Collar Swaging End-Effector for Confined Space Access
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing automated assembly tools are inefficient in coupling collars to target objects in confined spaces, such as aircraft wing boxes, due to their large size and limited accessibility, requiring manual installation which is time-consuming and tedious.
Innovation Solution
A method and system utilizing a sensor and actuator system with a collar swaging tool that is moveable along multiple axes and rotatable, coupled with a gas cylinder system and camera subsystems, to precisely position and install collars in confined spaces, facilitated by a wrist coupled to a robot system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If large, heavy multi-function end effectors are used to couple collars to fasteners, then the coupling function is achieved, but the tool cannot access confined spaces such as wing boxes
Solution Approach 1:
The end effector is divided into modular components including a head, body, wrist, and interchangeable tools. This segmentation allows the system to access confined spaces while maintaining full coupling functionality through coordinated operation of smaller modular parts rather than requiring one large monolithic tool
Solution Approach 2:
The patent introduces multiple degrees of freedom through the wrist mechanism with rotational joints, enabling the end effector to reach confined spaces by operating in three-dimensional space rather than being constrained to linear movement, thus accessing areas that would be unreachable with simpler tools
2Ease of operation
If manual collar installation is performed in confined spaces, then accessibility is achieved, but installation time increases and productivity decreases
Solution Approach 1:
The end effector incorporates automated collar feeding and positioning mechanisms that eliminate the need for manual collar handling. The system automatically retrieves collars, positions them on fasteners, and performs swaging operations, thereby maintaining high productivity while accessing confined spaces that were previously suitable only for manual work
Solution Approach 2:
Manual mechanical operations are replaced with automated actuation systems including electric or pneumatic motors that control the collar feeding, positioning, and swaging processes. This substitution maintains the ability to work in confined spaces while dramatically increasing installation speed and reducing operational complexity
3Productivity
If automated assembly tools are used to couple collars, then productivity increases, but the tools are too large to access confined spaces
Solution Approach 1:
The automated assembly system is segmented into compact modular components that can be arranged in confined spaces. The head, body, and wrist sections are designed as separate units with reduced individual volumes, allowing the automated system to fit into tight areas while maintaining full automation functionality
Solution Approach 2:
The end effector design incorporates nested or telescoping components where parts can be stored within other parts when not in use. This nesting capability reduces the overall volume of the moving object, enabling the automated tool to access confined spaces without sacrificing automation capabilities
4Manufacturing precision
If precise positioning of collar swaging tool is achieved through sensor systems, then manufacturing precision increases, but device complexity increases
Solution Approach 1:
Optical sensors and cameras provide real-time feedback on the position and orientation of the end effector and collar swaging tool. This feedback is processed by control systems that automatically adjust actuator commands to achieve precise positioning, thereby maintaining high manufacturing precision while managing device complexity through intelligent control algorithms
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An assembly tool includes a head and an actuator system. The head includes a collar swaging tool that is moveable along a first axis substantially perpendicular to a longitudinal axis of the assembly tool. A sensor system detects a first position of the head within the confined space, and a second position of the collar swaging tool relative to the target object. The actuator system positions the head within the confined space, and the collar swaging tool relative to the target object.