Fastener Alignment Tool for Batch Transfer in Tight Assemblies
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Solution Overview
Problem
The installation of fasteners in manufactured assemblies, particularly in spatially constrained and ergonomically challenging environments like aircraft, is time-consuming and prone to errors, with a high risk of fastener loss.
Innovation Solution
A fastener alignment system comprising a fastener orienting structure, a fastener alignment tool, and a transfer structure that orients and retains fasteners in a predetermined pattern, allowing for efficient transfer and alignment with fastening locations on a manufactured assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fasteners are installed sequentially one by one, then each fastener can be properly tightened to predetermined torque, but the installation process becomes extremely time-consuming and labor-intensive
Solution Approach 1:
The system pre-arranges multiple fasteners in predetermined locations on an orienting structure before installation begins. This preliminary organization allows multiple fasteners to be transferred and installed simultaneously or in rapid succession, dramatically improving installation speed while maintaining quality through the predetermined pattern design.
Solution Approach 2:
The fastener orienting structure serves as an intermediary device that holds multiple fasteners in the correct positions and orientations before transfer to the manufactured assembly. This intermediary structure enables efficient batch transfer of fasteners while ensuring proper alignment and orientation, resolving the contradiction between speed and quality.
2Manufacturing precision
If fasteners are manually handled and transferred individually, then precise placement can be achieved, but the risk of fastener loss increases and the process becomes more complex
Solution Approach 1:
The system merges multiple fastener handling operations into a single integrated transfer process. Multiple fasteners are transferred together from the orienting structure to the manufactured assembly in one coordinated action, reducing the number of handling steps and minimizing the risk of individual fasteners being lost while maintaining precise placement through the predetermined pattern.
Solution Approach 2:
Fasteners are pre-positioned and secured in the orienting structure in a predetermined pattern before transfer. This preliminary arrangement ensures that fasteners are organized and protected during handling, reducing loss risk while enabling accurate placement through the pre-established pattern alignment.
3Device complexity
If traditional sequential fastener installation is used, then simple equipment is required, but the installation process is ergonomically challenging in spatially constrained environments
Solution Approach 1:
The fastener orienting structure extends into a third dimension away from the manufactured assembly, allowing fasteners to be pre-arranged and transferred from an accessible external location. This dimensional extension improves ergonomic accessibility in spatially constrained environments while maintaining relatively simple equipment architecture.
Solution Approach 2:
The orienting structure acts as an intermediary that positions fasteners in an ergonomically accessible location external to the constrained work area. This mediator allows technicians to prepare and transfer fasteners from a more accessible position, improving ease of operation without significantly increasing overall system complexity.
Data Source
AI summary
Fastener alignment systems, fastener alignment kits, and associated methods are disclosed herein. The fastener alignment systems include a fastener orienting structure, a fastener alignment tool, and a transfer structure. The fastener orienting structure is configured to orient a plurality of fasteners in a predetermined fastening location pattern. The fastener alignment tool is configured to operatively engage with the fastener orienting structure at a predetermined relative orientation, to receive a corresponding fastener in each of a plurality of fastener alignment receptacles, and to retain the corresponding fastener. The transfer structure is configured to selectively transfer the plurality of fasteners from the fastener orienting structure to the fastener alignment tool. The fastener alignment kits include the fastener alignment tool and the plurality of fasteners. The methods include methods of utilizing the fastener alignment system.