Barrel Nut Positioning Frame for Bore Alignment Stability
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Solution Overview
Problem
Barrel nuts in aerospace applications are prone to rotation and translation within bores, making alignment with fasteners difficult and time-consuming, leading to inefficiencies in assembly processes, particularly in automated systems, and risking loss of the nuts during transport or assembly.
Innovation Solution
A barrel nut positioning frame that engages with a bore's positioning feature to restrict movement, ensuring the barrel nut remains aligned and stable within the bore, allowing for efficient assembly and enabling use in automated processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If barrel nut is placed freely in the bore without positioning features, then the assembly process becomes simpler, but the barrel nut cannot maintain proper alignment with fasteners and requires time-consuming manual repositioning
Solution Approach 1:
The positioning feature is pre-formed in the bore during component manufacturing, and the barrel nut is pre-configured with engagement features. When the barrel nut is inserted into the bore, the pre-existing positioning feature automatically engages with the barrel nut, preliminarily establishing the correct alignment before the fastener is inserted. This eliminates the need for manual alignment adjustments during assembly.
2Productivity
If barrel nut is allowed to rotate and translate freely, then the assembly process is faster, but the barrel nut changes orientation causing delays in automated assembly lines
Solution Approach 1:
The positioning feature in the bore creates a pre-existing constraint that prevents the barrel nut from rotating or translating out of position. This preliminary anti-action counteracts the natural tendency of the barrel nut to move freely, ensuring it maintains consistent orientation throughout the assembly process, including during automated assembly operations.
3Reliability
If barrel nut is retained in the bore during transport, then loss of the nut is prevented, but the nut may still rotate or translate and require re-alignment upon arrival
Solution Approach 1:
The positioning feature merges the retention function and alignment function into a single integrated solution. The same feature that prevents the barrel nut from falling out during transport also maintains its correct alignment by preventing rotation and translation. This dual functionality eliminates the need for separate retention and alignment mechanisms.
4Manufacturing precision
If manual intervention is used to re-orientate barrel nuts during automated assembly, then alignment is achieved, but the automated process is interrupted causing significant delays
Solution Approach 1:
The barrel nut assembly performs self-alignment through the engagement between the positioning feature in the bore and the engagement feature on the barrel nut. When the barrel nut is inserted into the bore, it automatically orients itself correctly without requiring external intervention. This self-service capability allows the automated assembly line to operate continuously without interruptions for manual repositioning.
Data Source
AI summary
A barrel nut positioning frame for maintaining a barrel nut in a desired position in a bore of a component is disclosed having a frame body configured to receive a barrel nut therein, the frame body being adapted to fit, together with a received barrel nut, within a bore, and a bore engagement element configured to engage with a positioning feature in the bore so as to restrict movement of the frame within the bore.