Ergonomic Bucking Bar Apertures and Compliant Grip
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Solution Overview
Problem
Conventional bucking bars used in riveting operations are heavy and transmit excessive vibrations to the operator, leading to discomfort and fatigue during prolonged use in aircraft assembly and other riveting applications.
Innovation Solution
An ergonomic bucking bar design featuring a bar body with weight-reduced proximal end apertures and a compliant hand grip to absorb vibrations, optionally with increased mass at the distal end through inserts, to reduce operator fatigue and discomfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional solid steel bucking bars are used, then structural strength is maintained, but weight increases causing operator fatigue
Solution Approach 1:
The bucking bar is divided into multiple sections with apertures (holes) created in the bar body. This segmentation reduces the overall weight of the bucking bar while maintaining structural integrity through the distributed aperture design, directly resolving the contradiction between weight reduction and strength maintenance.
Solution Approach 2:
The bucking bar incorporates a porous structure with multiple apertures throughout the bar body. This porous design reduces material density and weight while preserving sufficient structural strength for riveting operations, addressing the trade-off between weight and strength.
2Object-affected harmful factors
If conventional solid steel bucking bars are used, then structural integrity is maintained, but vibration transmission increases causing operator discomfort
Solution Approach 1:
The apertures segment the continuous steel structure into isolated sections, disrupting the transmission path of vibrations while preserving the overall structural integrity of the bucking bar. This segmentation reduces vibration transmission to the operator's hand without compromising the bar's ability to perform riveting functions.
Solution Approach 2:
The porous structure with distributed apertures acts as a vibration dampening mechanism, scattering and reducing vibration energy transmission through the bar body while maintaining sufficient structural stability for the intended application.
3Ease of operation
If weight is reduced through apertures, then operator fatigue is reduced, but manufacturing complexity increases
Solution Approach 1:
The manufacturing process parameters are changed to directly form apertures during additive manufacturing or to accommodate easy post-processing of aperture features. This approach simplifies the overall manufacturing complexity while achieving the weight reduction necessary for operator comfort.
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 ergonomic design significantly reduces operator fatigue and discomfort by minimizing weight and vibration transmission during riveting operations, enhancing operational efficiency and safety.
Implementation Method 1
a compliant hand grip positioned over the proximal end of the bar body for reducing vibrations transmitted through the bar body during a riveting operation using the bucking bar
Data Source
AI summary
An ergonomic bucking bar is disclosed herein. The ergonomic bucking bar includes a bar body having a proximal end and a distal end. The proximal end includes a plurality of apertures formed therein for reducing weight of the bar body at the proximal end. The ergonomic bucking bar includes a compliant hand grip positioned over the proximal end of the bar body for reducing vibrations transmitted through the bar body during a riveting operation using the bucking bar. Optionally, the distal end includes at least one aperture formed therein for receiving an insert to increase the weight of the bar body at the distal end.