Compliant Fastener End-Effector for Multi-Hole Self-Alignment
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Solution Overview
Problem
Existing manufacturing processes are limited by the ability of machines to insert fasteners one at a time, and the number of machines that can be used is constrained by the size of the workpiece and machine, leading to inefficiencies in fastener installation.
Innovation Solution
A fastener installation assembly with retainer assemblies and actuators that allow multiple fasteners to be aligned and inserted into holes of a workpiece, utilizing compliance apparatuses for self-alignment and a method that includes a container with fingers and actuators to eject and insert fasteners efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple machines are used to insert fasteners simultaneously, then productivity is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple fastener insertion functions into a single automated assembly system. The container holds multiple retainer assemblies, each with fingers that can independently eject fasteners into workpiece holes. This merging of multiple insertion operations into one machine eliminates the need for multiple separate machines while maintaining high productivity.
Solution Approach 2:
The system segments the fastener insertion function into multiple independent retainer assemblies within a single container. Each retainer assembly with its fingers can operate independently to insert fasteners at different locations, allowing the single machine to perform multiple insertion operations simultaneously without requiring complex coordination between separate machines.
2Manufacturing precision
If precise alignment of fasteners with holes is required, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The compliance apparatus enables self-alignment of fasteners with holes through elastic deformation of the fingers. As each finger ejects a fastener toward its target hole, the finger can flex independently to accommodate minor misalignments, allowing the fastener to self-align with the hole without requiring complex external alignment mechanisms or precise pre-positioning.
Solution Approach 2:
The system changes the physical state of the fingers from rigid to elastic through the compliance apparatus. This allows the fingers to dynamically adjust their position and orientation during the ejection process, accommodating variations in fastener positioning and hole locations while maintaining precise alignment through the elastic deformation of the finger materials.
3Productivity
If manual fastener insertion is used, then device complexity is reduced, but productivity and labor costs decrease
Solution Approach 1:
The system performs preliminary actions by pre-positioning multiple fasteners in the container on retainer assemblies before the insertion process begins. The fingers are pre-loaded with fasteners and positioned over the workpiece holes, ready for simultaneous ejection. This preliminary preparation enables automated high-speed insertion without requiring manual loading during the insertion process, significantly improving productivity.
Data Source
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AI summary
A fastener installation assembly, an end-effector tool, and a method for installing fasteners into respective holes of a workpiece includes a container and retainer assemblies supported by the container. Each of the retainer assemblies include fingers configured to retain a respective one of the fasteners between the fingers in a pre-installed position. A first actuator is configured to move the respective fasteners to an installed position by ejecting the respective one of the fasteners out of the respective retainer assemblies and inserting the respective one of the fasteners into one of the holes of the workpiece. Each of the retainer assemblies include a compliance apparatus configured to allow the respective fasteners and the respective fingers to move independently of each other to self-align the respective fasteners with the respective one of the holes as the first actuator moves the respective fasteners from the pre-installed position to the installed position.