Fastener Conductivity Testing for Accurate Automated Installation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing automated fastener systems struggle to accurately identify the material of fasteners due to similar appearances and unreliable color vision systems, and hardness testing methods cause damage to fasteners.
Innovation Solution
An automated fastener system with integrated eddy current conductivity probes that non-destructively test fasteners by measuring their electrical conductivity to determine material, using a processing system to compare measurements against predetermined values for acceptance or rejection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If color vision systems are used to identify fastener material, then fastener type classification is enabled, but the system cannot distinguish between similar colors and is unreliable when coatings are incorrect
Solution Approach 1:
The patent replaces optical/color-based identification systems with electrical conductivity measurement systems. Instead of using cameras and color vision algorithms to identify fastener material, the invention uses eddy current probes to measure electrical conductivity, which directly correlates to material composition. This substitution eliminates the fundamental limitation of color-based systems that cannot distinguish between similar colors or detect material beneath coatings.
Solution Approach 2:
The patent changes the measurement parameter from optical properties (color) to electrical properties (conductivity). By measuring electrical conductivity instead of color, the system gains the ability to accurately identify material composition regardless of surface appearance or coating color. Different materials have distinct conductivity signatures that are not affected by visual characteristics.
2Measurement precision
If hardness testing methods are used to determine fastener material, then material identification is possible, but the fastener surface is damaged
Solution Approach 1:
The patent replaces mechanical hardness testing methods (such as indentation or scratching) with non-contact electrical conductivity measurement. Instead of physically contacting and deforming the fastener surface to determine material properties, the invention uses electromagnetic fields to measure conductivity, completely eliminating mechanical damage to the fastener.
Solution Approach 2:
The patent introduces an electromagnetic field as an intermediary between the measurement system and the fastener. The eddy current probe uses electromagnetic induction to detect material properties without physical contact, serving as a non-invasive mediator that provides material identification information without causing surface damage.
3Productivity
If automated fastener installation is implemented, then assembly efficiency is improved, but the risk of installing incorrect fasteners increases
Solution Approach 1:
The patent implements preliminary verification of fastener material composition through conductivity measurement before the fastener is installed. The system measures the electrical conductivity of each fastener and compares it against expected values for the specific application, ensuring the correct material is selected before installation occurs. This preliminary check prevents incorrect fastener installation while maintaining automated assembly efficiency.
Solution Approach 2:
The patent incorporates a feedback mechanism where the measured conductivity values are compared against predetermined specifications for the application. The system provides real-time verification and can reject fasteners that do not meet the required material properties, ensuring that only correctly specified fasteners are installed. This closed-loop feedback maintains both automation and reliability.
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 adverse issues in structures like aircraft.
Implementation Method 1
An automated eddy current conductivity probe system comprises an eddy current conductivity probe assembly integrated in one of, the one or more shuttle cups, the inspection center shaft, the two or more inspection gripper fingers, the end effector center shaft, or the two or more end effector gripper fingers.
Data Source
AI summary
There is provided an automated fastener system having fastener conductivity testing. The automated fastener system has an automated fastener holder assembly holding fastener(s); an automated fastener shuttle assembly having shuttle cup(s); an automated fastener inspection system having an inspection center shaft, and inspection gripper fingers; an automated delivery system having a delivery device; an automated fastener installation system having an end effector with an end effector center shaft, and end effector gripper fingers; an automated eddy current conductivity probe system; and a processing system. The eddy current conductivity probe system has an eddy current conductivity probe assembly integrated in one of, the one or more shuttle cups, the inspection center shaft, the inspection gripper fingers, the end effector center shaft, or the end effector gripper fingers. The eddy current conductivity probe assembly contacts a selected fastener to perform the fastener conductivity testing, and to obtain an electrical conductivity measurement.