Composite Panel Fastener Insert Installation With Timed Adhesive Dispensing
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Solution Overview
Problem
The installation of fastener inserts in composite panels requires high precision and conformance to tolerances, and existing methods are labor-intensive and prone to errors, leading to potential scrap materials due to imprecise installation and the limited working time of special adhesive materials.
Innovation Solution
An automated fastener insert installation system comprising a panel handling module, a fastener insert assembly module, and an adhesive material preparation module, which secures the panel, determines the insert configuration, selects the correct insert, and dispenses adhesive material within a predetermined time frame, ensuring precise installation and minimizing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual installation methods are used for fastener inserts, then flexibility in handling different insert configurations is maintained, but installation precision and consistency deteriorate leading to rework and scrap
Solution Approach 1:
The system uses vision sensors to automatically detect insert configuration and the controller to automatically select and install the correct insert type, enabling the system to serve itself without human intervention for each installation decision, thereby achieving high precision while managing complexity through automation
Solution Approach 2:
Manual visual inspection and decision-making are replaced with automated vision systems and control algorithms that detect insert configurations and determine appropriate insert types, substituting human cognitive functions with automated sensing and processing systems to improve precision
2Productivity
If adhesive material is prepared in advance, then installation speed is improved, but adhesive material may expire before use reducing reliability
Solution Approach 1:
The system prepares adhesive material just before it is needed for each specific installation task based on real-time detection of insert configuration and panel requirements, performing the preparation action in advance of actual use but within the usable time window, thereby maintaining both speed and reliability
Solution Approach 2:
The adhesive preparation timing is dynamically adjusted based on the detected insert configuration and the specific installation sequence, allowing the system to optimize the timing of adhesive preparation for each unique scenario to ensure material is ready when needed without expiring
3Adaptability or versatility
If multiple insert configurations are supported, then system versatility is improved, but difficulty in selecting correct insert increases leading to errors
Solution Approach 1:
The vision system provides real-time feedback about the detected insert configuration and the controller uses this feedback to automatically select and install the correct insert type, creating a closed-loop system that verifies detection accuracy and correct selection, thereby managing versatility while maintaining selection accuracy
Solution Approach 2:
The system creates a digital representation or model of the detected insert configuration through the vision system, comparing this digital copy against known insert types in the database to automatically identify and select the correct insert, replacing difficult manual matching with automated pattern recognition
4Ease of operation
If rework opportunities are allowed after adhesive application, then installation flexibility is maintained, but time consumption and potential scrap increase
Solution Approach 1:
The system performs preliminary detection of insert configuration and automatically selects the correct insert type before adhesive application, ensuring the correct component is installed from the start and eliminating the need for rework, thereby saving time while maintaining operational flexibility through automated decision-making
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 system enables precise and efficient installation of fastener inserts in composite panels, reducing labor-intensive rework and material scrap by automating the process and optimizing adhesive material usage, thereby improving the structural integrity and reliability of the assembled product.
Implementation Method 1
an adhesive material preparation module being configured to mix and actuate the adhesive material in an adhesive material kit
Implementation Method 2
dispense an adhesive material through the installation aide and into the insert-receiving orifice about selected fastener insert such that the adhesive material secures the selected fastener insert within the insert-receiving orifice
Data Source
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AI summary
Automated fastener insert installation system (100) for composite panels comprising a module (300) that receives and secures a composite panel (75) with respect to an origin of a first coordinate system (1200), wherein the composite panel has opposed major surfaces and defines an insert-receiving orifice (25) extending through one of the major surfaces, and is secured such that one of the major surfaces is externally accessible, wherein the system also comprises a module (700) that engages each of a plurality of fastener inserts (50) with an installation aide (45), and a module (900) that determines a configuration of the orifice defined by the composite panel, selects a corresponding one of the fastener inserts engaged with the installation aide, inserts the selected fastener insert into the orifice, and dispenses an adhesive material through the installation aide and into the orifice about selected fastener insert such that the adhesive material secures the selected fastener insert within the orifice.