System and fastener insertion gun

Abstract

A system and method for drilling holes and installing fasteners in a vehicle structure. A drill plate having apertures and associated machine-readable elements is positioned on the structure. A drill gun is positioned in the particular aperture and reads hole information from the associated element, and a computer determines whether the drill gun is properly set up to drill the hole. A fastener insertion gun is positioned in the particular aperture and reads fastener information from the element, and a computer determines whether the hole has been drilled and, if so, whether the fastener insertion gun is properly set up to insert the fastener. A fastener delivery subsystem stores, tracks, and delivers fasteners to the fastener insertion gun. A system computer monitors the drilling of each hole, the insertion of each fastener, and the overall operation of the fastener delivery subsystem.

Description

Technical Field

[0001] The present invention relates to a system and method for drilling holes and installing fasteners within a vehicle structure. More particularly, embodiments relate to a system and method for drilling holes within an aircraft fuselage or other aerospace, or vehicle body or structure, transporting, sealing, inserting, or otherwise installing fasteners within the holes.

Background Art

[0002] It is often desirable to install various types of fasteners within an aerospace or other vehicle structure (e.g., an airframe or other body). There are several techniques for accomplishing this task, but all are subject to different disadvantages. On one hand, holes may be drilled manually using simple tools, and fasteners may be installed within the holes manually using simple tools. This provides a simple solution, but increases the risk of defects or other errors with respect to inaccurately drilling the holes or inaccurately installing the fasteners. Further, this solution may require a significant amount of time and expense to train operators. On the other hand, the processes of drilling holes and installing fasteners may be highly automated and performed by sophisticated machines. This solution greatly reduces the risk of defects or other errors, but is also much more complex and expensive to implement and maintain. For example, many manufacturers of aircraft airframes use Flex Track automated machines that may cost over $16 million, or "Monument" machines that may cost over $30 million, to drill and secure airframe assemblies.

[0003] This discussion of background art is not intended to necessarily provide information on the present invention, which is not prior art.

Summary of the Invention

[0004] The embodiments address the limitations and other disadvantages of the prior art described above by providing systems and methods for drilling holes in an aircraft airframe or other aerospace, or in a vehicle structure or fuselage, and for transporting, sealing, inserting, or otherwise installing fasteners within the holes. In particular, the embodiments provide solutions that favorably combine higher quality and lower cost compared to the prior art.

[0005] In one embodiment, a system is provided for drilling a hole in a vehicle structure and installing a fastener in the hole. The system may include a first drilling plate, which may include a plate body, an opening, and a machine-readable element. The plate body may be temporarily attached to a first surface of the vehicle structure. The opening may extend through the plate body to the first surface of the vehicle structure. The machine-readable element may be associated with the opening and may provide information about drilling a hole and installing a fastener in the hole. During operation, the opening may receive a drilling gun to drill a hole in the first surface, and then the opening may receive a fastener insertion gun to install a fastener in the hole.

[0006] In various implementations of the embodiments described above, the system may further include one or more of the following features: The plate body may be constructed from carbon fiber reinforced resin. The machine-readable element may be a radio frequency identification element that communicates information electronically or, instead, a code that can be used to retrieve the information. The information may include hole information relating to how the hole will be drilled, and the hole information may include the size of the drilling bit for drilling the hole. The information may include fastener information relating to the fastener to be installed in the hole and how the fastener will be installed in the hole, and the fastener information may include the type and size of the fastener to be installed in the hole. There may be multiple openings and a single machine-readable element associated with the multiple openings, or instead, there may be multiple openings and multiple machine-readable elements. The system may further include an electronic memory element that records whether the hole has been drilled and whether the fastener has been installed in the hole. The system may further include a second perforating plate that is temporarily attached to a second surface of the vehicle structure and is physically aligned with the first perforating plate.

[0007] In another embodiment, a system is provided for drilling holes within an aircraft body and installing fasteners within those holes. The system may include a drilling plate, a drilling gun, and a fastener insertion gun. The drilling plate may include a plate temporarily attached to a first surface of the aircraft body, an opening extending through the plate to the first surface of the aircraft body, and a machine-readable element associated with the opening and providing fastener information relating to the fasteners to be installed in the holes. The drilling gun may be inserted into the opening and drill a hole with a drilling bit in the first surface, and then removed from the opening. The fastener insertion gun may be inserted into the opening and install fasteners within the holes. The fastener insertion gun may include a fastener insertion gun reader element for reading fastener information.

[0008] In various implementations of the embodiments described above, the system may further include one or more of the following features: Fastener information may include the required fastener type and required fastener size of the fastener to be installed in the hole. The system may further include a computer that compares the required fastener type and required fastener size with the actual fastener type and actual fastener size of the fastener in the fastener insertion gun, and shuts off the fastener insertion gun if the required fastener type and required fastener size do not match the actual fastener type and actual fastener size. Machine-readable elements may further provide hole information regarding how the hole will be drilled, and the hole information may include the required drilling bit size for drilling the hole, and the drilling gun may include a drilling gun reader element that reads the hole information. The computer may compare the required drilling bit size with the actual drilling bit size of the drilling bit installed in the drilling gun, and may shut off the drilling gun if the required drilling bit size does not match the actual drilling bit size. The system may further include an electronic memory element that records whether a hole has been drilled and whether a fastener has been placed inside the hole.

[0009] In another embodiment, a fastener insertion gun is provided for inserting a fastener in a hole within a vehicle structure. The fastener insertion gun may include a gun body, a concentric collet, a reader mechanism, a plurality of internal air valves, and a gun computer. The gun body may include a front portion and a rear portion. The concentric collet may be mounted on the front portion of the gun body to mechanically secure the fastener insertion gun during fastener insertion, and may selectively expand within an opening adjacent to the hole in the vehicle structure. The reader mechanism may be associated with the front portion of the gun body and may receive information associated with the hole in the vehicle structure from a machine-readable element. The plurality of internal air valves may be located within the gun body and may selectively provide pressurized air used for inserting the fastener. The gun computer may be housed within the gun body and may receive information via the reader mechanism, insert the fastener based on the information from the reader mechanism, and actuate one or more of the plurality of internal air valves to provide pressurized air used for inserting the fastener.

[0010] In various implementations of the embodiments described above, the fastener insertion gun may further include one or more of the following features: The machine-readable element may be a radio frequency identification element that communicates a code that can be used to communicate information electronically or, instead, to retrieve information from a database. The information may include fastener information relating to the fastener to be installed in the hole and how the fastener will be installed in the hole, such as the type and size of the fastener. The fastener insertion gun may further include a fastener supply tube connected to the gun body for transporting fasteners from a fastener supply container to the gun body. The fastener insertion gun may further include a fastener feeding window mounted through the gun body, which allows the operator of the fastener insertion gun to view fasteners inside the gun body.

[0011] The fastener insertion gun may further include an impact mechanism for applying an impact force to the end of a fastener, the impact mechanism including an impact tube having a forward port connected to a first internal air valve of a plurality of internal air valves and a rear port connected to a second internal air valve of a plurality of internal air valves; an impact rod moving forward within the impact tube to apply an impact force to the end of a fastener and moving backward to reset; an impact mass moving forward within the impact tube to abut against the impact rod and moving backward to reset; and a gun computer controlling the first and second internal air valves to move the impact rod and impact mass forward and backward by selectively introducing pressurized air into the impact tube through the forward and rear ports.

[0012] The impact mechanism may further include a front and rear first guidance sensor for detecting the location of the impact mass within the impact tube, and a gun computer that receives the location of the impact mass from the front and rear first guidance sensors and controls first and second internal air valves based on the location of the impact mass within the impact tube. The impact mechanism may further include a plurality of front second guidance sensors for detecting the location of the impact mass at the front end of the impact tube, and a gun computer that determines when the fastener is fully seated in the hole based on the location of the impact mass at the front end of the impact tube. The impact mechanism may further include one or more variable pressure regulators for controlling the pressure of pressurized air entering the impact tube through front and rear ports, and a gun computer that controls one or more variable pressure regulators to change the impact force applied to the end of the fastener by the impact rod. The impact mechanism may further include a rod and mass retractor that moves backward to reset the impact rod and impact mass; a bumper located at the front end of the impact tube that absorbs the remaining portion of the impact force of the impact rod; and a bushing located at the front end of the impact tube through which the impact rod moves to reduce wear.

[0013] The fastener insertion gun may further include a sealant dispensing module containing a cartridge containing sealant, the sealant dispensing module selectively applying sealant to the fastener before installation, and the gun computer controls the selective application of sealant. The fastener insertion gun may further include a display mechanism mounted on the gun body that visually communicates operational information from the gun computer to the operator of the fastener insertion gun, and an operator interface mounted on the gun body that facilitates the input of operational information from the operator of the fastener insertion gun to the gun computer.

[0014] This summary is not intended to identify essential features of the invention, nor is it intended to be used to limit the scope of the claims. Those and other aspects of the invention are described in more detail below. [Brief explanation of the drawing]

[0015] Embodiments of the present invention will be described in detail below with reference to the accompanying drawings. [Figure 1] This is a high-level representation of an embodiment of a system for drilling holes within a vehicle structure and installing fasteners within those holes, the system comprising a drilling plate, a drilling gun, a fastener transport subsystem, and a fastener insertion gun. [Figure 2] This is a plan view of the mounting configuration of the perforated plate component of the system shown in Figure 1, positioned on the vehicle structure. [Figure 3] This is an isometric view of the perforated plate shown in Figure 2, positioned within the vehicle structure. [Figure 4] This is an isometric view of the implementation configuration of the system shown in Figure 1, which includes multiple perforated plate components. [Figure 5A] This is a cross-sectional elevation view of the first version of the implementation configuration shown in Figure 4. [Figure 5B] This is a cross-sectional elevation view of the second version of the implementation shown in Figure 4. [Figure 5C] This is a cross-sectional elevation view of the third version of the implementation shown in Figure 4. [Figure 6] Figure 1 is a side elevation view of the drilling gun component of the system. [Figure 7] Figure 1 is a first fragmentary isometric view of the fastener insertion gun component of the system. [Figure 8] Figure 7 is a second fragmentary isometric view of the fastener insertion gun. [Figure 9] Figure 7 is a cross-sectional isometric view of the fastener insertion gun. [Figure 10] Figure 7 is a cross-sectional elevation view of the impactor auxiliary component of a fastener insertion gun, showing the impactor in a retracted position. [Figure 11] Figure 10 is a cross-sectional elevation view of the impactor, showing the impactor in the middle position. [Figure 12] A cross-sectional elevation view of the impactor of FIG. 10, showing the impactor in a forward position. [Figure 13A] A cross-sectional elevation view of the mounting aspect of the impactor of FIG. 11, showing a first inductive sensor for controlling the impact cycle. [Figure 13B] A cross-sectional elevation view of the mounting aspect of the impactor of FIG. 11, showing a second inductive sensor for determining the fastener height. [Figure 14] A cross-sectional perspective view of the fastener insertion gun of FIG. 7, showing the sealing material discharge module components. [Figure 15] A perspective view of the first auxiliary component of the sealing material discharge module of FIG. 14. [Figure 16] An isometric view of the second auxiliary component of the sealing material discharge module of FIG. 14. [Figure 17] A fragmentary cross-sectional side elevation view of the fastener insertion gun component and the fastener supply tube component of the fastener conveyance subsystem of FIG. 1. [Figure 18] A flowchart of the steps involved in the use and operation of the perforated plate. [Figure 19] A flowchart of the steps involved in the use and operation of the fastener discharge subsystem. The drawings are not intended to limit the invention to the specific embodiments they depict. The figures are not necessarily to the same scale.

Best Mode for Carrying Out the Invention

[0016] The following detailed description of embodiments of the invention refers to the accompanying drawings. The embodiments are intended to describe aspects of the invention in sufficient detail to enable one skilled in the art to practice the invention. Other embodiments may be utilized and changes may be made without departing from the scope of the claims. Accordingly, the following description is not limiting. The scope of the invention is defined only by such claims according to the full scope of equivalents to which the appended claims are entitled.

[0017] In this description, any reference to “one embodiment,” “embodiment,” or “embodiment (or multiple embodiments)” means that the feature or feature(s) referred to is included in at least one embodiment of the invention. Separate references to “one embodiment,” “embodiment,” or “embodiment (or multiple embodiments)” in this description do not necessarily refer to the same embodiment and do not exclude each other unless otherwise stated. In particular, features, parts, actions, steps, etc., described in one embodiment may, but not necessarily, be included in other embodiments. Thus, a particular implementation of the invention may include various combinations and / or integrations of the embodiments described herein.

[0018] Broadly speaking, the embodiments provide a system and method for drilling holes in an aircraft fuselage or other aerospace, or in a vehicle body or structure, and for transporting, sealing, inserting, or otherwise installing fasteners within the holes. The embodiments provide a solution that combines higher quality and lower cost favorably with the prior art and can favorably reduce defects associated with improper drilling or fastener installation by 90 percent. This is achieved by a combination of a smart drilling plate, a smart drilling gun, a smart fastener insertion gun, and a comprehensive quality control mechanism that protects the surface of the fuselage or other structure and identifies proper drilling and fastener parameters. Operators no longer need to memorize information such as hole diameter, fastener type, and grip length for hundreds or thousands of locations on the fuselage, thus reducing training time from several months to one week.

[0019] Referring to Figure 1, an embodiment of a system 30 configured to drill holes in an aircraft fuselage or other aerospace, or in a vehicle body or structure 32, and to transport, seal, insert, or otherwise install fasteners within the holes. The system 30 may include one or more drilling plates 34, a drilling gun 36, a fastener transport subsystem 38, a fastener insertion gun 40, and some or all of a system computer 42.

[0020] Referring also to Figures 2 and 3, one or more perforating plates 34 may be temporarily attached to the structure 32 or otherwise physically positioned on the structure 32 and configured to notify and physically guide the operation of the drilling gun 36 when drilling holes within the structure 32 and to notify and physically guide the operation of the fastener insertion gun 40 when installing fasteners in the holes. In one implementation, each perforating plate 34 may include a plate body 46, one or more openings 48 through which holes can be drilled and fasteners can be installed, and one or more machine-readable elements 50 associated with the openings 48.

[0021] The plate 46 may have substantially any suitable shape which is desirable or required to fulfill its function, may be constructed from substantially any suitable material which is such as carbon fiber reinforced polymer or aluminum, and may be constructed using substantially any suitable technique which is such as three-dimensional printing or computer-controlled milling. For at least some applications, three-dimensional printing can allow for reductions in cost, assembly, maintenance, size, and weight. The plate 46 may be physically positionable at a location on the structure 32 to avoid damage to the surface of the structure which may otherwise occur during the drilling and fastener installation process. The plate 46 may be temporarily attached to the structure 32 using substantially any suitable technique which is such as hole positioning / mapping by loosening-resistant bushings and mechanical mechanisms (WedgeLocks®). The plate 46 may have one or more openings 48 extending through the plate 46, through which holes can be drilled in the structure 32 and fasteners can be installed. The openings 48 may have relatively precise tolerances which is desirable or required for a particular application.

[0022] One or more machine-readable elements 50 may be configured to store and communicate information relating to drilling holes and installing fasteners. Such information may include the size of the drilling bit; the drilling speed; the type, size, or grip length of the fastener; the drilling machine feed by laminated material; whether a coolant should be used; hammer time; and whether a sealant should be applied. The machine-readable elements 50 may employ substantially any suitable machine-readable technology. Although described herein as radio frequency identification (RFID) elements, the machine-readable elements may instead be, for example, readable barcodes or quick response (QR) codes.

[0023] The RFID element 50 may be embedded in the surface of the plate 46 in close proximity to the opening 48, or it may be attached to the surface of the plate 46. The actual distance between the RFID element 50 and its corresponding opening 48 may depend on factors such as the strength of the RF signal. In one implementation, each opening may be associated with its own RFID element, and in another implementation, some or all of the openings may be associated with a single RFID element. As will be discussed in more detail below, other elements of the system 30, such as the drilling gun 36 and the fastener insertion gun 40, may include a reader mechanism configured to read information stored in the RFID element 50, and may use that information to ensure that the drilling and installation process is performed without error. In one implementation, the information may be stored in the RFID element 50, and in another implementation, the information may be stored in an electronic memory element 54, and the RFID element 50 may provide an identification code (e.g., a 24-bit alphanumeric identifier) ​​that can be used to electronically access the information from the electronic memory element 54. In one implementation, the RFID element 50 may be further configured to determine, through electronic interaction with the piercing gun 36 and the fastener insertion gun 40, whether a hole has been pierced, whether a fastener has been inserted through each opening 48, and whether the information can be stored in the electronic memory element 54.

[0024] In one implementation, each RFID element 50 may include a transmitter and an integrated antenna, and each reader mechanism 56, 110 may include a receiver and an integrated antenna; in another implementation, both the RFID elements 50 and the reader mechanisms 56, 110 may include transceivers and integrated antennas for bidirectional communication. The transmit power, antenna design, and other aspects of the RFID elements 50 and the reader mechanisms 56, 110 may be optimized for a particular application. In one exemplary application, the transmit power and antenna design of the reader mechanisms 56, 110 may be optimized to read the RFID elements 50 within approximately 12 millimeters of the aperture 48 in either direction. If the apertures 48 are close to each other, a particular RFID element 50 may be readable from several different aperture locations. In one implementation, if the reader mechanism reads more than one RFID element 50 from a particular opening, the system 30 may then determine which opening 48 is most strongly correlated with the group of RFID elements 50 and whether to proceed based on the information from the electronic memory element 54.

[0025] Referring also to Figures 4-5C, in another embodiment, the system 30 may employ two perforating plates 34A, 34B for each hole and fastener. More specifically, the structure 32 may have multiple layers, and the first perforating plate 34A may be positioned on a first surface (e.g., internal) of the multilayer structure 32, and the second perforating plate 34B may be positioned on a second surface (e.g., external) of the multilayer structure 32, so that the first and second plates 34A, 34B are aligned with each other. The first and second plates 34A, 34B may then be fixed together through the structure 32 in such a manner that the multiple layers of the structure 32 are compressed and clamped together to facilitate more precise perforation of holes and insertion of fasteners through the multiple layers, or they may otherwise be temporarily secured in appropriate positions on the structure 32.

[0026] In the relevant embodiments, the system 30 may employ two perforating plates 34A, 34B for each hole and fastener, where the fastener is a rivet. More specifically, the first perforating plate 34A may be positioned on a first surface of a structure 32 (which may have one or more layers), and the second perforating plate 34B may be positioned on a second surface of the structure 32, so that the first and second plates 34A, 34B are aligned with each other. The first and second plates 34A, 34B may then be fixed together through the structure 32, or otherwise temporarily secured in a suitable position on the structure 32.

[0027] Riveting aerospace structures presents specific challenges. The conventional process is entirely manual and requires two technicians, one on each side of the structure. One technician selects and inserts the appropriate rivets and then uses a rivet hammer with the appropriate set to form the rivets. The other technician uses a backing bar to prepare the surface for rivet formation as the hammer moves. This requires the two technicians to be aware of each other's actions and synchronize their actions to avoid exterior quality defects.

[0028] In one embodiment, the perforating plates 34A and 34B described above can be used, providing an improved manual process in which the perforating and countersinking can be performed automatically by a drill that drills holes and sets countersinks within the structure 32. The perforating plates 34A and 34B advantageously protect the outer plate and precisely locate the holes.

[0029] A placement device may be used to facilitate the positioning of the rivet R in the hole while the perforated plate 34B is being installed. In one implementation, the placement device may be a bushing that slides into the opening 48 within the perforated plate 34B. The placement device may have an inner diameter approximately the same size as the rivet R, thereby allowing the rivet R to travel through the perforated plate 34B to the countersinked hole without inversion or rotation. In another implementation, the placement device may have one or more fingers that grip and restrain the rivet R, thereby allowing manual positioning of the rivet R into the hole.

[0030] A rivet set may be used, which is swiveled to a diameter that slides into the opening 48 within the perforated plate 34B and fits with the rivet hammer. The opening within the perforated plate 34B may be directly aligned with the rivet set at the top of the rivet R, so that it is within the structure 32. This favorably restricts the rivet hammer during its impact cycle, thereby improving the exterior quality by reducing defects such as the rivet hammer being off-center, misaligned, or uncontrollable, which can result in exterior panel dents, scratches, or improperly set rivets.

[0031] In one implementation configuration, which may involve only an external perforating plate 34B, a second technician on the opposite side of the structure 32 may use a substantially conventional backing bar in sync with the first technician setting the rivets. In another implementation configuration, as seen in Figure 5A, an internal perforating plate 34A may be used to back each rivet R, which can advantageously reduce or eliminate the need for a second technician. The internal perforating plate 34A may be positioned on the opposite side of the structure 32 from the external perforating plate 34B and may be configured to provide the reaction force required to form the rivets R. The internal perforating plate 34A may perform the function of a backing bar, thereby advantageously enabling a single technician to set the rivets and reducing the number of exterior panel quality defects. Furthermore, the use of an internal perforating plate 34A reduces or eliminates the impact routinely absorbed by a second technician.

[0032] The internal perforation plate 34A may take substantially any suitable form, including a thin metal (e.g., aluminum or steel) plate having pocket-shaped forming regions 202 at the locations where rivets will be placed. At each such location, the inertia of the internal perforation plate 34A provides a reaction force to the impact of the rivet hammer so as to form the rivets R.

[0033] Referring to Figure 5B, in another implementation, the internally perforated plate 34A may take the form of a three-dimensional printed or machined plate having spring-loaded masses across each location where rivets will be placed. The springs 204 and masses 206 may be adjusted to an impact ratio that ensures contact with the rivets R at each impact of the hammer. This can be achieved by assuming a single-degree-of-freedom vibrating system in which the natural frequency of the system is tuned by modifying the springs 204 or masses 206. The springs 204 may be sheet metal that has been cut and folded to provide initial pretension, and the masses 206 may be mounted on a flange of sheet metal and may serve as the forming surface for the rivets R.

[0034] Referring to Figure 5C, in the relevant implementations, each mass 206 may be associated with an actuator 208, rather than being associated with a spring. The mass 206 may also serve as the forming surface of the rivet R, and the actuator 208 may provide the desired or required contact force. In one version, the actuator 208 may be a pneumatic actuator configured to apply a pneumatic spring force along with pressurizing capacity. The air pressure and mass 206 may vary during impact to maintain contact between the mass 206 and the rivet R. In another version, the actuator 208 may be a hydraulic actuator, and the mass 206 and its associated actuator location may be hydraulically coupled. This allows the forming surface to be semi-rigidly force-coupled with the surrounding mass, and the movement of one mass transmits force / motion to the surrounding mass. This can be advantageously reduced in weight and complexity compared to the pneumatic version.

[0035] In another embodiment, a semi-automated or fully automated process is provided in which the perforating plates 34A, 34B described above can be used. In a broad sense, the process is accompanied by a handheld rivet insertion gun (such as a fastener insertion gun 40, described below) which a technician can lock inside the perforating plate 34B and, with the press of a single button, (1) be able to identify the hole and the desired or required type of rivet, (2) be able to request the rivet from a fastener supply system (such as a fastener transport subsystem 38, described below), (3) be able to receive and insert the rivet and place it in the hole, and (4) be able to form the rivet through multiple impacts.

[0036] In one implementation, the rivet insertion gun 40 may be configured to mimic the impact cycle of a rivet set for use with aluminum and titanium rivets. Some or all of the operation of the rivet insertion gun 40 may be electronically controlled to adapt to one or more of the following backing techniques. In one implementation, the rivet insertion gun 40 may be secured within the drilling plate 34B using a concentric collet 112. This allows for greater control of the force applied directly to the rivet R, which facilitates the repeatable formation of the rivet R through the number of impacts or the duration of periodic impacts, based on the rivet diameter and grip length.

[0037] A modified backing bar may be integrated into the control system (both of which are described below, such as the system computer 42 or the fastener insertion gun computer 98) to provide a signal when in contact with the rivet R. This signal may be used with the rivet insertion gun 40 to provide synchronized feedback indicating when to begin the impact process. Alternatively, the internal drilling plate 34A may function as an internal backing plate that allows the rivet R to form in either hole. In another implementation, an electronically activated impact module 118 (described below), 206 / 208 (described above) on both sides of the rivet R may be adjusted to impact the rivet R simultaneously. The drilling plates 34A, 34B and the rivet insertion gun 40 may identify the hole and request the desired or required rivet R. The internal drilling plate 34A may be configured similarly to the external drilling plate 34B described above, having a lockable bushing. Because the impact module 118 of the rivet insertion gun 40 is fully programmable via an electronic valve, the impact modules 118, 206 / 208 on each side of the rivet R may be synchronized or collide simultaneously or at a programmed offset. Since the force acts on the rivet from the opposite side rather than within the structure itself, this results in increased control and improved quality when forming the rivet R.

[0038] During operation, the internal and external drilling plates 34A, 34B, and the first and second technicians, respectively, may be positioned on the opposite side of the structure 32. The rivet insertion gun 40 may be positioned on the external drilling plate 34B and may read the RFID elements 50 associated with each hole, request the desired or required rivet R, and place the rivet R in the hole. The second standalone impact module 206 / 208 may be positioned on the internal drilling plate 34A and may be electronically synchronized with the rivet insertion gun 40. Impact parameters for a particular rivet may be loaded into both the gun computer 98 of the rivet insertion gun 40 and the module computer 210 of the second impact module 210. The computers 98 and 210 may be synchronized with each other and may initiate impact cycles synchronized with each other to collide with the rivet R simultaneously or at a programmed offset to form the rivet R.

[0039] Referring also to Figure 6, the drilling gun 36 may be configured to cooperate with the drilling plate 34 to drill a hole in the structure 32 to receive a fastener. In one embodiment, the drilling gun 36 may be substantially conventional in design and operation, except as otherwise described herein.

[0040] In one embodiment, the drilling gun 36 may include a drilling gun reader mechanism 56, a drilling gun display 58, and a drilling gun computer 60. The drilling gun reader mechanism 56 may be configured to read hole information stored in an RFID element 50 associated with a hole in an opening 48 in a drilling plate 34, and to determine the size, depth, and other relevant characteristics of the hole to be drilled based on the hole information. The drilling gun display device 58 may be configured to display the hole information or other relevant information for consideration by the operator of the drilling gun 36. In one implementation, the drilling gun computer 60 may be configured to compare the hole information with the setup of the drilling gun 36 (e.g., installed drilling bits 60, set drilling depth) and to automatically stop or otherwise shut down the drilling gun 36 if the hole information does not accurately reflect the setup of the drilling gun 36, thereby avoiding errors when drilling holes. In another implementation, this function may be performed by a system computer 42 in association with the drilling gun 36.

[0041] Referring again to Figure 1, the fastener transport subsystem 38 may be configured to store, track, and transport fasteners to the fastener insertion gun 40. In one implementation, the fastener transport subsystem 38 may be configured to manage and supply fasteners of multiple diameters and grip lengths to the fastener insertion gun 40, as desired or required. In one implementation, the fastener transport subsystem 38 may be configured to transport fasteners to multiple installation locations (i.e., to multiple fastener insertion guns 40). In one implementation, the fastener transport subsystem 38 coupled to the fastener insertion gun 40 may be configured to transport and wet-install approximately 5,000 hi-lok fasteners per hour. To satisfy this throughput rate, there may be 18 fastener insertion guns 40 connected to the fastener transport subsystem 38. Each fastener insertion gun 40 attached to the fastener transport subsystem 38 may have the capability to call, receive, and install fasteners within 6 seconds.

[0042] Embodiments of the fastener transport subsystem 38 may include a cabinet 64, a rack 66, one or more fastener cassettes 68, a pneumatic cassette union 70 and locking mechanism 72, a rail 74, an integrator 76, a diverter 78, a booster 80, a display device 82, and a fastener transport subsystem computer 84. In one implementation embodiment, the fastener subsystem may further include one or more sensors 86 located within or throughout the fastener transport subsystem 38 to monitor the position of fasteners as they travel from the fastener cassettes 68 to the fastener insertion gun 40.

[0043] The cabinet 64 may be configured to house one or more (e.g., approximately two to four or three) racks 66, each rack 66 having the capacity to hold one or more (e.g., approximately 15 to 20 or 18) cassettes or other fastener supply containers 68. The cassettes 68 may be existing commercially available cassettes or modified or custom-designed technologies. In one implementation, each cassette may include an RFID or other machine-readable element configured to store and communicate cassette information relating to the fastener cassette and its contents. In one implementation, the cabinet 64 may house all of the other components, or connect to all of the other components, and may control the fastener transport subsystem 38.

[0044] When a cassette 68 is mounted in a rack 66, it may engage with a pneumatic cassette union 70. The pneumatic cassette union 70 may be configured to supply pressurized air to the cassette 68. A locking mechanism 72, which may include a latch component, may be integrated into the pneumatic cassette union 70 to engage with the cassette 68 and prevent it from being removed without the operator requesting its release from the fastener transport subsystem computer 84. This feature facilitates the fastener transport subsystem computer 84 in accurately tracking the quantity and type of fastener cassettes mounted in the cabinet 64. Proximity sensors 90 may be integrated into each cassette location to verify whether a cassette 68 is mounted or not in that location.

[0045] The rail 74 may include a reader mechanism 92 configured to read cassette information from an RFID or other machine-readable element on the cassette 68 and report the cassette information to a fastener transport subsystem computer 84, which may store, track, and report the cassette information. The rail 74 may be further configured to cooperate with a locking mechanism 72 when locking and unlocking the cassette 68. In one implementation, a pneumatic cylinder may be incorporated into the rail 74 and may extend to release the locking mechanism 72, or may otherwise act. When the locking mechanism 72 is released, an ejector mechanism (e.g., one or more additional pneumatic cylinders) may extend to release the cassette 68 from the pneumatic cassette union 70, or may otherwise act. This feature allows the operator to visually identify which cassette has been released and also makes it easier to remove the released fastener cassette from the rack 66.

[0046] The integrator 76 may be configured to receive fasteners from the outputs of each cassette 68, integrate all the outputs of the cassette 68 into a common flow, and transport it to the diverter 78. The diverter 78 may be configured to receive the flow of fasteners from the integrator 76 and direct the individual fasteners to one or more outputs, each output leading to one of the fastener insertion guns 40. The diverter 78 may be directly driven by a servo motor. A ring sensor may be used to verify that a fastener has passed through an output. A signal from the ring sensor may activate a booster 80, which may be configured to pneumatically accelerate the fastener to a minimum speed (e.g., approximately 40-80 feet per second, or approximately 58 feet per second). A signal from the ring sensor may also instruct the diverter 78 to process the next fastener in the flow. The booster 80 may be turned off when a fastener is detected in the fastener insertion gun 40.

[0047] The output of the diverter 78 may be directly attached to the fastener insertion gun 40 through the fastener supply tube 94. The tube length may be substantially any desired or required length (e.g., 1000 feet or more in some cases), and thus the fastener speed may be a factor in achieving a desired fastener installation time (e.g., approximately 3 to 9 seconds or 6 seconds).

[0048] Any surface of the diverter 78 that experiences a relatively higher degree of wear may be designed to be immediately and easily replaceable.

[0049] The display device 82 may be configured to display cassette and fastener information for consideration by the operator of the system 30. In one implementation, the fastener transport subsystem computer 84 may be configured to monitor fastener availability and fastener movement through the fastener transport subsystem 38 and to automatically stop or otherwise interrupt fastener transport if the required fastener is not available or if there is a problem with fastener movement. In another implementation, this function may be performed by the system computer 42. If a stop or other interruption occurs, the reason for the stop or other interruption may be communicated via the display device 82 to facilitate remediation of the problem.

[0050] Referring also to Figures 7-16, the fastener insertion gun 40 may be configured to receive fasteners from the diverter 78 via a fastener supply tube 94 and to insert each fastener through one of the openings 48 in the perforation plate 34 and into corresponding holes previously perforated in the structure 32. Embodiments of the fastener insertion gun 40 may include a gun body 96; a fastener insertion gun computer 98, a display device 100, an operator interface 102; a fastener feeding window 104; one or more electronic air valves 106; an internal air transport subsystem 108; a leader mechanism 110; a concentric collet 112; a concentric collet and cycle start button 114; an impact mechanism 108; and a sealant discharge module 120.

[0051] The gun body 96 may be configured to house or otherwise physically support other components of the fastener insertion gun 40. The gun body 96 may have substantially any suitable shape which is desirable or required to fulfill its function, may be constructed from substantially any suitable material which is such as carbon fiber reinforced polymer or aluminum, and may be constructed using substantially any suitable technique which is such as three-dimensional printing or computer-controlled milling technology. For at least some applications, three-dimensional printing can allow for reductions in cost, assembly, maintenance, size, and weight. The gun body 96 may include internal porting for the pneumatic lines of the internal air conveying subsystem 108.

[0052] The reader mechanism 110 may be configured to read or otherwise receive information from the RFID or other machine-readable element 50 of the perforated plate 34, or to exchange information with the RFID or other machine-readable element 50. In one implementation where the machine-readable element 50 is an RFID element, the reader mechanism 110 may be an RFID reader mechanism. The information may be provided to a faster gun computer 98.

[0053] The fastener insertion gun computer 98 may be configured to control some or all aspects of the operation of the fastener insertion gun 40, such as detecting and reading information from machine-readable elements 50 on the perforation plate 34, activating internal air valves, feeding fasteners, hammering, applying sealant, and other operations. The fastener insertion gun computer 98 may also be configured to engage in wireless communication with other systems, machinery, or databases to receive or transmit relevant information. The display device 100 may be configured to visually communicate operational information relevant to the operator of the fastener insertion gun 40.

[0054] In one implementation, the fastener insertion gun computer 98 may be configured to compare fastener information with the setup of the fastener insertion gun 40 and, if the fastener information is not accurately reflected in the setup of the fastener insertion gun 40, to automatically stop or otherwise shut off the fastener insertion gun 40, thereby avoiding errors when selecting and inserting fasteners in a hole. In another implementation, this function may be performed by the system computer 42.

[0055] The display device 100 may employ substantially any suitable display technology, for example, a conventional 2-point 2-inch display. The operator interface 102 may be configured to allow an operator to provide input to the fastener insertion gun computer 98. The operator interface 102 may employ substantially any suitable interface technology (e.g., a keypad). In one implementation, the display device 100 may include touch-sensitive interface technology to satisfy the functions of the operator interface 102.

[0056] The fastener feeding window 104 may be configured to facilitate visual observation of the movement of fasteners through the fastener insertion gun 40. In one implementation, the fastener feeding window 104 may include a transparent material through which the operator can directly visually observe the movement of each fastener.

[0057] The electronic air valve 106 may be configured to selectively open to deliver pressurized air to the fastener insertion gun 40 and selectively close to block air, as desired or required to perform the operation. The internal air transport subsystem 108 may be configured to disperse the pressurized air from the air valve 106 within the fastener insertion gun 40 for use by other components (e.g., the impact mechanism 118).

[0058] The concentric collet 112 may be inserted into the opening 48 within the perforating plate 34 and then actuated to expand within the opening 48, mechanically securing the fastener insertion gun 40 in the correct position during the actual insertion of the fastener. Once the fastener is inserted, the concentric collet 112 may actuated to contract, allowing the fastener insertion gun 40 to be retracted from the opening 48. In one implementation, the concentric collet 112 may be conventional overall in design and operation. The concentric collet and the cycle start button 114 may be actuated by the operator of the fastener insertion gun 40, respectively, to actuate the concentric collet 112 and initiate the process of inserting the fastener into the hole.

[0059] Referring particularly to Figures 9-13B, the impact mechanism 118 may be configured to apply an impact force to the end of a fastener in order to drive the fastener into a hole in the structure 32. In one implementation, the impact mechanism 118 may include an impact tube 124; an impact rod 126; a mass 128 associated with the rear end of the impact rod 126; a rod tip 130 and bushing 132 associated with the front end of the impact rod 126; and a rod and mass retractor 134 configured to reset the impact rod 126 after operation. In one implementation, the impact mechanism 118 may be configured to mount a fastener having a relatively long grip length and to be able to retract completely to allow a subsequent fastener to move into position. The impact rod 126 and impact mass 128 may move forward and backward along the longitudinal axis within the impact tube 124. A rubber bumper 136 may be provided at the front end of the impact tube 124 to absorb any remaining impact force of the impact rod 126. To reduce wear caused by repeated movement of the impact rod 126, a bushing 132 may be provided at the front end of the impact tube 124 through which the impact rod 126 moves. One or more ports 138 may be provided in the wall of the impact tube 124 to allow pressurized air to be introduced to drive the impact rod 126 and impact mass 128 forward and backward, thereby acting and resetting them.

[0060] The impact rod 126 and impact mass 128 act in series but may be separate components that reset together. In one implementation, once the fastener is positioned for insertion, pressurized air may be introduced into the port within the wall of the impact tube 124 to move the impact rod 126 forward while the impact mass 128 remains at the rear (as seen in Figure 11). The force applied by the impact rod 126 alone may loosely set the fastener in the hole. When the fastener insertion gun 40 is activated, air may be discharged from the front port 138A or introduced into the rear port 138B to drive the impact mass 128 into the rear end of the impact rod 126 (as seen in Figure 12), and this force may be transmitted to the fastener via the impact rod 126 to firmly set the fastener in the hole. Pressurized air may then be introduced into the impact tube 124 via the forward port 138A to drive the retractor 134 back to its rear position, and the retractor 134 may also serve to return the impact rod 126 and impact mass 128 to their rear positions.

[0061] In one embodiment, the hammering action of the impact mechanism 118 may be entirely electrically controlled. The computer 98 may circulate the air valves 106 in a precise sequence to accelerate the impact mass 128 to the front or rear surface of the impact tube 124. Their circulation may be controlled to collide with the fastener a specific number of times that is desirable or required to set the fastener for a particular grip length. The open-loop implementation of the impact mechanism 118 may open and hold the corresponding air valves 106 for a predetermined period (e.g., measured in milliseconds) that is sufficient for the overall cruising of the impact mass 128. After the predetermined period has expired, the computer 98 may circulate the air valves 106 to reverse the direction of the impact mass 128, and may open and hold those corresponding air valves 106 for a predetermined period. The computer 98 may repeat this procedure for a certain number of hits based on a particular grip length of the fastener to be set.

[0062] Referring also to Figure 13A, the closed-loop implementation of the impact mechanism 118 may use inductive sensing to detect the location of the impact mass 128 within the impact tube 124. The electrical operation of the impact mass 128 may function substantially the same as or identical to that of the open-loop implementation, except that there is no need for fixed timing for the air valve 106. One or more first inductive sensors 140 may be provided inside or on the impact tube 124 to detect whether the impact mass 128 has reached the front or rear surface of the tube 124. Based on the data from the first sensors 140, the computer 98 may arrange the air valve 106 during the impact cycle based on the detected position of the impact mass 124. The operation of the first sensors 140 may be optimized by positioning them slightly ahead of the front or rear surface of the impact tube 124 to compensate for the mechanical lag in the opening of the air valve 106. The closed-loop implementation can offer several advantages, including transmitting less impact force to the perforated plate 34 and structure 32, providing an increased number of impact cycles per second, and providing an extended lifespan by compensating for wear in the impact mechanism 118.

[0063] Referring also to Figure 13B, in one embodiment, a plurality of second inductive sensors 142 may be incorporated within the forward section of the impact tube 124 to locate the impact mass 128. Each second sensor 142 may establish an electromagnetic field that provides a set inductance, which may be measured (e.g., by a Texas Instruments LDC1614 integrated circuit) and communicated to a computer 98. As the impact mass 128 enters the electromagnetic field of each second sensor 142, the inductance changes. This provides a variable inductance that is closely related to the position of the impact mass 128 relative to the second sensor 142. The plurality of second sensors 142 may be positioned in series within a bank of two to four sensors to cover the entire range of movement of the impact mass 128 while it is hammering the fastener. The ability to detect where the impact mass 128 is located on the front of the impact tube 124 allows for determining when the fastener will be fully installed in the hole, based on the stacking of the impact mass 128 and the impact rod 126. This may be calibrated by extending the mass 128 and rod 126 onto a plane simulating the installed fastener, and then measuring an inductance value from a second sensor 142 that is unique to the location of the impact mass 128.

[0064] The impact force for each cycle may be controlled by one of several methods. The kinetic energy stored in the impact mass 128 at the moment of impact is transferred through the impact rod 126, which acts directly on the fastener. Assuming a velocity of 0 at the point of impact, the impact energy is given by the kinetic energy equation: 0.5 × mass × velocity 2This is equivalent to the kinetic energy described by the equation: force × distance = workpiece. The kinetic energy conserved in impact mass 128 is equivalent to that of the workpiece applied to mass 128 as described by the equation: force × distance = workpiece. Therefore, the force applied to impact mass 128 or the distance traveled by impact mass 128 may be modified to reduce the impact energy exerted on the fastener.

[0065] In a first implementation, variable pressure restriction may be used to reduce the force acting on the mass 128. This can be achieved by either a manually or electronically controlled regulator supplying air valve 106. In a second implementation, a variable restrictor may be positioned before air valve 106 to reduce the filling rate of the impact tube 126. This may function similarly to the first implementation, except that it provides an initial high-pressure pulse before the air capacity is exhausted between the restrictor and air valve 106. In a third implementation, air valve 106 at the front end of the impact tube 126 may be restricted. During operation, the front end of the impact tube 126 may be open to avoid increasing the pressure at the rear end that drives the impact mass 128 forward and reduces the resultant force acting on the impact mass 128. This opening may be intentionally varied, either manually or electrically, by restricting the exhaust flow to reduce the impact energy. In the fourth embodiment, one or more air valves may be controlled to cut off the supply air earlier in the impact action to reduce the overall force applied to the impact mass 128. The effect of applying the entire force to only a portion of the length of the impact tube 124 is equivalent to shortening the tube 124.

[0066] Referring particularly to Figures 14-16, the sealant dispensing module 120 may be configured to dispense sealant as necessary to seal the fastener within the hole. In one implementation, the sealant dispensing module 120 may receive a removable cartridge containing the sealant to be dispensed. The sealant cartridge may be disposable, refillable, or recyclable. A plunger 146 may be actuated to move the sealant from the cartridge to an applicator outlet mechanism 148, which applies the sealant to the fastener before insertion. The plunger 146 may be driven along one or more guide rods 150 by an electric stepping motor 152.

[0067] In one implementation, the sealant dispensing module 120 may use a standard (e.g., 5 cubic centimeters) cartridge. An electronically controlled stepping motor 152, via a high-pitch screw 154 attached to a plunger 146, may be used to pump out a specific amount of sealant. This positive displacement design allows for precise dispensing of the sealant material. A standard 6 mm tube may extend between the 5 cubic centimeter cartridge and the applicator outlet mechanism 148. The outlet mechanism 148 may be actuated by an electric motor 156 to an "up" position of approximately 15 mm where it can "capture" a fastener, or it may be actuated to a "down" position through which the fastener and impact rod 126 pass. The sealant is injected through the outlet mechanism 148, and as a result, the sealant is applied to the captured fastener during operation. Multiple (e.g., three) ports may be exposed to apply sealant at multiple (e.g., three) locations across the fastener. One or more (e.g., two) locations may apply sealant along the side of the fastener, and one or more (e.g., one) locations may apply sealant to the bottom of the fastener, thereby creating the required seal. The outlet mechanism 148 may be a consumable item that is replaced as the sealant loses its effectiveness. The operation of the outlet mechanism 148 may be achieved electrically or pneumatically and may be controlled by the gun computer 98. The impact rod 126 in a low-pressure state can provide the capture required to fully seat the fastener within the outlet mechanism 148.

[0068] The system computer 42 may include a quality control system (QMS) 150 configured to collect information from one or more components of the system (e.g., a perforating plate 34, a perforating gun 36, a fastener transport subsystem 38, a fastener insertion gun 40), and, if desired or necessary, to collect information from external sources, and to display or otherwise communicate quality control information, including errors. In one implementation, the QMS 150 may be configured to perform a variety of relevant and useful functions, such as automatically preventing fasteners from being placed in unperforated holes, preventing failures in placing fasteners in perforated holes, avoiding inaccurate perforation or insertion sequences, avoiding the use of ineffective or inaccurate sealants, avoiding the use of inaccurate perforating plates for specific applications, and assisting in identifying and addressing problems caused by the movement of fasteners through the system. In connection with this, the QMS 150 may be configured to track the progress of each job, such as which holes have been perforated and which fasteners have been installed. QMS150 may be further configured to generate a report detailing perforated or undone holes, and installed or uninstalled fasteners.

[0069] As discussed, in one implementation, the system computer 42 may be configured to compare the required hole and fastener information with the setup of other components of the system, and to automatically stop or otherwise shut off the drilling gun 36 or fastener insertion gun 40 if the required hole and fastener information does not accurately reflect the setup (e.g., installed drilling bits or available fasteners), thereby preventing the drilling of incorrect holes and the insertion of incorrect fasteners.

[0070] Referring to Figure 17, the fastener capture mechanism 214 may be along each fastener supply path and may include a capture device 216, a first capture port 218, and a second capture port 220. The capture device 216 may be spliced ​​into the fastener supply tube 94 and may include one or more inductive sensing coils 222 configured to detect the presence of a fastener in the supply tube 94, and one or more openings 224 configured to release air pressure to slow the fastener before it enters the fastener insertion gun 40. The first capture port 218 may provide pressurized air to further slow and capture the fastener in the fastener insertion gun 40, and the second capture port 220 may provide pressurized air to create a venturi effect to guide the fastener to its final position 226 in the fastener insertion gun 40 for placement.

[0071] Referring also to Figure 18, a perforating plate 34 may be used and may be operated substantially as follows: As shown in step 300, one or more perforating plates 34 showing the opening 48 may be located in the aircraft body or other aerospace, or in a specific location on the vehicle body or structure 32.

[0072] As shown in step 302, the drilling bit may be mounted in the drilling gun 36, which may transmit relevant drilling gun setup information (e.g., type, diameter, length, material) and other relevant operating parameters regarding the drilling bit to the drilling gun computer 60 or system computer 42. As shown in 304, the drilling gun 36 may be brought within physical proximity to one particular opening 48 through which a hole can be drilled in the structure 32, and a reader mechanism 56 on the drilling gun 36 may read relevant hole information from an RFID or other machine-readable element 50 associated with the particular opening 48. As shown in 306, the drilling gun computer 60 or system computer 42 may compare the drilling gun setup information with the hole information to determine whether the setup is accurate or inaccurate for the hole. If the setup is inaccurate for the hole, the drilling gun computer 60 or system computer 42 may then notify the operator via the display device 58 on the drilling gun 36, as shown in 308, and prevent the drilling gun 36 from being operated until the setup is corrected. If the setup is accurate for the hole, the drilling gun computer 60 or system computer 42 may then allow the operator to drill the hole, as shown in 310, and record in the electronic memory element 54 that the hole has been drilled.

[0073] As shown in 312, the fastener insertion gun 40 may be brought into physical proximity to a particular one of the openings 48 through which a fastener can be placed in a previously drilled hole, and a reader mechanism 110 on the fastener insertion gun 40 may read the relevant hole information from an RFID or other machine-readable element 50 associated with the particular opening 48. As shown in 314, the fastener insertion gun computer 98 or system computer 42 may compare the fastener insertion gun setup information with the hole information to determine whether the hole was actually drilled through the particular opening, and if so, whether the fastener insertion gun setup is inaccurate or accurate with respect to the hole. If the hole was not actually drilled, or if the fastener insertion gun setup is inaccurate with respect to the hole, the fastener insertion gun computer 98 or system computer 42 may then notify the operator via a display device 100 on the fastener insertion gun 42, as shown in 316, and prevent the fastener insertion gun 42 from being operated until the fastener insertion gun setup is corrected. If the hole has actually been drilled and the setup is accurate for the hole, the fastener insertion gun computer 98 or system computer 42 may then allow the operator to insert the fastener into the hole, as shown in 318, and may record in the electronic memory element 54 that the fastener has been inserted.

[0074] Referring also to Figure 19, a fastener transport subsystem 38 may be used and may be operated substantially as follows: As shown in 400, one or more cassettes 68 of fasteners may be mounted in a rack 66 within a cabinet 64. As each cassette 68 is mounted in the rack 66, the cassette 68 may engage with pneumatic union and locking mechanisms 70, 72, as shown in 402. As shown in 404, a proximity sensor 90 integrated into the cassette location may confirm that a cassette 68 has been mounted. When a cassette 68 is detected by the proximity sensor 90, a reader mechanism 92 on the rail 74 may read and store relevant information from a machine-readable element associated with the cassette 68, as shown in 406. Once all cassettes 68 have been mounted, the fastener transport subsystem 38 may be initialized, as shown in 408, and then await requests for fasteners from the fastener insertion gun 40.

[0075] As shown in 410, when a fastener request is received from the fastener insertion gun 40, the fastener transport subsystem 38 may select a suitable fastener from one of the cassettes 68 in the rack 66 and route it to the fastener insertion gun 40 through subsystem 38. When multiple cassettes are loaded with fasteners of the same type, the fastener subsystem computer 98 may strategically pull fasteners from the same cassette 68 to completely exhaust one before switching to another cassette 68. When two or more fasteners of the same type and grip length are requested simultaneously, the fastener transport subsystem computer 98 may pull them first from the primary cassette and then from the secondary cassette. The fastener transport subsystem 38 may include parallel fastener transport paths to multiple fastener insertion guns 40 to increase the throughput and redundancy of primary components required to complete the process.

[0076] As shown in 412, when the fastener cassette 68 is depleted (or if an error occurs), the operator may use the operator interface 102 with the fastener transport subsystem computer 98 to select the cassette 68 and release the cassette 68 from the rack 66. As shown in 414, a sensor 86 located within the fastener transport subsystem 38 may monitor the position of the fastener as it travels from the cassette 68 to the fastener insertion gun 40. As shown in 416, if any problem occurs during the fastener transition, the operator may be visually notified via the display device 100 on the fastener insertion gun 40 as well as on the display device 82 on the cabinet 64.

[0077] Therefore, having described one or more embodiments of the invention, any that are novel and required to be claimed will be protected by a patent document including the following: [Other adjacent items] (Item 1) A system for drilling holes in the vehicle structure and installing fasteners in the holes, wherein the system is A plate temporarily attached to the first surface of the above vehicle structure, An opening extending through the plate body to the first surface of the above vehicle structure, A first perforating plate comprising a machine-readable element associated with the above-mentioned opening and providing information relating to drilling the above-mentioned hole and installing the above-mentioned fastener within the above-mentioned hole, During the operation, the opening receives a drilling gun that drills the hole in the first plane, and then the opening receives a fastener insertion gun that installs the fastener in the hole. system. (Item 2) The system described in Item 1, wherein the plate is constructed from carbon fiber reinforced resin. (Item 3) The system described in Item 1, wherein the machine-readable element is a radio frequency identification element that electronically communicates the above information. (Item 4) The system described in Item 1, wherein the machine-readable element is a radio frequency identification element that electronically communicates the code used to obtain the above information. (Item 5) The system described in Item 1, including hole information regarding how the above-mentioned holes will be drilled. (Item 6) The hole information described above includes the size of the drilling bit for drilling the hole, as described in Item 5. (Item 7) The system described in Item 1, including the fastener to be installed in the hole and fastener information relating to how the fastener will be installed in the hole. (Item 8) The fastener information described above includes the type and size of the fastener to be installed in the hole, as described in Item 7. (Item 9) The system described in Item 1, wherein there are multiple openings and a single machine-readable element associated with the multiple openings. (Item 10) The system according to Item 1, wherein there are multiple openings and multiple machine-readable elements, and different machine-readable elements of the multiple machine-readable elements are associated with each of the multiple openings. (Item 11) The system according to Item 1, further comprising an electronic memory element for recording whether the above-mentioned hole has been drilled and whether the above-mentioned fastener has been installed in the above-mentioned hole. (Item 12) The system according to Item 1, further comprising a second perforating plate temporarily attached to a second surface of the vehicle structure and physically aligned with the first perforating plate. (Item 13) A system for drilling holes inside an aircraft and installing fasteners within those holes, wherein the system is It is a perforated plate, A plate temporarily attached to the first surface of the aircraft body, An opening extending through the plate body is provided on the first surface of the aircraft body, A machine-readable element that provides fastener information relating to the required fasteners to be installed in the opening described above, The perforating plate includes, A drilling gun is inserted into the opening and drills the hole in the first plane with a drilling bit, and then removed from the opening. A fastener insertion gun is inserted into the opening and sets the fastener within the hole, the fastener insertion gun includes a fastener insertion gun reader element that reads the fastener information, A system that includes these features. (Item 14) The fastener information described above includes the required fastener type and required fastener size of the required fastener to be installed in the hole, as described in Item 13. (Item 15) The system as described in Item 14, further comprising a computer that compares the required fastener type and required fastener size with the actual fastener type and actual fastener size of the fastener in the fastener insertion gun, and shuts off the fastener insertion gun if the required fastener type and required fastener size do not match the actual fastener type and actual fastener size. (Item 16) The system as described in Item 13, wherein the machine-readable element further provides hole information relating to how the hole is drilled, the hole information includes the required drill bit size for drilling the hole, and the drilling gun further includes a drilling gun reader element for reading the hole information. (Item 17) The system according to Item 16, further comprising a computer that compares the required drilling bit size with the actual drilling bit size of the drilling bit installed in the drilling gun, and shuts off the drilling gun if the required drilling bit size does not match the actual drilling bit size. (Item 18) The system according to Item 13, further comprising an electronic memory element for recording whether the hole has been drilled and whether the fastener has been installed in the hole. (Item 19) A system for drilling multiple holes in the body of an aircraft and installing fasteners in each of the multiple holes, wherein the system is A plurality of first perforating plates, each of which first perforating plates is A plate temporarily attached to the first surface of the aircraft fuselage, Multiple openings extending through the plate body are provided on the first surface of the aircraft fuselage, One or more machine-readable elements that provide fastener information relating to the required fasteners to be installed in each of the above multiple openings, The above-mentioned plurality of first perforating plates, Inserted into each opening, the drilling bit drills the hole in the first plane, and then the drilling gun is removed from the opening. A fastener insertion gun, which is inserted into each opening and installs a specific fastener in each hole, wherein the fastener insertion gun includes a fastener insertion gun reader element that reads the fastener information, the fastener information includes the required fastener type and required fastener size of the required fastener to be installed in the hole, A computer compares the required fastener type and size with the actual fastener type and size of the fastener in the fastener insertion gun, and if the required fastener type and size do not match the actual fastener type and size, the computer shuts off the fastener insertion gun. An electronic memory element that records whether each hole has been drilled and whether the specific fastener mentioned above has been installed in each hole, A system that includes these features. (Item 20) The system according to Item 19, further comprising a plurality of second perforating plates, each second perforating plate being temporarily attached to a second surface of the aircraft body and aligned with a particular first perforating plate of the plurality of first perforating plates. (Item 21) A fastener insertion gun for installing fasteners in holes within the vehicle structure, wherein the fastener insertion gun is A gun body including the front and rear sections, During the installation of the fastener, a concentric collet is mounted on the front portion of the gun body and selectively expands within an opening adjacent to the hole in the vehicle structure, in order to mechanically secure the fastener insertion gun. A reader mechanism associated with the front portion of the gun body and receiving information associated with the hole in the vehicle structure via a machine-readable element, Multiple internal air valves located within the above-mentioned cancerous tissue and selectively supplying pressurized air used to install the above-mentioned fastener, A gun computer housed within the above-mentioned cancer body, which receives information from the above-mentioned reader mechanism, attaches the fastener based on the above-mentioned information from the above-mentioned reader mechanism, and operates one or more of the above-mentioned internal air valves to provide the above-mentioned pressurized air used to install the fastener, A fastener insertion gun equipped with a fastener. (Item 22) The fastener insertion gun as described in Item 21, wherein the machine-readable element is a radio frequency identification element that electronically communicates the above information. (Item 23) The fastener insertion gun described in Item 21, wherein the machine-readable element is a radio frequency identification element that electronically communicates a code used to retrieve the above information from a database. (Item 24) The fastener insertion gun described in Item 21, which includes fastener information relating to the fastener to be installed in the hole and how the fastener will be installed in the hole. (Item 25) The fastener information described above includes the type and size of the fastener to be installed in the hole, as described in Item 24 of the fastener insertion gun. (Item 26) The fastener insertion gun according to Item 21, further comprising a fastener supply tube connected to the gun body for transporting fasteners from a fastener supply container to the gun body. (Item 27) The fastener insertion gun according to Item 21, further comprising a fastener feeding window mounted through the gun body, which allows the operator of the fastener insertion gun to view the fastener inside the gun body. (Item 28) The fastener is further provided with an impact mechanism for applying an impact force to the end of the fastener, and the impact mechanism is An impact tube including a front port connected to the first internal air valve of the plurality of internal air valves and a rear port connected to the second internal air valve of the plurality of internal air valves, An impact rod moves forward within the impact tube to apply the impact force to the end of the fastener and moves backward to reset it, An impact mass moves forward within the impact tube so as to strike the impact rod, and then moves backward to reset, The gun computer controls the first and second internal air valves to move the impact rod and impact mass forward and backward by selectively introducing the pressurized air into the impact tube through the forward and rear ports described above, A fastener insertion gun, including the one described in item 21. (Item 29) The fastener insertion gun according to Item 28, further comprising: first forward and rear guidance sensors for detecting the location of the impact mass within the impact tube; and a gun computer that receives the location of the impact mass from the first forward and rear guidance sensors and controls the first and second internal air valves based on the location of the impact mass within the impact tube. (Item 30) The fastener insertion gun according to Item 28, further comprising: a plurality of forward second guidance sensors for detecting the location of the impact mass at the forward end of the impact tube; and a gun computer that determines when the fastener is fully seated in the hole based on the location of the impact mass at the forward end of the impact tube. (Item 31) The fastener insertion gun according to Item 28, further comprising: one or more variable pressure regulators that control the pressure of the pressurized air entering the impact tube through the front and rear ports; and a gun computer that controls the one or more variable pressure regulators to change the impact force applied to the end of the fastener by the impact rod. (Item 32) The above impact mechanism is, A rod and mass retractor that moves backward to reset the impact rod and the impact mass, A bumper located at the front end of the impact tube absorbs the remaining portion of the impact force of the impact rod, A bushing located at the front end of the impact tube, through which the impact rod moves to reduce wear, The fastener insertion gun described in item 28, further including the following. (Item 33) The fastener insertion gun according to Item 21, further comprising a sealant dispensing module containing a cartridge containing sealant, wherein the sealant dispensing module selectively applies the sealant to the fastener before installation, and the gun computer controls the selective application of the sealant. (Item 34) A display mechanism mounted on the gun body, which visually communicates operational information from the gun computer to the operator of the fastener insertion gun, An operator interface mounted on the gun body, which facilitates the input of operational information from the operator of the fastener insertion gun to the gun computer, A fastener insertion gun, as described in item 21, further equipped with the following features. (Item 35) A fastener insertion gun for installing fasteners in holes within the vehicle structure, wherein the fastener insertion gun is A gun body including the front and rear sections, During the installation of the fastener, a concentric collet is mounted on the front portion of the gun body and selectively expands within an opening adjacent to the hole in the vehicle structure, in order to mechanically secure the fastener insertion gun. A reader mechanism that receives information via a radio frequency identification element associated with the front portion of the gun body and associated with the hole in the vehicle structure, wherein the information includes fastener information relating to a fastener to be installed in the hole, and the reader mechanism Multiple internal air valves located within the above-mentioned cancerous tissue and selectively supplying pressurized air used to install the above-mentioned fastener, An impact mechanism for applying impact force to the end of the fastener, wherein the impact mechanism is An impact tube including a front port connected to the first internal air valve of the plurality of internal air valves and a rear port connected to the second internal air valve of the plurality of internal air valves, An impact rod moves forward within the impact tube to apply the impact force to the end of the fastener and moves backward to reset it, An impact mass moves forward within the impact tube so as to strike the impact rod, and then moves backward to reset, The impact mechanism described above includes, A gun computer housed within the gun body, which receives the information from the reader mechanism, attaches the fasteners based on the fastener information from the reader mechanism, and controls the first and second internal air valves to move the impact rod and impact mass forward and backward by selectively introducing the pressurized air into the impact tube through the front and rear ports. A fastener insertion gun equipped with a fastener. (Item 36) The fastener information described above includes the type and size of the fastener to be installed in the hole, as described in Item 35, for the fastener insertion gun. (Item 37) The fastener insertion gun according to Item 35, further comprising: first forward and rear guidance sensors for detecting the location of the impact mass within the impact tube; and a gun computer for receiving the location of the impact mass from the first forward and rear guidance sensors and controlling the first and second internal air valves based on the location of the impact mass within the impact tube. (Item 38) The fastener insertion gun according to Item 35, further comprising: a plurality of forward second guidance sensors for detecting the location of the impact mass at the forward end of the impact tube; and a gun computer that determines when the fastener is fully seated in the hole based on the location of the impact mass at the forward end of the impact tube. (Item 39) The fastener insertion gun according to Item 35, further comprising a sealant dispensing module containing a cartridge containing sealant, wherein the sealant dispensing module selectively applies the sealant to the fastener before installation, and the gun computer controls the selective application of the sealant. (Item 40) A fastener insertion gun for installing fasteners in holes within the vehicle structure, wherein the fastener insertion gun is A gun body including the front and rear sections, During the installation of the fastener, a concentric collet is mounted on the front portion of the gun body and selectively expands within an opening adjacent to the hole in the vehicle structure, in order to mechanically secure the fastener insertion gun. A reader mechanism that receives information via a radio frequency identification element associated with the front portion of the gun body and associated with the hole in the vehicle structure, wherein the information includes fastener information, including the type and size of the fastener to be installed in the hole, and the reader mechanism A sealant dispensing module including a cartridge containing sealant, wherein the sealant dispensing module selectively applies the sealant to the fastener before installation, Multiple internal air valves located within the above-mentioned cancerous tissue and selectively supplying pressurized air used to install the above-mentioned fastener, An impact mechanism for applying impact force to the end of the fastener, wherein the impact mechanism is An impact tube including a front port connected to the first internal air valve of the plurality of internal air valves and a rear port connected to the second internal air valve of the plurality of internal air valves, An impact rod moves forward within the impact tube to apply the impact force to the end of the fastener and moves backward to reset it, An impact mass moves forward within the impact tube so as to strike the impact rod, and then moves backward to reset, The impact mechanism described above includes, A gun computer, housed within the gun body, receives the information from the reader mechanism, attaches the fasteners based on the fastener information from the reader mechanism, controls the selective application of the sealant by the sealant dispensing module, and controls the first and second internal air valves to move the impact rod and impact mass forward and backward by selectively introducing the pressurized air into the impact tube through the front and rear ports. A fastener insertion gun equipped with a fastener. (Item 41) A fastener insertion gun for installing fasteners in holes within vehicle structures, wherein the fastener insertion gun is A gun body including the front and rear sections, During the installation of the fastener, a concentric collet is mounted on the front portion of the gun body and selectively expands within an opening adjacent to the hole in the vehicle structure, in order to mechanically secure the fastener insertion gun. A reader mechanism associated with the front portion of the gun body and receiving information associated with the hole in the vehicle structure via a machine-readable element, Multiple internal air valves located within the above-mentioned cancerous tissue and selectively supplying pressurized air used to install the above-mentioned fastener, A gun computer housed within the above-mentioned cancer body, which receives information from the above-mentioned reader mechanism, attaches the fastener based on the above-mentioned information from the above-mentioned reader mechanism, and operates one or more of the above-mentioned internal air valves to provide the above-mentioned pressurized air used to install the fastener, A fastener insertion gun equipped with a fastener. (Item 42) The fastener insertion gun described in item 41, wherein the machine-readable element is a radio frequency identification element that electronically communicates the above information. (Item 43) The above information includes fastener information relating to the fastener to be installed in the above hole and how the fastener will be installed in the above hole, as described in item 41, for the fastener insertion gun. (Item 44) A fastener supply tube connected to the above-mentioned gun body, which transports the fastener from the fastener supply container to the above-mentioned gun body, or A fastener feeding window, which is mounted through the above-mentioned gun body and allows the operator of the fastener insertion gun to view the fastener inside the gun body, or A display mechanism mounted on the gun body for visually communicating operational information from the gun computer to the operator of the fastener insertion gun, and an operator interface mounted on the gun body to facilitate the input of operational information from the operator of the fastener insertion gun to the gun computer. A fastener insertion gun, as described in item 41, further equipped with the following features. (Item 45) The above fastener is further equipped with an impact mechanism that applies impact force to the end, and the impact mechanism is An impact tube including a front port connected to the first internal air valve of the plurality of internal air valves and a rear port connected to the second internal air valve of the plurality of internal air valves, An impact rod moves forward within the impact tube to apply the impact force to the end of the fastener and moves backward to reset it, An impact mass moves forward within the impact tube so as to strike the impact rod, and then moves backward to reset, The gun computer controls the first and second internal air valves to move the impact rod and impact mass forward and backward by selectively introducing the pressurized air into the impact tube through the forward and rear ports described above, A fastener insertion gun, including the one described in item 41. (Item 46) The above impact mechanism is, One or more variable pressure regulators that control the pressure of the pressurized air entering the impact tube through the front and rear ports, and a gun computer that controls the one or more variable pressure regulators to change the impact force applied to the end of the fastener by the impact rod. or A rod and mass retractor that moves backward to reset the impact rod and impact mass; a bumper located at the front end of the impact tube that absorbs the remaining portion of the impact force of the impact rod; and a bushing located at the front end of the impact tube through which the impact rod moves to reduce wear. The fastener insertion gun described in item 45, further including the following. (Item 47) The above machine-readable element is a radio frequency identification element associated with the above hole in the above vehicle structure, The above-mentioned reader mechanism receives information via a radio frequency identification element, and the information includes fastener information relating to the fastener to be installed in the above-mentioned hole. Fastener insertion gun as described in item 45. (Item 48) The fastener information described above includes the type and size of the fastener to be installed in the hole, as described in item 47 of the fastener insertion gun. (Item 49) The impact mechanism includes first forward and rear guidance sensors that detect the location of the impact mass within the impact tube, and a gun computer that receives the location of the impact mass from the first forward and rear guidance sensors and controls the first and second internal air valves based on the location of the impact mass within the impact tube. or The impact mechanism includes a plurality of forward second guidance sensors that detect the location of the impact mass at the forward end of the impact tube, and a gun computer that determines when the fastener is fully installed in the hole based on the location of the impact mass at the forward end of the impact tube. The fastener insertion gun described in item 45 or 47, further including the following. (Item 50) The fastener insertion gun described above further comprises a sealant dispensing module containing a cartridge containing sealant, the sealant dispensing module selectively applies the sealant to the fastener before installation, and the gun computer controls the selective application of the sealant, as described in any one of items 41, 45, or 47. (Item 51) The above machine-readable element is a radio frequency identification element associated with the above hole in the above vehicle structure, The above-mentioned reader mechanism receives information via a radio frequency identification element, and the information includes fastener information, including the type and size of the fastener to be installed in the above-mentioned hole. The fastener insertion gun further comprises a sealant dispensing module including a cartridge containing sealant, the sealant dispensing module selectively applies the sealant to the fastener before installation. Fastener insertion gun as described in item 45.

Claims

1. A system for drilling holes within a vehicle structure and installing fasteners within those holes, wherein the system is A plate temporarily attached to the first surface of the vehicle structure, An opening extending through the plate body to the first surface of the vehicle structure, A first perforating plate includes a machine-readable element associated with the opening and providing information regarding drilling the hole and installing the fastener within the hole, During operation, the opening receives a drilling gun for drilling the hole in the first plane, and then the opening receives a fastener insertion gun for installing the fastener in the hole. The vehicle structure is temporarily attached to a second surface and comprises a second perforating plate that is physically aligned with the first perforating plate. system.

2. The system according to claim 1, wherein the information includes hole information relating to how the hole will be drilled, or fastener information relating to the fastener to be installed in the hole and how the fastener will be installed in the hole.

3. A system for drilling multiple holes inside an aircraft and installing fasteners in each of the multiple holes, wherein the system is A plurality of first perforating plates, each of which first perforating plates is A plate temporarily attached to the first surface of the aircraft body, The first surface of the aircraft body has a plurality of openings extending through the plate body, One or more machine-readable elements that provide fastener information relating to the required fasteners to be installed in each of the plurality of holes, Includes, A drilling gun is configured to be inserted into each opening, drill the hole with a drilling bit in the first plane, and then removed from the opening, A fastener insertion gun is inserted into each opening and configured to install a specific fastener within the opening, wherein the fastener insertion gun includes a fastener insertion gun reader element for reading the fastener information, A computer configured to compare the required fastener type and required fastener size with the actual fastener type and actual fastener size of the fastener in the fastener insertion gun, and to shut off the fastener insertion gun if the required fastener type and required fastener size do not match the actual fastener type and actual fastener size, An electronic memory element that records whether each hole has been drilled and whether the specific fastener has been installed in each hole, A system equipped with these features.

4. The system according to claim 3, wherein the fastener information includes the required fastener type and required fastener size of the required fastener to be installed in the hole, or the machine-readable element further provides hole information relating to how the hole will be drilled, the hole information includes the required drill bit size for drilling the hole, and the drilling gun further includes a drilling gun reader element for reading the hole information.

5. Equipped with a computer, The computer compares the required drilling bit size with the actual drilling bit size of the drilling bit installed in the drilling gun, and if the required drilling bit size does not match the actual drilling bit size, it shuts off the drilling gun. or The required fastener type and required fastener size are compared with the actual fastener type and actual fastener size of the fastener in the fastener insertion gun, and if the required fastener type and required fastener size do not match the actual fastener type and actual fastener size, the fastener insertion gun is shut off. The system according to claim 4.

6. The system according to claim 1 or 3, further comprising an electronic memory element for recording whether the hole has been drilled and whether the fastener has been placed in the hole.

7. The system according to claim 3, further comprising a plurality of second perforating plates, each of which is temporarily attached to a second surface of the aircraft body and aligned with a particular first perforating plate of the plurality of first perforating plates.

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