Break-Off Mandrel Stapling Sleeve for Automated Temporary Fastening
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Solution Overview
Problem
The existing stapling devices for temporarily fastening components, such as in aircraft fuselage production, are costly, require significant manual effort, and are difficult to automate, with high expenses for reusable tacking devices and time-consuming processes.
Innovation Solution
A stapling device featuring a deformable sleeve with a mandrel that breaks at a predetermined point, allowing for automatic insertion, crimping, and easy removal, utilizing a holding unit for high tacking force and low-cost production, with a design suitable for robotic handling and one-time use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reusable tack welding devices are used for temporary fastening, then high tacking force is achieved, but manual effort and cost increase significantly
Solution Approach 1:
The patent employs disposable stapling devices instead of reusable tack welding equipment. Each stapling device is a low-cost, single-use component that is inserted into the workpiece, performs the temporary fastening function, and is then removed. This eliminates the need for expensive reusable devices and significant manual effort, while still providing sufficient tacking force for alignment during riveting operations.
Solution Approach 2:
The invention extracts the temporary fastening function from complex reusable tack welding devices and implements it through simple, disposable stapling mechanisms. The stapling device is inserted through pre-drilled holes and provides temporary attachment, which is then removed after riveting is complete, leaving only the permanent rivet connections.
2Productivity
If automated tack welding is implemented, then productivity increases, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex automated tack welding systems with simple disposable stapling devices that can be easily handled and positioned by robotic systems. The stapling devices require no complex control systems, sensors, or adjustment mechanisms, making them ideal for automated application while maintaining low cost and simplicity.
Solution Approach 2:
The invention substitutes the mechanical tack welding process with a simpler mechanical insertion and crimping process. The stapling device is inserted through holes and secured by crimping the sleeve, eliminating the need for complex welding automation while achieving the same temporary fastening function.
3Manufacturing precision
If multiple drilling and repositioning steps are performed, then precise alignment is achieved, but time and process complexity increase
Solution Approach 1:
The patent performs preliminary drilling of all holes before any fastening operation. The stapling devices are then inserted through these pre-drilled holes to provide temporary alignment, eliminating the need for iterative drilling and repositioning. After riveting is complete, the stapling devices are removed and the same holes are used for permanent rivet installation.
Solution Approach 2:
The invention merges the alignment and temporary fastening functions into a single stapling device insertion step. The stapling devices provide both positioning and temporary attachment simultaneously, eliminating the need for separate alignment operations and reducing overall process time.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces costs and manual effort, enables automated processing, and provides a high tacking force, facilitating efficient and inexpensive temporary fastening of components with simplified setup and removal processes.
Implementation Method 1
the sleeve comprises a deformable material which, when the stapling device is inserted into an opening of a component, is pressed against the component when the head end of the clamping mandrel is moved towards the first end of the sleeve
Implementation Method 2
the sleeve comprises a deformable material which, when the stapling device is inserted into an opening of a component, is pressed against the component
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
A stapling device (2) for at least temporarily fastening components (4, 6) to one another comprises a sleeve with a collar (16) projecting radially at a first end and an elongated clamping mandrel (30) with a head end (32) and a clamping end (34), wherein the clamping mandrel can be inserted into the axial bore at the second end of the sleeve, can be brought into contact with a sleeve edge surface with its head end and, in the inserted state, projects out of the sleeve beyond its first end, wherein a holding unit (41) is provided which is designed to hold the clamping mandrel when the stapling device is inserted into an opening of a component, wherein the sleeve comprises a deformable material which, when the stapling device is inserted into an opening of a component, is pressed against the component when the head end of the clamping mandrel is moved towards the first end of the sleeve, and wherein the clamping mandrel has a predetermined breaking point.