Fastener Insertion Force Correlation for Rivet Gun Limits
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Solution Overview
Problem
The forces exerted by a rivet gun during fastener insertion can degrade components, while hydraulic presses used for testing do not accurately replicate these forces, leading to uncertainty in manufacturing processes.
Innovation Solution
A system and method that correlate the forces exerted by a rivet gun with those of a hydraulic press using force sensors and a control unit to determine safe insertion limits, employing a predictive model based on fastener and hole dimensions and material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a hydraulic press is used to perform tests on representative samples, then manufacturers can know the limits of forces, but the forces exerted by the press do not accurately replicate those exerted by a rivet gun
Solution Approach 1:
A correlation model serves as an intermediary between press force measurements and rivet gun force characteristics. The system uses force sensors to measure press forces, then applies a correlation model (developed through comparative testing) to translate these measurements into equivalent rivet gun force values, allowing accurate prediction of rivet gun effects through press testing
Solution Approach 2:
The system creates a virtual copy of rivet gun force characteristics through the correlation model. By establishing mathematical relationships between press and rivet gun forces through comparative testing, the system replicates rivet gun force behavior using the more controllable and measurable press, enabling accurate force limit determination without directly measuring rivet gun forces
2Strength
If the rivet gun exerts excessive force into the fastener or component, then fastening is achieved, but the structures can be degraded
Solution Approach 1:
The system implements feedback by using force sensors to measure actual forces during fastening operations and comparing them against correlated safe thresholds. The control unit receives force sensor data, applies the correlation model to determine equivalent rivet gun forces, and provides feedback signals when forces approach dangerous levels, allowing real-time prevention of component degradation while maintaining adequate fastening strength
Solution Approach 2:
The system changes the measurement parameter from direct rivet gun force (difficult to measure) to press force (easy to measure with high precision), then uses parameter transformation through the correlation model to maintain accuracy. By establishing mathematical relationships between different force parameters through comparative testing, the system enables precise control of rivet gun forces through press testing data
Data Source
AI summary
A system and a method include a component formed of a material. The component has one or more first holes. A test piece is formed of the material. The test piece has one or more second holes. A first tool is configured to insert one or more first fasteners into one or both of the first hole(s) or the second hole(s). A second tool is configured to insert one or more second fasteners into one or both of the first hole(s) or the second hole(s). One or more force sensors are coupled to one or both of the component or the test piece. The force sensor(s) are configured to detect (a) one or more first aspects of one or more first forces exerted during operation of the first tool to insert the first fastener(s) into one or both of the first hole(s) or the second hole(s), and (b) one or more second aspects of one or more second forces exerted during operation of the second tool to insert the second fastener(s) into one or both the first hole(s) or the second hole(s). A control unit is in communication with the force sensor(s), and is configured to correlate the first aspect(s) of the first force(s) with the second aspect(s) of the second force(s).