Multi-Piece Fastener Installation With In-Process Swage Verification
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Solution Overview
Problem
The existing methods for installing structural fasteners, such as lockbolts, often result in improper deformation of the fastening collar onto the pin, leading to inefficient and inaccurate verification of proper installation, requiring additional steps and tools like swage gauges, which are time-consuming and subjective.
Innovation Solution
A multi-piece fastener system comprising a fastening collar and a pin with structural features of differing configurations, along with a programmable hardware device in an installation apparatus that measures load and stroke length to determine if the collar has been properly deformed onto the pin's features during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional structural fasteners are installed using conventional methods, then the fastening process can be completed, but the verification of proper installation is inaccurate and time-consuming requiring additional tools like swage gauges
Solution Approach 1:
The patent incorporates sensors that provide real-time feedback during the fastening process, measuring parameters such as collar deformation, pin movement, and applied force. This feedback enables automated verification of proper installation without requiring separate inspection steps or additional tools like swage gauges, thereby improving measurement precision while reducing time loss.
Solution Approach 2:
The patent replaces manual mechanical verification methods (such as visual inspection with swage gauges) with electronic sensing and measurement systems. Sensors detect collar deformation, pin position, and force application, converting mechanical installation verification into electronic signals that can be automatically analyzed, thus improving accuracy and eliminating time-consuming manual verification steps.
2Productivity
If conventional fastening methods are used, then the process is simple, but the collar deformation verification is subjective and requires additional verification steps
Solution Approach 1:
The installation apparatus is designed to perform multiple functions: applying the fastening force, measuring collar deformation, tracking pin movement, and verifying proper installation all in one integrated system. This multi-functionality eliminates the need for separate verification tools and steps, improving productivity while the modular design keeps the added complexity manageable through standardized sensor interfaces and automated decision logic.
3Manufacturing precision
If the collar is deformed onto the pin without precise control, then the fastening process is faster, but the positioning accuracy of the collar relative to the pin features is poor
Solution Approach 1:
The patent incorporates preliminary measurement and control actions during the fastening process. Before final collar deformation is complete, sensors detect the position of pin features (such as grooves or shoulders) and adjust the deformation process to ensure precise collar positioning. This preliminary control maintains manufacturing precision while the automated nature of the process keeps the overall procedure relatively simple.
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 efficient and accurate verification of proper fastener installation during the process, eliminating the need for additional verification steps and improving manufacturing efficiency by ensuring accurate collar positioning relative to the pin.
Implementation Method 1
deforming the fastening collar onto a shank of the pin
Implementation Method 2
measuring a load applied to the multi-piece fastener by the installation apparatus
Implementation Method 3
measuring a stroke length of the collet during installation of the multi-piece fastener
Data Source
AI summary
Multi-piece fasteners, multi-piece fastener installation apparatus, and methods of fastening are provided. The multi-piece fastener comprises a fastening collar and a pin. The fastening collar comprises a first collar end and a second collar end. A collar cavity extends from the first collar end to the second collar end. The pin is configured to be at least partially received by the collar cavity. The pin comprises a first pin end, a second pin end, and a shank extending intermediate the first pin end and the second pin end. The shank comprises a plurality of structural features. A first feature of the plurality of structural features has a first configuration and the second feature of the plurality of structural features has a second configuration. The first configuration and the second configuration differ.