Collar Feeder Aligns Swaging Collars to Fastener Axis

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Solution Overview

Problem

Current methods for presenting collars to fasteners are prone to operator error, leading to foreign object debris and excessive stress in swaged connections due to manual alignment or excessive sealant use.

Innovation Solution

An apparatus and method featuring a collar feeder with a cam surface, cam follower, and resilient flexure to align and retain collars concentrically with fasteners, allowing for precise alignment and reduced operator fatigue, while minimizing sealant usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If collars are presented to the fastener by hand, then the operator can control the collar placement, but operator error may lead to fallen collars that create foreign object debris

Engineering Contradiction:

Improvemanual collar placement controlVSAvoidcollar placement accuracy

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The collar feeder device enables self-service operation by automatically presenting collars to the fastener without requiring manual handling. The device feeds collars through a controlled mechanism that positions them automatically, eliminating operator error while maintaining reliable placement.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The collar feeder acts as an intermediary between the collar supply and the fastener. It includes components like a collar holder, positioning mechanism, and feeding structure that mediate the transfer of collars, ensuring accurate and debris-free placement without direct manual intervention.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If excess sealant is used for temporary attachment of a collar to a fastener, then the collar is securely attached before swaging, but sealant trapped between the collar and lock grooves may cause excessive stress in the swaged connection

Engineering Contradiction:

Improvetemporary attachment securityVSAvoidswaged connection stress

Core Design Contradiction:

StrengthVSStress or pressure

Solution Approach 1:

The invention extracts the temporary attachment function from the swaging process entirely. By using a collar feeder that holds and positions collars without sealant, the harmful element (excess sealant) is removed, preventing trapped sealant from causing stress in the final swaged connection.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The device uses a disposable or easily replaceable collar holder that can be quickly changed between operations. This eliminates the need for reusable sealant application mechanisms and allows for rapid collar presentation without temporary attachment, avoiding the sealant stress problem entirely.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of operation

If manual alignment methods are used, then the operator can position the collar, but operator fatigue increases and productivity decreases

Engineering Contradiction:

Improvecollar alignment capabilityVSAvoidswaging operation efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The collar feeder performs the alignment function automatically through its built-in positioning mechanism. The device self-adjusts to present collars concentrically with the fastener and swager axis, eliminating repetitive manual alignment operations that cause operator fatigue and reduce productivity.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The invention replaces manual mechanical alignment operations with an automated mechanical feeding system. The collar feeder uses guided mechanical movements, cam surfaces, and positioning fixtures to automatically align and present collars, substituting operator skill and effort with a reliable mechanical system that increases throughput.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Improves ergonomics and access in overhead work, reduces operator fatigue, and minimizes stress in swaged connections by ensuring precise alignment and controlled delivery of collars, enhancing productivity and reducing foreign object debris.

Implementation Method 1

retaining the collar at the outlet of the collar feeder using at least one resilient flexure of the collar feeder

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

a cam surface, configured to be stationary relative to the swager. The apparatus additionally comprises a cam follower coupled to the collar feeder. The cam surface is configured to guide the cam follower and the cam follower is configured to be moveable along the cam surface

Methodology Applied

Scientific EffectCam mechanism: Cam

Data Source

PatentUS10288108B2Methods for manipulating swaging collars

Publication Date: 2019.05.14 THE BOEING CO

AI summary

A method of delivering a collar between a fastener and a swager is provided. The method comprises steps of: (i) advancing the collar from a collar source to a collar feeder, where the collar source is operatively coupled to the collar feeder via a collar-supply tube, (ii) presenting the collar at an outlet of the collar feeder concentrically in line with a central axis of the fastener and with a working axis of the swager, and (iii) retaining the collar at the outlet of the collar feeder using at least one resilient flexure of the collar feeder.