Eddy Current Fastener Verification in Automated Installation
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Solution Overview
Problem
Existing automated fastener systems struggle to accurately identify the material of fasteners due to similarities in appearance and color, leading to potential installation of incorrect fasteners with inadequate strength, and existing hardness testing methods cause damage to fasteners.
Innovation Solution
An automated fastener system utilizing eddy current conductivity probes integrated at various points to non-destructively test the conductivity of fasteners, determining their material based on electrical conductivity measurements, and a processing system to compare these measurements against predetermined values for acceptance or rejection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If color vision systems are used to identify fastener material, then identification speed is improved, but measurement precision deteriorates because they cannot distinguish between similar colors or detect material under incorrect coatings
Solution Approach 1:
The patent replaces optical/color-based identification systems with electrical conductivity measurement systems. The conductivity probe measures the electrical conductivity of the fastener, which directly correlates to the base material type. This substitution eliminates the limitations of color vision systems while maintaining automated identification speed, as conductivity measurement is both rapid and material-specific.
Solution Approach 2:
The patent changes the identification parameter from optical properties (color) to electrical properties (conductivity). By measuring electrical conductivity, the system accesses a physical property that is intrinsic to the material and unaffected by surface coatings or color variations, thereby achieving both speed and precision in material identification.
2Measurement precision
If hardness testing methods are used to determine material, then measurement precision is improved, but object-generated harmful factors worsen due to damage to the fastener
Solution Approach 1:
The patent replaces mechanical hardness testing methods (which involve indentation, scratching, or compression) with electrical conductivity measurement. The conductivity probe makes light contact to measure electrical properties without applying destructive mechanical forces, thereby achieving material identification precision without causing fastener damage.
Solution Approach 2:
The patent introduces electrical conductivity as an intermediary measurement parameter that correlates to material type without requiring direct mechanical interaction with the fastener. This intermediary measurement method provides material information while avoiding the harmful effects of mechanical testing.
3Productivity
If automated fastener selection is implemented, then productivity is improved, but reliability deteriorates due to potential installation of incorrect fasteners
Solution Approach 1:
The patent implements a feedback mechanism where the conductivity probe measures the electrical conductivity of each fastener, and this measurement is fed back to the control system. The control system compares the measured conductivity against predetermined ranges for different material types, automatically identifying and selecting the correct fastener. This closed-loop feedback ensures both high productivity through automation and high reliability through accurate material verification.
Solution Approach 2:
The patent replaces unreliable visual identification methods with electrical conductivity measurement for automated fastener selection. Since conductivity is an intrinsic material property that cannot be faked by surface coatings or color markings, the automated system achieves both high speed and high reliability in selecting the correct fastener material.
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
Enables accurate material identification of fasteners without damage, ensuring correct installation and preventing potential structural issues by distinguishing between different materials based on conductivity.
Implementation Method 1
an automated eddy current conductivity probe system comprising an eddy current conductivity probe assembly
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
There is provided an automated fastener system (10) having fastener conductivity testing (12). The automated fastener system (10) has an automated fastener holder assembly (40) holding fastener(s) (18); an automated fastener shuttle assembly (44) having shuttle cup(s) (46); an automated fastener inspection system (48) having an inspection center shaft (50), and inspection gripper fingers (52); an automated delivery system (56) having a delivery device (58); an automated fastener installation system (64) having an end effector (66) with an end effector center shaft (68), and end effector gripper fingers (70); an automated eddy current conductivity probe system (80); and a processing system (98). The eddy current conductivity probe system (80) has an eddy current conductivity probe assembly (82) integrated in one of, the one or more shuttle cups (46), the inspection center shaft (50), the inspection gripper fingers (52), the end effector center shaft (68), or the end effector gripper fingers (70). The eddy current conductivity probe assembly (82) contacts a selected fastener (18a) to perform the fastener conductivity testing (12), and to obtain an electrical conductivity measurement (14).