Electromagnetic Bucking Bar Alignment for Riveting Tools

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Solution Overview

Problem

The manual installation of rivets in large structures like aircraft fuselage structural pieces is challenging due to difficulties in maintaining bucking bar normality and ergonomic issues from absorbing hammering vibrations, with existing automated systems being costly and unsuitable for outsized workpieces.

Innovation Solution

A riveting tool with a magnetically attractive housing and a non-magnetically attractive bucking bar, actuated by a mechanism to ensure coaxial alignment and reduce ergonomic strain, using a magnetic field to secure the bucking bar assembly relative to the workpiece.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual riveting process is used with two workers, then flexibility and adaptability to various workpiece sizes are maintained, but manufacturing precision of bucking bar alignment deteriorates and worker ergonomics worsen

Engineering Contradiction:

Improveadaptability to various workpiece sizesVSAvoidbucking bar alignment precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent replaces the manual mechanical alignment system with an electromagnetic system. A magnet is positioned on one side of the workpiece to attract and hold the bucking bar assembly on the opposite side, automatically ensuring precise coaxial alignment without requiring manual positioning by workers. This electromagnetic substitution resolves the alignment precision problem while maintaining manual adaptability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The magnet acts as an intermediary between the workpiece and the bucking bar assembly. It provides a force field that automatically positions and holds the bucking bar in the correct orientation, serving as a mediator that eliminates the need for manual alignment while preserving the flexibility of manual operation for various workpiece sizes.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If manual riveting process is used with two workers, then adaptability to various workpiece sizes is maintained, but ease of operation deteriorates due to ergonomic strain

Engineering Contradiction:

Improveadaptability to various workpiece sizesVSAvoidworker ergonomics

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patent substitutes the manual force application system with an electromagnetic holding system. The magnet provides continuous holding force to maintain bucking bar position and alignment, eliminating the need for workers to physically brace and stabilize the bucking bar against hammering forces. This reduces ergonomic strain while preserving manual adaptability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If automated riveting systems are used, then manufacturing precision and ease of operation are improved, but device complexity and cost increase

Engineering Contradiction:

Improvebucking bar alignment precisionVSAvoidsystem complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent extracts only the essential alignment and holding function from complex automated riveting systems. Instead of implementing a full automated system with multiple actuators and controls, it isolates and applies only the magnetic holding function to achieve precise bucking bar positioning. This simplification maintains manufacturing precision while dramatically reducing device complexity and cost.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces complex mechanical positioning and holding mechanisms with a simple electromagnetic field. A single magnet provides both the alignment and holding functions that would otherwise require complex mechanical systems, reducing device complexity while maintaining precision.

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

The solution enables accurate and ergonomic rivet tail formation by ensuring proper bucking bar alignment and reducing worker strain, while being cost-effective and adaptable to various workpiece sizes.

Implementation Method 1

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Data Source

PatentUS9259779B2Riveting tool and method with electromagnetic bucking bar normalization

Publication Date: 2016.02.16 THE BOEING CO

AI summary

A riveting tool including a magnet, a magnetically attractive housing, a non-magnetically attractive bucking bar received in the housing, the bucking bar being moveable relative to the housing along a bucking bar axis, and an actuation mechanism to move the bucking bar along the bucking bar axis.