68, such as selected shuttle cup 68 a, is transported or moved by shuttle cup transport 217 action to automated washer supply system 60 to pick up selected washer 16, such as selected washer 16 a. FIG. 8 illustrates automated washer supply system 60 of automated fastener system 10, which holds and dispenses washers 16, such as aircraft washer 18. In one version, each washer 16, such as each aircraft washer 18 shown in FIG. 8, is a countersunk washer 22 and is a conductive washer 20. In other versions, washer 16 may comprise a chamfered washer 25 (see FIG. 4A ) and / or may not be conductive. As shown in FIG. 8 , a selected aircraft washer 18a, e.g., a selected washer 16a, such as a selected conductive washer 20a, is pushed through a feeding device 62, such as a tube feeder 64, by a washer pushing action 209a and dropped or released from the automated washer feeding system 60 into an internal through-opening 210 of a shuttle cup 68, such as a selected shuttle cup 68a, of an automated shuttle assembly 70 by a washer releasing action 209b. Alternatively, the tube feeder 64 may be vertical, gravity may be used to dispense the washers 16, such as the selected washer 16a, and a retaining finger may be used to hold and release each washer 16, such as each selected washer 16a. The automated washer feeding system 60 includes a trigger gate 65 to allow only one selected washer 16a at a time to be dispensed, dropped, or transferred from the feeding device 62 into a shuttle cup 68, such as a selected shuttle cup 68a.

[0137] 8, automated washer feeding system 60 includes a washer orientation system 72 for orienting and placing countersunk washers 22 in a properly oriented position 75 as they are conveyed along feeding device 62, such as tube feeder 64, for dispensing, dropping, transporting, and inserting into shuttle cup 68, such as selected shuttle cup 68a. As shown in FIG. 8, washer orientation system 72 is coupled to automated washer feeding system 60 by connector 211a.

[0138] As further shown in FIG. 8 , the automatic washer dispensing system 60 includes a washer type determination system 80 for viewing the geometric shape 82 (see FIG. 1 ) of the washer 16 and determining the type of the washer 16 based on the geometric shape 82, for example, determining whether the washer 16 is a countersunk washer 22 type or a chamfered washer 25 type. As shown in FIG. 8 , the washer type determination system 80 includes a vision system 84 for viewing the geometric shape 82 of the washer 16. The vision system 84 includes a camera, a camera and laser line scanner, a multi-laser line scanner, a radio frequency identification (RFID) scanner, or another optical or camera-based system for viewing the geometric shape 82 (see FIG. 1 ) of the washer 16 passing through the automatic washer dispensing system 60 to determine the type of the washer 16. As shown in FIG. 8 , the washer type determination system 80 includes a sensor 85. The washer type determination system 80 may further include connectors or other components known in the art of vision systems.

[0139] As further shown in FIG. 8 , the automatic washer dispensing system 60 includes a washer material verification system 86, such as an inspection module, to determine and verify the washer color 87 (see FIG. 1 ) and / or determine and verify the base washer material 52 (see FIG. 1 ) of a washer 16, such as a selected washer 16a. As shown in FIG. 8 , the washer material verification system 86 includes a vision system 84a, such as a camera, a camera and laser line scanner, a multi-laser line scanner, a radio frequency identification (RFID) scanner, or another optical or camera-based system, to view the washer color 87 of the washer 16 passing through the automatic washer dispensing system 60 and to determine and verify the base washer material 52 of the washer 16 based on the washer color 87. As shown in FIG. 8 , the washer material verification system 86 further includes a conductivity measurement system 88 for use when the base washer material 52 cannot be determined based on the washer color 87. As discussed above, the conductivity measurement system 88 measures a conductivity measurement value 89 (see FIG. 1 ) of a washer 16, such as a selected washer 16a, compares it to a predetermined conductivity value range for a given base washer material, and determines the base washer material 52 (see FIG. 1 ) based on the conductivity measurement value 89 obtained by the conductivity measurement system 88. In one version, as discussed above, the conductivity measurement system 88 includes one or more eddy current conductivity probe assemblies having one or more eddy current conductivity probes with one or more coils coupled to electrical wires, and one or more sensors coupled to the one or more eddy current conductivity probes via electrical wires. As shown in FIG. 8 , the washer type determination system 80 and the washer material verification system 86 are coupled to the automated washer feeding system 60 via one or more connectors 211b. The automated washer feeding system 60, including the washer orientation system 72, the washer type determination system 80, and the washer material verification system 86, is controlled by the control system 130 (see FIG. 8 ).

[0140] As shown in Figure 8, a selected aircraft washer 18a, e.g., a selected washer 16a, such as selected conductive washer 20a, is released or transported into an interior through-opening 210 of a shuttle cup 68, such as selected shuttle cup 68a, by a washer transport 213. As further shown in Figure 8, the selected aircraft washer 18a, e.g., a selected washer 16a, such as selected conductive washer 20a, is transported by a washer transport 214 in a shuttle cup 68, such as selected shuttle cup 68a, to the automated inspection system 94 for picking up a selected aircraft fastener 28a, e.g., a selected fastener 26a, such as countersunk fastener 30, after inspection by the automated inspection system 94.

[0141] As shown in FIG. 8 , after a shuttle cup 68, such as a selected shuttle cup 68a, conveys a selected aircraft washer 18a, e.g., a selected washer 16a, such as a selected conductive washer 20a, to the automated inspection system 94, after inspection 218, a selected aircraft fastener 28a, e.g., a selected fastener 26a, such as countersunk fastener 30, is released by the inspection gripper fingers 96a into the interior through-opening 210 of the shuttle cup 68, such as the selected shuttle cup 68a, and into the through-opening 155 of the selected aircraft washer 18a, e.g., a selected washer 16a, such as countersunk washer 22, seated within the selected shuttle cup 68a. In the automatic washer installation 12, a selected aircraft fastener 28a, e.g., a selected fastener 26a, such as a countersunk fastener 30, is assembled with a selected aircraft washer 18a, e.g., a selected washer 16a, such as a countersunk washer 22, to form a fastener and washer assembly 14 (see FIG. 8), such as an aircraft fastener and conductive washer assembly 14a (see FIG. 8), or in this version, a countersunk fastener and countersunk washer assembly 14b (see FIG. 8).

[0142] 8 , after a selected aircraft fastener 28a, e.g., a selected fastener 26a, such as a countersunk fastener 30, is assembled with a selected aircraft washer 18a, e.g., a selected washer 16a, such as a countersunk washer 22, using the automated washer installation 12 to form the fastener and washer assembly 14, the fastener and washer assembly 14 is picked up and gripped by the inspection gripper fingers 96a in an action of gripping the fastener and washer assembly 219. The inspection gripper fingers 96a then release the fastener and washer assembly 14 into an automated transport system 100 (see FIG. 8 ) of the automated fastener system 10. The automated transport system 100 includes a transport device 102 (see FIG. 13 ), such as a transport shuttle 104 (see FIG. 13 ), for transporting the fastener and washer assembly 14.

[0143] 8, the fastener and washer assembly 14 is transported via an automated transport system 100 to an automated installation system 110 of the automated fastener system 10. The automated installation system 110 may include a robotic system 114 (see FIG. 14A) in one version, or a gantry system 116 (see FIG. 14B) in another version.

[0144] As further shown in Figure 8, automated washer supply system 60, automated shuttle assembly 70, automated fastener holder assembly 90, automated inspection system 94, automated transport system 100, and automated installation system 110 are controlled and operated via control system 130, which are connected by control system connections 212. Control system connections 212 may include wired connections 212a (see Figures 7 and 8) or wireless connections 212b (see Figure 9). As shown in Figure 8, control system 130 includes controller 132, one or more power sources 134, and computer system 136.

[0145] Referring now to FIG. 9, FIG. 9 is a schematic diagram of a process flow 208, such as a third process flow 208c, using another exemplary version of the automated fastener system 10 of the present disclosure, illustrating automated washer installation 12 in an automated installation system 110.

[0146] As shown in FIG. 9, the automatic fastener system 10 includes an automatic fastener holder assembly 90 as shown and described with respect to FIGS. 7 and 8, an automatic shuttle assembly 70 as shown and described with respect to FIGS. 7 and 8, an automatic inspection system 94 as shown and described with respect to FIGS. 7 and 8, an automatic transport system 100, and an automatic installation system 110.

[0147] As further shown in FIG. 9 , in one version, the automatic washer supply system 60 includes a selected holder 66a, e.g., a holder 66, such as a cup holder 66b, into which a selected washer 16a, e.g., a selected aircraft washer 18a, e.g., a selected conductive washer 20a, is dispensed, dropped, or transferred from a supply device 62, such as a tube feeder 64, into the selected holder 66a, e.g., the cup holder 66b, instead of being dispensed, dropped, or transferred into a shuttle cup 68 (see FIGS. 7 and 8), such as a selected shuttle cup 68a (see FIGS. 7 and 8) of an automatic shuttle assembly 70.

[0148] FIG. 9 illustrates an automatic washer supply system 60 of the automatic fastener system 10 that holds and dispenses washers 16, such as aircraft washers 18. In one version, each washer 16, such as each aircraft washer 18 shown in FIG. 9, is a countersunk washer 22 and a conductive washer 20. In other versions, the washer 16 may comprise a chamfered washer 25 (see FIG. 4A ) and / or may not be conductive. As shown in FIG. 9 , a selected aircraft washer 18a, e.g., a selected washer 16a, such as a selected conductive washer 20a, is pushed through a supply device 62, such as a tube feeder 64, by a washer pushing action 209a and dropped or released from the automatic washer supply system 60 into a selected holder 66a, e.g., a cup holder 66b, of the automatic washer supply system 60 by a washer releasing action 209b. Alternatively, tube feeder 64 may be vertical and gravity may be used to dispense washers 16, such as selected washer 16 a, and retention fingers may be used to hold and release each selected washer 16, such as each selected washer 16 a. Automated washer feeding system 60 includes a trigger gate 65 to allow only one selected washer 16 a at a time to be dispensed, dropped, or transferred from feeding device 62 to a holder 66, such as selected holder 66 a.

[0149] As further shown in Figure 9, automated washer supply system 60 includes a washer orientation system 72 for orienting and placing countersunk washers 22 in a properly oriented position 75 as they are conveyed along supply device 62, such as tube feeder 64, for dispensing, dropping, transporting, and inserting into a holder 66, such as a selected holder 66a. Orientation device 74 is discussed in further detail above with respect to Figures 1, 7, and 8. As shown in Figure 9, washer orientation system 72 is coupled to automated washer supply system 60 by connector 211a.

[0150] As further shown in FIG. 9 , the automatic washer dispensing system 60 includes a washer type determination system 80 for viewing the geometric shape 82 (see FIG. 1 ) of the washer 16 and determining the type of the washer 16 based on the geometric shape 82, for example, determining whether the washer 16 is a countersunk washer 22 type or a chamfered washer 25 type. As shown in FIG. 9 , the washer type determination system 80 includes a vision system 84 for viewing the geometric shape 82 of the washer 16. The vision system 84 includes a camera, a camera and laser line scanner, a multi-laser line scanner, a radio frequency identification (RFID) scanner, or another optical or camera-based system for viewing the geometric shape 82 (see FIG. 1 ) of the washer 16 passing through the automatic washer dispensing system 60 to determine the type of the washer 16. As shown in FIG. 9 , the washer type determination system 80 includes a sensor 85. The washer type determination system 80 may further include connectors or other components known in the art of vision systems.

[0151] As further shown in FIG. 9 , the automatic washer dispensing system 60 includes a washer material verification system 86, such as an inspection module, to determine and verify the washer color 87 (see FIG. 1 ) and / or determine and verify the base washer material 52 (see FIG. 1 ) of a washer 16, such as a selected washer 16a. As shown in FIG. 9 , the washer material verification system 86 includes a vision system 84a, such as a camera, a camera and laser line scanner, a multi-laser line scanner, a radio frequency identification (RFID) scanner, or another optical or camera-based system, to view the washer color 87 of the washer 16 passing through the automatic washer dispensing system 60 and to determine and verify the base washer material 52 of the washer 16 based on the washer color 87. As shown in FIG. 9 , the washer material verification system 86 further includes a conductivity measurement system 88 for use when the base washer material 52 cannot be determined based on the washer color 87. As discussed above, the conductivity measurement system 88 measures a conductivity measurement value 89 (see FIG. 1 ) of a washer 16, such as a selected washer 16a, compares it to a predetermined conductivity value range for a given base washer material, and determines the base washer material 52 (see FIG. 1 ) based on the conductivity measurement value 89 obtained by the conductivity measurement system 88. In one version, as discussed above, the conductivity measurement system 88 includes one or more eddy current conductivity probe assemblies having one or more eddy current conductivity probes with one or more coils coupled to electrical wires, and one or more sensors coupled to the one or more eddy current conductivity probes via electrical wires. As shown in FIG. 9 , the washer type determination system 80 and the washer material verification system 86 are coupled to the automated washer feeding system 60 via one or more connectors 211b. The automated washer feeding system 60, including the washer orientation system 72, the washer type determination system 80, and the washer material verification system 86, is controlled by the control system 130 (see FIG. 9 ).

[0152] As shown in FIG. 9 , a selected aircraft washer 18a, e.g., a selected washer 16a, such as selected conductive washer 20a, is released or transferred into holder 220, such as selected holder 66a, by a washer transfer action to holder 66. As further shown in FIG. 9 , in this version, a selected aircraft washer 18a, e.g., a selected washer 16a, such as selected conductive washer 20a seated in holder 66, e.g., selected holder 66a, is transferred to automated conveyance system 100. Holder 66, such as selected holder 66a, may be moved by an automated conveyance mechanism (not shown), which may include, for example, a rail system or track system, or a hanging rail system or a hanging track system, along which holder 66 automatically moves between automated washer supply system 60 and automated conveyance system 100. The automated conveyance mechanism may also include another suitable conveyance system.

[0153] As shown in FIG. 9 , in the automated installation system 110, a selected aircraft fastener 28 a, e.g., a selected fastener 26 a, such as a countersunk fastener 30, is picked up and grasped by a gripper finger 96, such as an end effector gripper finger 96 b, from a transport device 102 (see FIG. 13 ), such as a transport shuttle 104 (see FIG. 13 ), and the selected aircraft fastener 28 a, e.g., the selected fastener 26 a, such as a countersunk fastener 30, is placed on a selected aircraft washer 18 a, e.g., a selected washer 16 a, such as a selected conductive washer 20 a, in a holder 66, such as a selected holder 66 a. The end effector gripper fingers 96b open and close with an opening and closing action 215 (see FIG. 9) including a closing action 215a and an opening action 215b (see FIG. 9) to grip and release the selected fastener 26a and thereafter the fastener and washer assembly 14.

[0154] 9 , the selected aircraft fastener 28a, e.g., the selected fastener 26a, such as the countersunk fastener 30, is transferred to the selected aircraft washer 18a, e.g., the selected washer 16a, such as the selected conductive washer 20a, in the holder 66, such as the selected holder 66a, by the fastener transfer action to the washer 221. The end effector gripper fingers 96b perform an opening and closing action 215, such as an opening action 215b, to release the selected aircraft fastener 28a, e.g., the selected fastener 26a, such as the countersunk fastener 30, into the selected aircraft washer 18a, e.g., the selected washer 16a, such as the selected conductive washer 20a, in the holder 66, such as the selected holder 66a, to perform the automatic washer installation 12. In the automatic washer installation 12, a selected aircraft fastener 28a, e.g., a selected fastener 26a, such as a countersunk fastener 30, is assembled with a selected aircraft washer 18a, e.g., a selected washer 16a, such as a countersunk washer 22, to form a fastener and washer assembly 14 (see FIG. 9), such as an aircraft fastener and conductive washer assembly 14a (see FIG. 9), or in this version, a countersunk fastener and countersunk washer assembly 14b (see FIG. 9).

[0155] As further shown in FIG. 9 , after a selected aircraft fastener 28a, e.g., a selected fastener 26a, such as countersunk fastener 30, is assembled with a selected aircraft washer 18a, e.g., a selected washer 16a, such as countersunk washer 22, using the automated washer installation 12 to form a fastener and washer assembly 14, such as an aircraft fastener and conductive washer assembly 14a, e.g., a countersunk fastener and countersunk washer assembly 14b, the fastener and washer assembly 14 is picked up and gripped by the end effector gripper fingers 96b in an action of gripping the fastener and washer assembly 219 with an opening and closing action 215 that includes a closing action 215a. The end effector gripper fingers 96b of the automated installation system 110 then install the fastener and washer assembly 14, such as the aircraft fastener and conductive washer assembly 14a, e.g., the countersunk fastener and countersunk washer assembly 14b, into the structure 40 (see FIG. 9), such as the aircraft structure 42 (see FIG. 9), via installation 38 (see FIG. 9).

[0156] 9, automated washer supply system 60, automated shuttle assembly 70, automated fastener holder assembly 90, automated inspection system 94, automated transport system 100, and automated installation system 110 are controlled and operated via control system 130, which are connected by control system connections 212. Control system connections 212 may include wired connections 212a (see FIGS. 7 and 8) or wireless connections 212b (see FIG. 9). As shown in FIG. 9, control system 130 includes controller 132, one or more power sources 134, and computer system 136.

[0157] 10 , which is a front perspective view of an exemplary automated fastener holder assembly 90 that holds fasteners 26, such as aircraft fasteners 28, e.g., countersunk fasteners 30, and illustrates an exemplary version of the automated shuttle assembly 70 positioned below the automated fastener holder assembly 90. As shown in FIG. 10 , the automated fastener holder assembly 90 holds and dispenses fasteners 26, such as aircraft fasteners 28, e.g., countersunk fasteners 30, and provides selected fasteners 26a, such as selected aircraft fasteners 28a, for automated washer installation 12. In one version, as shown in FIG. 10 , the automated fastener holder assembly 90 includes a fastener holder 92, such as a vertical tube holder 92a. In other versions, one or more fastener holders 92 may include a cassette, a chute, a hanger, or other suitable fastener holder structure. The fastener holders 92 may accommodate fasteners 26 of different size diameters, for example, one fastener holder 92 may hold fasteners 26 of one diameter size and another fastener holder 92 may hold fasteners 26 of another diameter size. The fastener holders 92 may receive fasteners 26, such as aircraft fasteners 28, from a fastener feeder device (not shown), such as a bowl feeder or other suitable fastener feeder device, located upstream from the automated fastener holder assembly 90 of the automated fastener system 10. The automated fastener holder assembly 90 is controlled by a control system 130 (see FIGS. 1, 7-9).

[0158] FIG. 10 illustrates an automated shuttle assembly 70 having a shuttle cup 68, such as a selected shuttle cup 68a, holding a selected aircraft washer 18a, e.g., a selected washer 16a, such as a selected conductive washer 20a in the form of a countersunk washer 22, within an interior through-opening 210 of the shuttle cup 68. FIG. 10 further illustrates the through-opening 155 of the selected aircraft washer 18a, e.g., the selected washer 16a, such as a selected conductive washer 20a in the form of a countersunk washer 22. FIG. 10 further illustrates the washer carrying 214 action of the selected aircraft washer 18a, e.g., the selected washer 16a, such as a selected conductive washer 20a in the form of a countersunk washer 22, within the shuttle cup 68, such as a selected shuttle cup 68a, for movement beneath the automated fastener holder assembly 90. As shown in FIG. 10 , a selected fastener 26 a, such as selected aircraft fastener 28 a, is released or dropped through fastener holder opening 92 b and into through opening 155 of a selected washer 16 a, such as selected aircraft washer 18 a, e.g., selected conductive washer 20 a in the form of countersunk washer 22, within an interior through opening 210 in a shuttle cup 68, such as selected shuttle cup 68 a, by fastener transfer 216 action.

[0159] 11, which is a front perspective view of an exemplary version of an automated inspection system 94 that may be used in one version of the automated fastener system 10 (see FIG. 1) and automated method 270 (see FIG. 16B) of the present disclosure, showing gripper fingers 96, such as inspection gripper fingers 96a, holding or grasping a selected aircraft fastener 28a, e.g., a selected fastener 26a, such as countersunk fastener 30, above a partial cross-sectional view of an automated shuttle assembly 70 holding a selected washer 16a, such as a selected aircraft washer 18a, e.g., a selected conductive washer 20a in the form of a countersunk washer 22. As shown in FIG. 11, the automated inspection system 94 has a central shaft 95, such as inspection center shaft 95a, with a central shaft end 95c of the central shaft 95 aligned with and in contact with an alignment portion 168 of an upper end 162 of a fastener head 160.

[0160] 11, in one version, the automated inspection system 94 includes a camera 97 and a laser scanner 98, both of which are configured to perform an inspection of a selected fastener 26a, such as a selected aircraft fastener 28a, held and grasped by the inspection gripper fingers 96a and aligned with the inspection center shaft 95a. FIG. 11 further shows the automated inspection system 94 coupled to a control system 130 having a controller 132, a power supply 134, and a computer system 136 via a control system connection 212. The control system 130 is configured to control the movement of the inspection gripper fingers 96a and the inspection center shaft 95a.

[0161] 11 is an example of one version of an automated inspection system 94 that may be used in the automated fastener system 10 (see FIG. 1) and automated method 270 (see FIG. 16B) of the present disclosure. However, other versions of the automated inspection system having different or additional components may be used to accomplish inspection of the selected fasteners 26a, so long as the automated inspection system 94 has at least two or more inspection gripper fingers 96a.

[0162] 12A, which is a top front perspective view of an exemplary version of a shuttle cup 68, such as selected shuttle cup 68a, of automated shuttle assembly 70 (see FIG. 1) that may be used in versions of automated fastener system 10 (see FIG. 1) and automated method 270 (see FIG. 16B) of the present disclosure. As shown in FIG. 12A, shuttle cup 68, such as selected shuttle cup 68a, has an internal through-opening 210 formed therethrough. As shown in FIG. 12A, internal through-opening 210 includes a fastener head opening 210a and a shank opening 210b. In this version, fastener head aperture 210a, such as countersunk fastener head aperture 210c, is configured to support and retain countersunk fastener head 160a (see FIG. 2A) of countersunk fastener 30 (see FIG. 2A), and / or configured to support and retain countersunk washer 22, and / or configured to retain both countersunk washer 22 and countersunk fastener head 160a. Shank aperture 210b is configured to support and retain all or a portion of fastener shank 172 (see FIG. 2A) of countersunk fastener 30. The length of countersunk fastener 30, including fastener shank 172, may extend beyond interior through-opening 210 in the bottom of shuttle cup 68, or may extend wholly or partially through interior through-opening 210 of shuttle cup 68, depending on the length of fastener 26, such as countersunk fastener 30, and the length of fastener shank 172. 12A, in one version, the shuttle cups 68, such as selected shuttle cup 68a, have a cylindrical shape. However, the shuttle cups 68, such as selected shuttle cup 68a, may have another suitable shape.

[0163] 12B, which is a top front perspective view of another exemplary version of a shuttle cup 68, such as selected shuttle cup 68a, of an automated shuttle assembly 70 (see FIG. 1) that may be used in one version of the automated fastener system 10 (see FIG. 1) and automated method 270 (see FIG. 16B) of the present disclosure. As shown in FIG. 12B, a shuttle cup 68, such as selected shuttle cup 68a, has an internal through-opening 210 formed therethrough. As shown in FIG. 12B, internal through-opening 210 includes fastener head opening 210a and shank opening 210b. In this version, fastener head opening 210a, such as protruding fastener head opening 210d, is configured to support and retain protruding fastener head 160b (see FIG. 4A) of protruding-head fastener 32 (see FIG. 4A), and / or is configured to support and retain chamfered washer 25, and / or is configured to retain both chamfered washer 25 and protruding fastener head 160b. The shank opening 210b is configured to support and retain all or part of the fastener shank 172c (see FIG. 4A) of the protruding-head fastener 32. The length of the protruding-head fastener 32, including the fastener shank 172c, may extend beyond the internal through-opening 210 in the bottom of the shuttle cup 68, or may extend fully or partially through the internal through-opening 210 of the shuttle cup 68, depending on the length of the fastener 26, such as the protruding-head fastener 32, and the length of the fastener shank 172c. As further shown in FIG. 12B, in one version, the shuttle cup 68, such as selected shuttle cup 68a, has a cylindrical shape. However, the shuttle cup 68, such as selected shuttle cup 68a, may have another suitable shape.

[0164] Referring now to FIG. 13 , FIG. 13 is a top front perspective view of an exemplary version of a transport device 102, such as a transport shuttle 104, of an automated transport system 100 (see FIGS. 1 , 7-9 ) used in one version of the automated fastener system 10 (see FIG. 1 ) and automated method 270 (see FIG. 16B ) of the present disclosure, showing a fastener and washer assembly 14, such as an aircraft fastener and conductive washer assembly 14 a, held within the transport device 102, such as the transport shuttle 104.

[0165] FIG. 13 illustrates a fastener and washer assembly 14, such as an aircraft fastener and conductive washer assembly 14a, held within a transport device interior 102a, such as a transport shuttle interior 104a, of a transport device 102 of a transport shuttle 104. In one version, as shown in FIG. 13, the fastener and washer assembly 14 is shown after automated washer installation 12 (see FIGS. 7 and 8). FIG. 13 illustrates a selected washer 16a and a selected fastener 26a. FIG. 13 illustrates a fastener head 160 of the selected fastener 26a.

[0166] In another version, the selected fasteners 26a are transported in a transport device 102, such as a transport shuttle 104, and the selected washers 16a are transported in the transport device 102, such as a transport shuttle 104, separately from the selected fasteners 26a. In this version, once the selected fasteners 26a and the selected washers 16a are both transported to an automated installation system 110 (see FIG. 9), the selected fasteners 26a and the selected washers 16a are assembled in an automated washer installation 12 (see FIG. 9) to obtain or form a fastener and washer assembly 14 (see FIG. 9), such as an aircraft fastener and conductive washer assembly 14a (see FIGS. 1, 9, 17), prior to installation 38 in a structure 40 (see FIGS. 1, 9, 17), such as an aircraft structure 42 (see FIGS. 1, 9, 17).

[0167] 13 further illustrates a retaining element 222 contacting the fastener and washer assembly 14 to hold the fastener and washer assembly 14 in place within the transport device interior 102a, such as the transport shuttle interior 104a. Alternatively, the retaining element 222 may be located within the transport device interior 102a, and the fastener shank 172 (see FIGS. 2A-2B) and / or rear end 178 (see FIGS. 2A-2B) of the selected fastener 26a may be retained by the retaining element 222 disposed within the transport device interior 102a, such as the transport shuttle interior 104a, over the selected washer 16a and fastener head 160, instead of, or in addition to, the selected washer 16a and fastener head 160. Preferably, the fastener and washer assembly 14 is enclosed within the transport device interior 102a, such as the transport shuttle interior 104a. Preferably, the entire length of the selected washer 16a and selected fastener 26a is contained within a transport device interior 102a, such as a transport shuttle interior 104a.

[0168] The retaining elements 222 may include clamps, clips, catches, spring-loaded mechanisms, or other suitable fastener retaining elements that hold or secure the fastener and washer assembly 14, or the selected fastener 26a, or the selected washer 16a, within a transport device interior 102a, such as a transport shuttle interior 104a, during transport and transfer of the fastener and washer assembly 14, or the selected fastener 26a, or the selected washer 16a, within a transport device 102, such as a transport shuttle 104, through a transfer tube 108 (see FIG. 1), such as a vacuum tube 108a (see FIG. 1) or a pressure tube 108b (see FIG. 1), which is disposed between the automated inspection system 94 (see FIGS. 1, 7-9) and the automated installation system 110 (see FIGS. 1, 7-9). A transport device 102, such as a transport shuttle 104, carries and transports the fastener and washer assembly 14, or the selected fastener 26a, or the selected washer 16a, away from the automated inspection system 94 to an automated installation system 110 for installation 38 (see FIGS. 1, 9, 17) of a structure 40 (see FIGS. 1, 9, 17), such as an aircraft structure 42 (see FIGS. 1, 9, 17).

[0169] The transport device 102, such as the transport shuttle 104 shown in Figure 13, has a substantially cylindrical shape and is sized and shaped to be easily and efficiently advanced through a transfer tube 108 (see Figure 1), such as a vacuum tube 108a (see Figure 1), or a pressure tube 108b (see Figure 1). The transport device 102, such as the transport shuttle 104 shown in Figure 13, may be made of a metallic material 56 (see Figure 1), such as steel 56d (see Figure 1), stainless steel, aluminum 56b, or another suitable metallic material.

[0170] 13 is an example of one version that may be used in the automated transport system 100 (see FIG. 1) and automated method 270 (see FIG. 16B) of the automated fastener system 10 (see FIG. 1) of the present disclosure. However, other versions of the transport device 102, such as the transport shuttle 104 having different or additional parts to accomplish holding and transporting the fastener and washer assembly 14, selected fastener 26a, or selected washer 16a, may be used.

[0171] 14A, which is a side perspective view of an exemplary version of an automated installation system 110 that may be used in one version of the automated fastener system 10 (see FIG. 1) and automated method 270 (see FIG. 1) of the present disclosure, showing one version of the automated installation system 110 in the form of a robotic system 114 having an end effector 112 coupled to gripper fingers 96, such as end effector gripper fingers 96b, that hold a fastener and washer assembly 14, such as aircraft fastener and conductive washer assembly 14a. As shown in FIG. 14A, the end effector 112 is further coupled to a central shaft 95, such as end effector central shaft 95b.

[0172] The automated installation system 110 shown in FIG. 14A may, in one version, include an automated washer installation 12, as shown and discussed above with respect to FIG. 9, where after transporting the selected fastener 26a and the selected washer 16a to the automated installation system 110, the selected fastener 26a is assembled with the selected washer 16a using the automated washer installation 12 to obtain the fastener and washer assembly 14.

[0173] 14A, the robotic system 114 includes an end effector 112 attached to a robot 115. As further shown in FIG. 14A, in one version, the robot 115 includes a robot arm 224 connected to an elbow joint 226, which is connected to a shoulder 228, which is connected to a base assembly 230.

[0174] 14A, the robotic system 114 is coupled to the control system 130 via a control system connection 212 that includes a wired connection 212a. Alternatively, the control system connection 212 may include a wireless connection 212b. As shown in FIG. 14A, the control system 130 includes at least a controller 132, one or more power sources 134, and a computer system 136.

[0175] 14B, which is a side perspective view of another version of an automated installation system 110 that may be used in one version of the automated fastener system 10 (see FIG. 1) and automated method 270 (see FIG. 16B) of the present disclosure, shows one version of the automated installation system 110 in the form of a gantry system 116 having a gantry 118 having an end effector 112 coupled to gripper fingers 96, such as end effector gripper fingers 96b, that hold a fastener and washer assembly 14, such as aircraft fastener and conductive washer assembly 14a. As shown in FIG. 14A, the end effector 112 is further coupled to a central shaft 95, such as end effector central shaft 95b.

[0176] The automated installation system 110 shown in FIG. 14B may, in one version, include an automated washer installation 12, as shown and discussed above with respect to FIG. 9, where after transporting the selected fastener 26a and the selected washer 16a to the automated installation system 110, the selected fastener 26a is assembled with the selected washer 16a using the automated washer installation 12 to obtain the fastener and washer assembly 14.

[0177] As further shown in Figure 14B, the gantry system 116 comprises a horizontal beam 232 spanning between two support legs 234. As shown in Figure 14B, the gantry system 116 further comprises an arm portion 236 attached at one end to the end effector 112 and at the other end to the support leg 234. The gantry system 116 may further comprise one or more other components known to those skilled in the art, including, but not limited to, a trolley, a crane, one or more carriages, a controller, and other suitable components.

[0178] As further shown in Figure 14B, the gantry system 116 is coupled to the control system 130 via a control system connection 212 that includes a wireless connection 212b. Alternatively, the control system connection 212 may include a wired connection 212a. As shown in Figure 14B, the control system 130 includes at least a controller 132, one or more power sources 134, and a computer system 136.

[0179] Referring now to Figure 15, Figure 15 is a block diagram of an exemplary version of a computer system 136 that may be used with versions of the automated fastener system 10 (see Figure 1) and automated method 270 (see Figure 16B) of the present disclosure. As shown in Figure 15, the computer system 136 comprises one or more computers 138 having one or more processor devices 238 and an operating system 240. The computer system 136 (see Figure 15) may be used to implement one or more computers 138 (see Figure 15).

[0180] The one or more computers 138 (see FIG. 15 ) or one or more processor devices 238 (see FIG. 15 ) may be configured to control one or more functions of one or more elements of the automated fastener system 10 (see FIG. 1 ) by computer program instructions, such as a computer program product 242 (see FIG. 15 ), stored in a computer memory 244 (see FIG. 15 ) accessible to the one or more computers 138 (see FIG. 15 ) or one or more processor devices 238 (see FIG. 15 ).

[0181] 15, computer system 136 may further include one or more computer communication devices 246, such as network communication device 248, for coupling automated fastener system 10 (see FIG. 1), for example, to one or more separate systems. Network communication device 248 (see FIG. 15) may include network links between various computers and devices connected to each other in a network data processing system, to a network, a server, the Internet, or another system or device via wired connections, wireless communication links, fiber optic cables, or other suitable network connections.

[0182] One or more computer communication devices 246 (see FIG. 15) may be configured to provide communications according to any of several wired or wireless communication standards. One or more computers 138 (see FIG. 15) or one or more processor devices 238 (see FIG. 15) may also be configured to facilitate communications via one or more computer communication devices 246 (see FIG. 15), for example, by controlling hardware included within one or more computer communication devices 246 (see FIG. 15). One or more computer communication devices 246 (see FIG. 15) may include, for example, one or more antennas, transmitters, receivers, transceivers, and / or supporting hardware, including, for example, a processor for enabling communications.

[0183] 15, computer system 136 further comprises storage devices 250, such as computer memory 244 and persistent storage 252. Computer memory 244 (see FIG. 15) may include one or more of random access memory (RAM), including dynamic and / or static RAM, on-chip or off-chip cache memory, or other suitable computer memory. Persistent storage 252 (see FIG. 15) may include one or more of flash memory, hard drives, read-only memory (ROM), hard disks, floppy disk drives, and magnetic storage devices such as rewritable magnetic tape, rewritable optical disk drives and / or media, non-volatile random access memory (NVRAM), or other suitable persistent storage devices.

[0184] As shown in FIG. 15 , computer system 136 further includes one or more input / output units 254, a display 256, a data bus 258, and a power supply 134. One or more input / output units 254 (see FIG. 15 ) provide for input and output of data to and from other devices connected to computer system 136 (see FIG. 15 ), such as a computer interface. One or more input / output units 254 (see FIG. 15 ) may include devices such as a keyboard, a mouse, a joystick, or other input / output devices. For example, one or more input / output units 254 (see FIG. 15 ) may provide connections for user input via a keyboard and mouse, or may send output to a printer or other device.

[0185] Display 256 (see FIG. 15) provides a means for displaying conductivity measurements 89 (see FIG. 1) of a washer 16 (see FIG. 1), such as a selected washer 16a (see FIG. 1), or other data or information, to an operator, a user, an analyst, one or more separate automated systems, automated computer programs, automated apparatus, or devices, or another suitable separate system, program, or device. As shown in FIG. 15, data bus 258 provides communication between one or more computers 138, computer memory 244, persistent storage 252, computer communication device 246, one or more input / output units 254, and display 256. Power supply 134 (see FIG. 15) of computer system 136 (see FIG. 15) may include a battery, electricity, a solar charger, or other power source element.

[0186] As shown in Figure 15, a computer program product 242 is preferably used in computer system 136. Computer program product 242 (see Figure 15) includes a computer software program 140 (see Figure 15) having control logic 142 (see Figure 15). Control logic 142 may include an algorithm, program code, computer firmware, or another suitable system logic. As shown in Figure 15, computer program product 242 may include computer-readable medium 260. Computer-readable medium 260 (see Figure 15) may include a computer-readable storage medium 262 (see Figure 15), a computer-readable signal medium 264 (see Figure 15), or another suitable computer-readable medium.

[0187] The control logic 142 (see FIG. 15) can be stored in, retrieved from, and loaded into one or more computers 138 (see FIG. 15), one or more processor devices 238, or other programmable devices to perform operations executed on or by the one or more computers 138, one or more processor devices 238, or other programmable devices, and to configure and direct the one or more computers 138, one or more processor devices 238, or other programmable devices to function in a particular manner. Execution of the control logic 142 (see FIG. 15) implemented by a computer software program 140 can produce a computer-implemented system, process, or method whereby the control logic 142 executed by one or more computers 138 (see FIG. 15), one or more processor devices 238 (see FIG. 15), or other programmable devices provides operations to implement the functions disclosed herein.

[0188] Referring now to FIG. 16A , FIG. 16A is a flow diagram of an example version of a method 265 for distributing electrical current 144 (see FIG. 17 ) or energy in and through an aircraft structure 42 (see FIG. 17 ). The blocks in FIG. 16A represent operations and / or portions or elements thereof, and the lines connecting the various blocks do not imply a particular order or dependency of the operations or portions or elements thereof. FIG. 16A and the disclosure of the steps of method 265 described therein should not be construed as necessarily dictating the order in which the steps should be performed. Moreover, while one illustrative order is shown, it should be understood that the sequence of steps may be modified as appropriate. Accordingly, certain operations may be performed in a different order or simultaneously.

[0189] The method 265 includes providing an aircraft fastener and conductive washer assembly 14a, as described in detail above. The aircraft fastener and conductive washer assembly 14a is assembled using a version of the automated fastener system 10 (see FIG. 1), including the automated fastener installation 12 (see FIG. 1). The aircraft fastener and conductive washer assembly 14a includes a conductive washer 20 (see FIG. 1) made of a conductive material 54 (see FIG. 1), or having a conductive coating 53 (see FIG. 1), or made of the conductive material 54 and having the conductive coating 53. The conductive washer 20 includes an aircraft washer 18 (see FIG. 1), such as a selected aircraft washer 18a (see FIG. 1). The aircraft fastener 28 (see FIG. 1) is made of one of a metal material 56 (see FIG. 1) or a metal alloy material 58 (see FIG. 1). The aircraft fastener 28 includes a selected aircraft fastener 28a (see FIG. 1). The conductive washer 20 contacts and is positioned below the fastener head 160 (see FIGS. 2A, 4A) of the aircraft fastener 28 (see FIG. 1).

[0190] 16A, the method 265 includes a step 266 of installing the aircraft fastener and conductive washer assembly 14a in or within an aircraft structure 42. The aircraft structure 42 includes one or more of a wing section 284 (see FIG. 17), a fuselage 282 (see FIG. 17), a tail section 288 (see FIG. 17), or another suitable aircraft structure 42 of an aircraft 280a (see FIG. 17).

[0191] As discussed above, aircraft fastener and conductive washer assembly 14a includes conductive washer 20 made of conductive material 54 (see FIG. 1), or having conductive coating 53 (see FIG. 1), or made of conductive material 54 and having conductive coating 53, and aircraft fastener 28 (see FIG. 1) made of one of metal material 56 (see FIG. 1) or metal alloy material 58 (see FIG. 1). Conductive washer 20 contacts and is positioned below fastener head 160 (see FIGS. 2A, 4A) of aircraft fastener 28 (see FIG. 1).

[0192] Step 266 of installing the aircraft fastener and conductive washer assembly 14a in or within the aircraft structure 42 may further include installing the aircraft fastener and conductive washer assembly 14a, where the conductive washer 20 includes one of a countersunk washer 22 (see FIGS. 1, 2A) or a chamfered washer 25 (see FIGS. 1, 4A), including a symmetrical chamfered washer 25a (see FIG. 5A) or an asymmetrical chamfered washer 25b (see FIG. 5B).

[0193] Step 266 of installing the aircraft fastener and conductive washer assembly 14a within the aircraft structure 42 further includes installing the aircraft fastener and conductive washer assembly 14a, where the aircraft fasteners 28 include one or more of countersunk fasteners 30 (see FIG. 2A), raised head fasteners 32 (see FIG. 4A), clearance fit fasteners 34 (see FIG. 3B), interference fit fasteners 36 (see FIG. 3C), transition fit fasteners 37 (see FIG. 1), or another suitable fastener.

[0194] Step 266 of installing the aircraft fastener and conductive washer assembly 14a within the aircraft structure 42 further includes installing the aircraft fastener and conductive washer assembly 14a, wherein the conductive washer 20 includes a base washer material 52 including one or more of a metal material 56 as shown in FIG. 1 including copper 56a, aluminum 56b, nickel 56c, steel 56d, titanium 56e, silver 56f, zinc 56g, or gold 56h, or a metal alloy material 58 as shown in FIG. 1 including copper alloy 58a, nickel-chromium alloy 58b, brass 58c, bronze 58d, titanium alloy 58e, aluminum alloy 58f, nickel alloy 58g, steel alloy 58h, silver alloy 58i, zinc alloy 58j, or gold alloy 58k. Additionally, the aircraft fasteners 28 include a base fastener material 55 (see FIG. 1 ) that includes one or more of a metal material 56 as shown in FIG. 1 , including copper 56 a, aluminum 56 b, nickel 56 c, steel 56 d, titanium 56 e, silver 56 f, zinc 56 g, or gold 56 h, or a metal alloy material 58 as shown in FIG. 1 , including copper alloy 58 a, nickel-chromium alloy 58 b, brass 58 c, bronze 58 d, titanium alloy 58 e, aluminum alloy 58 f, nickel alloy 58 g, steel alloy 58 h, silver alloy 58 i, zinc alloy 58 j, or gold alloy 58 k.

[0195] 16A , the method 265 includes a step 268 of distributing the current 144 (see FIG. 17 ) or energy from a lightning strike 294 (see FIG. 17 ) applied to the aircraft structure 42 through the aircraft fastener and conductive washer assembly 14a to the aircraft structure 42. The conductive washer 20 transfers the current 144 or energy from the fastener head 160 of the aircraft fastener 28 to the aircraft structure 42. The conductive washer 20 of the aircraft fastener and conductive washer assembly 14a is used for electromagnetic effect (EME) mitigation to deliver the current 144 (see FIG. 17 ) or energy from the lightning strike 294 from the fastener head 160 of the aircraft fastener 28 to the aircraft structure 42 in a current path 144a (see FIG. 17 ).

[0196] Step 268 of distributing electrical current 144 from a lightning strike 294 applied to the aircraft structure 42 through the aircraft fastener and conductive washer assembly 14a includes the aircraft structure 42 (see FIG. 17 ) including a composite aircraft structure 42a (see FIG. 17 ) and the conductive washer 20 transferring the electrical current 144 or energy from the fastener head 160 of the aircraft fastener 28 to the composite fibers 43 (see FIG. 1 ) of the composite aircraft structure 42a.

[0197] Referring now to FIG. 16B , FIG. 16B is a flow diagram of an exemplary version of an automated method 270 of the present disclosure. In another version of the present disclosure, an automated method 270 is provided for performing automated washer installation 12 (see FIG. 1 ) within an automated fastener system 10 (see FIG. 1 ). The blocks in FIG. 16B represent operations and / or portions or elements thereof, and the lines connecting the various blocks do not imply a particular order or dependency of the operations or portions or elements thereof. The disclosure of the steps of the automated method 270 in FIG. 16B and herein should not be construed as necessarily dictating the order in which the steps are performed. Moreover, while one illustrative order is shown, it should be understood that the sequence of steps may be modified as appropriate. Thus, certain operations may be performed in a different order or simultaneously.

[0198] 16B, the automatic method 270 includes step 272 of providing an automatic fastener system 10. As discussed in detail above, the automatic fastener system 10 includes an automatic washer supply system 60 (see FIGS. 1, 7-9) that holds and dispenses one or more washers 16 (see FIGS. 1, 7-9), such as one or more aircraft washers 18 (see FIGS. 1, 7-9), and provides a selected washer 16a (see FIGS. 1, 7-9), such as a selected aircraft washer 18a (see FIGS. 1, 7-9) for automatic washer installation 12.

[0199] Step 272 of providing the automatic fastener system 10 may further include providing the automatic fastener system 10 (see FIG. 1) with an automatic washer supply system 60 (see FIGS. 1, 7-9), which further includes a washer orientation system 72 (see FIGS. 1, 7) for orienting and positioning one of the countersunk washer 22 (see FIGS. 1, 7) or the asymmetrical chamfered washer 25b (see FIG. 5B) for transfer and insertion into one of the selected holder 66a (see FIG. 9) or the selected shuttle cup 68a (see FIG. 7).

[0200] Step 272 of providing the automatic fastener system 10 may further include providing the automatic fastener system 10 (see FIG. 1) with an automatic washer supply system 60 (see FIGS. 1, 7-9), which further includes a washer type determination system 80 (see FIG. 1) to determine whether each of the one or more washers 16, such as each of the one or more aircraft washers 18, is a countersunk washer 22 (see FIGS. 1, 7) or a chamfered washer 25 (see FIGS. 1, 5A-5B).

[0201] Step 272 of providing the automatic fastener system 10 may further include providing the automatic fastener system 10 (see FIG. 1) with an automatic washer supply system 60 (see FIGS. 1, 7-9), which further includes a washer material verification system 86 (see FIG. 1) to verify the base washer material 52 (see FIG. 1) of a washer 16, such as a selected washer 16a (see FIGS. 1, 7), such as an aircraft washer 18, such as a selected aircraft washer 18a (see FIG. 1).

[0202] The automatic fastener system 10 further includes an automatic fastener holder assembly 90 that holds and dispenses one or more fasteners 26 (see FIGS. 1, 7-9), such as one or more aircraft fasteners 28 (see FIGS. 1, 7-9), and provides a selected fastener 26a (see FIGS. 1, 7-9), such as a selected aircraft fastener 28a (see FIGS. 1, 7-9), for automatic washer installation 12. In the automated washer installation 12, to obtain a fastener and washer assembly 14 (see FIGS. 1, 7-9), such as aircraft fastener and conductive washer assembly 14a (see FIG. 1), a selected fastener 26a, such as selected aircraft fastener 28a, is inserted into a selected aircraft washer 18a, such as selected washer 16a, e.g., selected conductive washer 20a (see FIG. 1), so that the selected aircraft washer 18a, such as selected washer 16a, e.g., selected conductive washer 20a, contacts and is positioned below the fastener head 160 of the selected fastener 26a, such as selected aircraft fastener 28a.

[0203] The automated fastener system 10 further includes an automated shuttle assembly 70 (see FIGS. 1, 7, 8) having one or more shuttle cups 68 (see FIGS. 1, 7, 8, 12A-12B). A selected shuttle cup 68a (see FIGS. 1, 7, 8) of the one or more shuttle cups 68 is configured to receive and transport one of a selected washer 16a, such as a selected aircraft washer 18a, from the automated washer supply system 60, a selected fastener 26a, such as a selected aircraft fastener 28a, from the automated fastener holder assembly 90, or a fastener and washer assembly 14.

[0204] The automated fastener system 10 further includes an automated inspection system 94 (see FIGS. 1, 7-9, 11) having two or more gripper fingers 96 (see FIG. 11), such as two or more inspection gripper fingers 96a (see FIG. 11), configured to pick up, inspect, and release a selected fastener 26a, such as a selected aircraft fastener 28a, or one of the fastener and washer assemblies 14.

[0205] The automated fastener system 10 further includes an automated transport system 100 (see FIGS. 1 , 7-8 ) having a transport device 102 (see FIGS. 1 , 11 ), such as a transport shuttle 104 (see FIG. 11 ), configured to transport and convey one or more of the selected fasteners 26 a, such as the selected aircraft fasteners 28 a, the selected washers 16 a, such as the selected aircraft washers 18 a, or the fastener and washer assemblies 14 away from the automated inspection system 94.

[0206] The automated fastener system 10 further includes an automated installation system 110 (see FIGS. 1, 7-9, 14A-14B) having an end effector 112 (see FIGS. 1, 14A, 14B) with two or more end effector gripper fingers 96b configured to pick up and grasp one or more of a selected fastener 26a, such as a selected aircraft fastener 28a, a selected washer 16a, such as a selected aircraft washer 18a, or a fastener and washer assembly 14 from a transport device 102 (see FIG. 1). The automated installation system 110 is configured to install the fastener and washer assembly 14 to a structure 40 (see FIGS. 1, 17), such as an aircraft structure 42 (see FIGS. 1, 17).

[0207] The automated fastener system 10 further includes a control system 130 (see FIG. 1) that includes at least a controller 132 (see FIG. 1), one or more power sources 134 (see FIG. 1), and a computer system 136 (see FIGS. 1, 15). The control system 130 is configured to control the automated fastener system 10 and the automated washer installation 12.

[0208] As shown in FIG. 16B , the automated method 270 further includes a step 274 of performing automated washer installation 12 at one or more of: before inspection of the selected fasteners 26a, such as selected aircraft fasteners 28a, by the automated inspection system 94; after inspection of the selected fasteners 26a, such as selected aircraft fasteners 28a, by the automated inspection system 94, such as before transfer to the automated transport system 100 and the automated installation system 110; or after transfer of the selected fasteners 26a, such as selected aircraft fasteners 28a, and selected washers 16a, such as selected aircraft washer 18a, by the automated transport system 100.

[0209] 16B , the automated method 270 further includes installing 276 the fastener and washer assembly 14 in a structure 40 (see FIGS. 1 , 17 ), such as an aircraft structure 42 (see FIGS. 1 , 17 ), using the automated installation system 110. Installing 276 the fastener and washer assembly 14 in the structure 40, such as the aircraft structure 42, may further include aligning, using an alignment assembly 120 (see FIG. 1 ), the fastener and washer assembly 14 with a hole 126 (see FIG. 1 ), such as a hole bore, in the structure 40, such as the aircraft structure 42, and maintaining the aligned position 128 (see FIG. 1 ) of the fastener and washer assembly 14 until a selected fastener 26 a, such as a selected aircraft fastener 28 a, is partially inserted through the hole 126 in the structure 40, such as the aircraft structure 42, and partially installed in the structure 40, such as the aircraft structure 42. As shown in FIG. 1 , the alignment assembly 120 includes one or more linear actuators 122 and alignment guides 124 to move one or more of the fastener and washer assembly 14, the selected fastener 26a, or the selected washer 16a to and from different positions within the automated installation system 110, such as home, pickup, and installation 38.

[0210] Referring now to FIG. 17, FIG. 17 is a perspective view of a vehicle 280, such as an aircraft 280a, incorporating one or more structures 40, such as one or more aircraft structures 42, having fastener and washer assemblies 14 (see FIGS. 1, 7-9) of a type that can be installed 38 (see FIG. 1) with a version of the automated fastener system 10 (see FIG. 1) and automated method 270 (see FIG. 16B) of the present disclosure. As shown in FIG. 17, the vehicle 280, such as the aircraft 280a, includes a fuselage 282, wings 284, an engine 286, and a tail section 288. As shown in FIG. 17, the tail section 288 includes a vertical stabilizer 290 and a horizontal stabilizer 292. The one or more structures 40, such as the one or more aircraft structures 42, may comprise wing panels, fuselage panels, tail panels, or other suitable aircraft panels, which may comprise a composite structure, such as a carbon fiber reinforced plastic (CFRP) structure, or another type of composite structure, which may comprise a metal structure, such as an aluminum, steel, or another type of metal structure, or may comprise a combination of composite and metal structures.

[0211] FIG. 17 further illustrates a lightning strike 294 striking the wing section 284, where a structure 40, such as the aircraft structure 42, mounted within the wing section 284 may include one or more fastener and conductive washer assemblies 14 (see FIG. 1), such as one or more aircraft fastener and washer assemblies 14a (see FIGS. 1, 7-9), that can distribute or transfer current 144 or energy from the lightning strike 294 applied to the aircraft structure 42 in a current path 144a through the fastener and washer assemblies 14, such as the aircraft fastener and conductive washer assemblies 14a, to the aircraft structure 42. The lightning strike 294 may also strike the fuselage 282, the tail section 288, or other areas of the aircraft 280a, and one or more aircraft fastener and conductive washer assemblies 14a (see Figures 1, 7-9) may be used in the fuselage 282, the tail section 288, or other areas of the aircraft 280a to distribute or transfer the current 144 or energy from the lightning strike 294 applied to the aircraft structure 42 in a current path 144a through the aircraft fastener and conductive washer assemblies 14a to the aircraft structure 42.

[0212] 17 generally represents a commercial passenger aircraft having one or more aircraft structures 42, the teachings of the disclosed versions of the automated fastening system 10 and automated method 270 may be applied to fasteners 26, such as aircraft fasteners 28, joining structures 40, such as aircraft structures 42 for other passenger aircraft. Additionally, the teachings of the disclosed versions of the automated fastening system 10 and automated method 270 may be applied to fasteners 26 joining structures 40, such as aircraft structures 42 for cargo aircraft, military aircraft, rotorcraft, and other types of aircraft or air vehicles, as well as aerospace vehicles, spacecraft, satellites, space launch vehicles, rockets, and other aerospace vehicles. Additionally, the teachings of the disclosed versions of the automated fastening system 10 and automated method 270 may be applied to fasteners 26 joining structures 40, such as watercraft, automobiles, trains, building structures, or other suitable vehicles or structures.

[0213] 18 and 19, FIG. 18 is a flow diagram of an exemplary aircraft manufacturing and service method 300, and FIG. 19 is an exemplary block diagram of an aircraft 316. With reference to FIG. 18 and 19, versions of the present disclosure may be described in the context of aircraft manufacturing and service method 300 as shown in FIG. 18 and aircraft 316 as shown in FIG. 19.

[0214] During pre-production, exemplary aircraft manufacturing and service method 300 may include specification and design 302 of the aircraft 316 and material procurement 304. During production, component and subassembly manufacturing 306 and system integration 308 of the aircraft 316 occurs. The aircraft 316 may then undergo certification and delivery 310 to enter service 312. While in customer service 312, the aircraft 316 may be scheduled for routine maintenance and service 314 (which may also include modifications, reconfigurations, refurbishments, and other appropriate service).

[0215] Each of the processes of aircraft manufacturing and service method 300 may be performed or implemented by a system integrator, a third party, and / or an operator (e.g., a customer). For purposes of this description, a system integrator may include, without limitation, any number of aircraft manufacturers and major system subcontractors. A third party may include, without limitation, any number of distributors, subcontractors, and suppliers. An operator may include an airline, a leasing company, a military agency, a service organization, and other suitable operators.

[0216] 19 , an aircraft 316 produced by exemplary aircraft manufacturing and service method 300 may include an airframe 318 having multiple systems 320 and an interior 322. Examples of multiple systems 320 may include one or more of a propulsion system 324, an electrical system 326, a hydraulic system 328, and an environmental system 330. Any number of other systems may be included. While an aerospace example is shown, the principles of the present disclosure may be applied to other industries, such as the automotive industry.

[0217] The methods and systems illustrated herein may be used during any one or more of the stages of aircraft manufacturing and service method 300. For example, components or subassemblies corresponding to component and subassembly manufacturing 306 may be fabricated or manufactured in a similar manner to components or subassemblies produced during service 312 of aircraft 316. Also, one or more apparatus embodiments, method embodiments, or a combination thereof may be utilized during component and subassembly manufacturing 306 and system integration 308, for example, by substantially facilitating or reducing the cost of assembly of aircraft 316. Similarly, one or more of apparatus embodiments, method embodiments, or a combination thereof may be utilized during service 312 of aircraft 316, as well as through maintenance and service 314, for example, without limitation.

[0218] The disclosed versions of the automated fastener system 10 (see FIG. 1) and automated method 270 (see FIG. 16B) provide automated washer installation 12 (see FIG. 1) and assembly and coupling of washers 16 (see FIG. 1), such as aircraft washer 18, and fasteners 26 (see FIG. 1), such as aircraft fastener 28 (see FIG. 1), to obtain a fastener and washer assembly 14, such as aircraft fastener and conductive washer assembly 14a. The fastener and washer assembly 14 disclosed herein provides a simple and effective system and method that allows electrical current 144 (see FIG. 17 ) or energy to be transferred through the metal material 56 or metal alloy material 58 of a fastener 26, such as a metal fastener, through the metal material 56 or metal alloy material 58 of a washer 16, such as a conductive washer 20, and through a highly conductive washer, e.g., a copper washer, a silver washer, an aluminum washer, a brass washer, a gold washer, or another highly conductive washer, to the fibers of a composite material and into the structure 40 itself, such as an aircraft structure 42, regardless of the fit of the fastener 26 with the hole 126 (see FIG. 3A ) within the structure 40. A washer 16, such as conductive washer 20, made of a conductive material 54 (see FIG. 1), such as copper 56a (see FIG. 1), is used under the fastener head 160 (see FIGS. 2A, 4A) of fastener 26 (see FIGS. 2A, 4A) to transfer current 144 (see FIG. 17) or energy from a lightning strike 294 (see FIG. 17) all the way from the fastener head 160 to the composite fibers 43 (see FIG. 1) of the main structure 40. The washer 16 (see FIGS. 1, 2A, 4A) is made of a highly conductive material, such as a metal material 56 (see FIG. 1) or a metal alloy material 58 (see FIG. 1), and is attached under the fastener head 160 (see FIGS. 2A, 4A). A washer 16, such as conductive washer 20 (see FIG. 1), distributes the large current 144 or energy from a lightning strike 294 from the fastener 26 to the main structure 40, such as the aircraft structure 42, for example, to a panel or skin of the wing section 284 (see FIG. 17), thereby directing or distributing the current 144 or energy. This prevents, for example, ignition sources from entering aircraft fuel tanks in the wing section 284.The highly conductive washer 20 acts as a large surface area to distribute the electrical current 144 or energy into multiple layers of the structure 40 and within the surface of the structure 40, such as an aircraft structure 42, for example, an aircraft composite structure 42a (see FIG. 17). It can also be combined with copper foil in the composite layup layer(s) to further spread the electrical current 144 or energy.

[0219] Washer 16 fully contacts fastener 26 below fastener head 160 and structure 40 itself. Countersunk washer 22 (see FIGS. 1 and 2A) for countersunk fastener 30 (see FIGS. 1 and 2A) contacts the entire depth and surface of angled countersunk portion 195 (see FIG. 3A). Chamfered washer 25 (see FIGS. 1 and 4A) for protruding-head fastener 32 (see FIGS. 1 and 4A) contacts the surface below protruding fastener head 160b (see FIG. 4B) and structure top 40a (see FIGS. 4A-4B) of structure 40. Chamfered washer 25 may be a symmetrical chamfered washer 25a (see FIG. 5A) or an asymmetrical chamfered washer 25b (see FIG. 5B). The symmetric chamfer washer 25a eliminates the need to orient the symmetric chamfer washer 25a relative to the protruding head fastener 32 (see FIG. 4B) and the structure 40 (see FIG. 4B). Conducting the current 144 or energy through the fastener head 160 and into the structure 40, such as the aircraft structure 42, allows for flexibility in the fastener 26, both in materials or coatings and in its fit with the hole 126 (see FIGS. 1 and 3A). This allows for more flexibility in design and manufacturing, as well as improved safety with respect to electromagnetic effects (EME) and other electrical events, reducing the need for additional mitigation measures, such as fastener cap seals, which add weight, time, and complexity. Successful distribution of the current 144 or energy along the exterior layers of the structure 40, such as the aircraft structure 42, may eliminate the need for extra features, such as fastener cap seals, edge seals, electrically insulating coatings or sealants, or other additional fastener materials. This further improves the manufacturing, efficiency, eg, weight reduction, sustainability, and maintenance of the structure 40, such as the aircraft structure 42.

[0220] The automated fastener system 10 (see FIG. 1) and automated method 270 (see FIG. 16B) provide an improved fastener system and method that is automated and provides automated washer installation 12 of washers 16, such as conductive washers 20, onto fasteners 26, such as metal fasteners, can be used for electromagnetic effects (EME) applications across multiple models of aircraft 280a (see FIG. 17), does not require special fastener materials with multiple parts, does not require the use of electrically insulating coatings or sealants and fastener cap seals, saves weight, and offers advantages over known fastener systems and methods. The automated fastener system 10 with automated washer installation 12 can improve design solutions, reduce manufacturing and performance impacts from multiple known methods, and improve sustainability and maintenance.

[0221] Additionally, automated installation of washers 16, such as conductive washers 20, can incorporate multiple in-process quality assurance measures. These include a washer orientation system 72 (see FIG. 1), a washer type determination system 80, and a washer material verification system 86 (see FIG. 1) to ensure proper installation 38 (see FIG. 9) within a structure 40, such as an aircraft structure 42. The automated washer installation 12 and verification method can be incorporated across multiple models of aircraft 280a for any washer 16 installation, including electromagnetic effect (EME) conductive washers 20. The automated fastener system 10 and automated method 270 (see FIG. 16B) may be used for any washer 16 under the fastener head 160, not just conductive electromagnetic effect (EME) conductive washers 20.

[0222] In one version, an automated fastener system 10 (see FIG. 1 ) and automated method 270 (see FIG. 16B ) uses an automated washer installation 12 to assemble a conductive washer 20 with a fastener 26, such as an aircraft fastener 28. The washer 16 is constructed of a conductive material 54, such as copper 56 a (see FIG. 1 ), and / or coated with a conductive coating 53 (see FIG. 1 ), to transport electrical current 144 from a lightning strike 294 (see FIG. 17 ) or other electromagnetic effect (EME) and electrical event through the fastener 26, such as a metal fastener, to the composite fibers 43 (see FIG. 1 ) of the composite material of the composite aircraft structure 42 a (see FIG. 17 ), and into the overall structure 40 itself, such as the aircraft structure 42 a, regardless of the fitment of the fastener 26 with the hole 126 in the structure 40. Conductive washers 20 are attached to fasteners 26 using automated fastener system 10 and automated method 270 to ensure attachment 38 (see FIG. 1) and proper orientation of washers 16, such as conductive washers 20. In the automated fastener system 10 for pulling fasteners 26, an automated washer supply system 60 (see FIGS. 1, 7-9) transfers the washer 16 to either a shuttle cup 68 (see FIGS. 1, 7, 8) or a holder 66 (see FIG. 9), such as cup holder 66b (see FIG. 9), of an automated shuttle assembly 70. The shuttle cup 68 or holder 66 is transferred to the fastener 26, where the fastener 26 is inserted into the washer 16 within the shuttle cup 68 or holder 66. This step may occur before or after inspection of the fastener 26 by the automated inspection system 94. The inspection gripper fingers 96a may be used to inspect and lift a fastener 26, such as the selected fastener 26a, or fastener and washer assembly 14 from its location and transport it to another location. The automated fastener system 10 continues the operation by pulling a second fastener 26, such as the selected fastener 26a, and performing an inspection on it. The automated fastener system 10 notifies the machine operator or user of the rejection of the fastener 26.

[0223] Those skilled in the art to which this disclosure pertains will be envisioned numerous modifications and other examples of the present disclosure having the benefit of the teachings set forth in the foregoing description and the associated drawings. The versions described herein are for illustrative purposes only and are not intended to be limiting or exhaustive. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Functionally equivalent methods and apparatuses within the scope of the present disclosure, in addition to those enumerated herein, are possible from the foregoing description. Such modifications and variations are intended to be included within the scope of the appended claims. The present disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. [Explanation of symbols]

[0224] 10 Automatic Fastening System 12 Automatic washer installation 14 Fastener and washer assembly 16 Washer 20 Conductive washer 25 Chamfered washer 26 Fasteners 28 Aircraft fasteners 30 Countersunk Fastener 32 Protruding head fastener 34 Clearance fit fastener 36 Interference fit fasteners 37 Transition Fit Fastener 40 Structure 42 Aircraft structure 43 Composite Fiber 52 Base washer material 53 Conductive Coating 54 Conductive Materials 56 Metal materials 58 Metal alloy materials 60 Automatic washer supply system 68 Shuttle Cup 70 Automatic Shuttle Assembly 72 Washer Orientation System 80 Washer Type Determination System 86 Washer Material Verification System 90 Automatic Fastener Holder Assembly 94 Automatic Inspection System 100 Automatic transport system 112 End Effector 120 Alignment Assembly 126 holes 130 Control System 132 Controller 134 Power supply 136 Computer Systems 144 Current 160 Fastener head

Claims

1. An automatic fastener system (10) having an automatic washer attachment (12), the automatic fastener system (10) comprising: an automatic washer supply system (60) that holds and dispenses one or more washers (16) and provides a selected washer (16a) for said automatic washer installation (12); an automated fastener holder assembly (90) for holding and dispensing one or more fasteners (26) and providing a selected fastener (26a) for said automated washer installation (12), wherein said selected fastener (26a) is inserted into said selected washer (16a) so that said selected washer (16a) contacts and is positioned below a fastener head (160) of said selected fastener (26a) to obtain a fastener and washer assembly (14); an automated shuttle assembly (70) having one or more shuttle cups (68), wherein a selected shuttle cup (68a) receives and carries one of the selected washer (16a) from the automated washer supply system (60), the selected fastener (26a) from the automated fastener holder assembly (90), or the fastener and washer assembly (14); an automated inspection system (94) having two or more inspection gripper fingers (96a) for picking up, inspecting, and releasing the selected fastener (26a) or one of the fastener and washer assemblies (14); an automated transport system (100) having a transport device (102) that transports one or more of the selected fastener (26a), the selected washer (16a), or the fastener and washer assembly (14); an automated installation system (110) having an end effector (112) with two or more end effector gripper fingers (96b) that picks up one or more of the selected fastener (26a), the selected washer (16a), or the fastener and washer assembly (14) from the transport device (102) and further installs the fastener and washer assembly (14) within a structure (40); a control system (130) comprising at least a controller (132), one or more power sources (134), and a computer system (136), wherein the control system (130) controls the automated fastener system (10) and the automated washer installation (12); Equipped with the automated washer installation (12) is performed at one or more of: before the automated inspection system (94) inspects the selected fastener (26a), after the automated inspection system (94) inspects the selected fastener (26a), or after the automated transport system (100) transports the selected fastener (26a) and the selected washer (16a) to the automated installation system (110); Automatic fastening system (10).

2. The automatic fastener system (10) of claim 1, wherein each of the one or more washers (16) is a conductive washer (20).

3. Each of the one or more washers (16) Countersunk washer (22) or Chamfered washers (25) including symmetrical chamfered washers (25a) or asymmetrical chamfered washers (25b) The automatic fastener system (10) of claim 1, wherein the automatic fastener system (10) is one of:

4. 2. The automated fastener system of claim 1, wherein the automated washer supply system comprises a washer orientation system for orienting and positioning one of a countersunk washer or an asymmetrical chamfered washer for transfer and insertion into one of a selected holder or the selected shuttle cup.

5. 2. The automated fastener system (10) of claim 1, wherein the automated washer supply system (60) comprises a washer type determination system (80) for determining whether each of the one or more washers (16) is a countersunk washer (22) or a chamfered washer (25).

6. 2. The automated fastener system (10) of claim 1, wherein the automated washer supply system (60) comprises a washer material verification system (86) for verifying the base washer material (52) of the selected washer (16a).

7. 2. The automated fastener system of claim 1, further comprising an alignment assembly for aligning the fastener and washer assembly with a hole in the structure and maintaining the aligned position of the fastener and washer assembly until the selected fastener is partially inserted through the hole and partially installed within the structure.

8. Each of the one or more washers (16) comprises a base washer material (52), the base washer material (52) comprising: Metallic materials (56) including copper (56a), aluminum (56b), nickel (56c), steel (56d), titanium (56e), silver (56f), zinc (56g), or gold (56h); a metal alloy material (58) including copper alloy (58a), nickel-chromium alloy (58b), brass (58c), bronze (58d), titanium alloy (58e), aluminum alloy (58f), nickel alloy (58g), steel alloy (58h), silver alloy (58i), zinc alloy (58j), or gold alloy (58k); The automated fastener system (10) of claim 1, comprising:

9. 2. The automated fastener system (10) of claim 1, wherein each of the one or more fasteners (26) comprises one or more of a countersink fastener (30), a protruding head fastener (32), a clearance fit fastener (34), an interference fit fastener (36), or a transition fit fastener (37).

10. 2. The automatic fastening system of claim 1, wherein the structure includes an aircraft structure, the fastener and washer assembly includes an aircraft fastener and conductive washer assembly, and wherein the aircraft fastener and conductive washer assembly is configured to distribute current from a lightning strike applied to the aircraft structure through the aircraft fastener and conductive washer assembly when the aircraft fastener and conductive washer assembly is installed within one or more of a wing, a fuselage, or a tail section of an aircraft.

11. A method (265) of using a conductive washer (20) to distribute electrical current (144) within an aircraft structure (42), the method (265) comprising: Installing an aircraft fastener and conductive washer assembly (14a) within the aircraft structure (42), the aircraft structure (42) including one or more of a wing section (284), a fuselage (282), or a tail section (288) of an aircraft (280a), the aircraft fastener and conductive washer assembly (14a) comprising: a conductive washer (20) made of a conductive material (54) or having a conductive coating (53); An aircraft fastener (28) made of one of a metal material (56) or a metal alloy material (58), wherein the conductive washer (20) contacts and is positioned below a fastener head (160) of the aircraft fastener (28); Step (266) comprising: distributing (268) the current (144) from a lightning strike (294) applied to the aircraft structure (42) through the aircraft fastener and the conductive washer assembly (14a), wherein the conductive washer (20) transfers the current (144) from the fastener head (160) of the aircraft fastener (28) to the aircraft structure (42); A method (265) comprising:

12. The step of attaching the aircraft fastener and conductive washer assembly to the aircraft structure includes attaching the aircraft fastener and conductive washer assembly, the conductive washer comprising: Countersunk washer (22) or Chamfered washers (25) including symmetrical chamfered washers (25a) or asymmetrical chamfered washers (25b) 12. The method (265) of claim 11, comprising one of:

13. 12. The method of claim 11, wherein installing the aircraft fastener and conductive washer assembly to the aircraft structure includes installing the aircraft fastener and conductive washer assembly, wherein the aircraft fastener comprises one of a countersunk fastener, a protruding head fastener, a clearance fit fastener, an interference fit fastener, or an intermediate fit fastener.

14. The step of installing the aircraft fastener and conductive washer assembly in the aircraft structure includes installing the aircraft fastener and conductive washer assembly, the conductive washer comprising: The metallic material (56) includes copper (56a), aluminum (56b), nickel (56c), steel (56d), titanium (56e), silver (56f), zinc (56g), or gold (56h); or The metal alloy material (58) includes copper alloy (58a), nickel-chromium alloy (58b), brass (58c), bronze (58d), titanium alloy (58e), aluminum alloy (58f), nickel alloy (58g), steel alloy (58h), silver alloy (58i), zinc alloy (58j), or gold alloy (58k). The method (265) of claim 11, further comprising a base washer material (52) comprising:

15. 12. The method of claim 11, wherein distributing the electrical current from the lightning strike applied to the aircraft structure through the aircraft fastener and conductive washer assembly to the aircraft structure further comprises: the aircraft structure including a composite aircraft structure; and the conductive washer transferring the electrical current from the fastener head of the aircraft fastener to composite fibers of the composite aircraft structure.

16. An automated method (270) for performing automated washer installation (12) in an automated fastener system (10), the automated method (270) comprising: an automatic washer supply system (60) that holds and dispenses one or more washers (16) and provides a selected washer (16a) for said automatic washer installation (12); an automated fastener holder assembly (90) for holding and dispensing one or more fasteners (26) and providing a selected fastener (26a) for said automated washer installation (12), wherein said selected fastener (26a) is inserted into said selected washer (16a) so that said selected washer (16a) contacts and is positioned below a fastener head (160) of said selected fastener (26a) to obtain a fastener and washer assembly (14); an automated shuttle assembly (70) having one or more shuttle cups (68), wherein a selected shuttle cup (68a) receives and carries one of the selected washer (16a) from the automated washer supply system (60), the selected fastener (26a) from the automated fastener holder assembly (90), or the fastener and washer assembly (14); an automated inspection system (94) having two or more inspection gripper fingers (96a) for picking up, inspecting, and releasing one of the selected fastener (26a) or the fastener and washer assembly (14); an automated transport system (100) having a transport device (102) that transports one or more of the selected fastener (26a), the selected washer (16a), or the fastener and washer assembly (14); an automated installation system (110) having an end effector (112) with two or more end effector gripper fingers (96b) that picks up one or more of the selected fastener (26a), the selected washer (16a), or the fastener and washer assembly (14) from the transport device (102); a control system (130) comprising at least a controller (132), one or more power sources (134), and a computer system (136), wherein the control system (130) controls the automated fastener system (10) and the automated washer installation (12); providing (272) the automated fastener system (10), comprising: performing the automated washer installation (274) at one or more of before the automated inspection system (94) inspects the selected fasteners (26 a), after the automated inspection system (94) inspects the selected fasteners (26 a), or after the automated transport system (100) transports the selected fasteners (26 a) and the selected washers (16 a) to the automated installation system (110); installing (276) the fastener and washer assembly (14) into a structure (40) using the automated installation system (110); The automated method (270) includes:

17. The step of providing the automated fastener system (10) (272) comprises: a washer orientation system (72) for orienting and positioning one of the countersunk washer (22) or the asymmetrical chamfered washer (25b) for transfer and insertion into one of the selected holder (66a) or the selected shuttle cup (68a); 17. The automated method (270) of claim 16, further comprising providing the automated fastener system (10) with the automated washer supply system (60), further comprising:

18. The step of providing the automated fastener system (10) (272) comprises: a washer type determination system (80) for determining whether each of the one or more washers (16) is a countersunk washer (22) or a chamfered washer (25), including a symmetrical chamfered washer (25a) or an asymmetrical chamfered washer (25b); 17. The automated method (270) of claim 16, further comprising providing the automated fastener system (10) with the automated washer supply system (60), further comprising:

19. The step of providing the automated fastener system (10) (272) comprises: a washer material verification system (86) for verifying the base washer material (52) of the selected washer (16a); 17. The automated method (270) of claim 16, further comprising providing the automated fastener system (10) with the automated washer supply system (60), further comprising one or more of:

20. 17. The automated method of claim 16, wherein installing the fastener and washer assembly within the structure further comprises aligning the fastener and washer assembly with a hole in the structure using an alignment assembly; and maintaining the aligned position of the fastener and washer assembly until the selected fastener is partially inserted through the hole in the structure and partially installed within the structure.

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