Fastening Collar Installation with Mandrel Bending Noise Reduction
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Solution Overview
Problem
Installing a fastening collar securely onto a mandrel can be difficult, time-consuming, and often results in the intentional breaking of the mandrel, leading to significant acoustic energy release, which can be amplified by the structure.
Innovation Solution
A fastening collar installation apparatus comprising an anvil, a sleeve, and a lever, where the lever moves between positions to align and misalign axes, allowing the anvil to deform the collar onto the mandrel and bend it, reducing acoustic energy release by bending rather than breaking the mandrel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the mandrel is broken to install the fastening collar, then the collar can be securely installed, but significant acoustic energy is released and amplified by the structure
Solution Approach 1:
The patent changes the fundamental parameter of mandrel failure mode from brittle breaking to ductile bending. The anvil cavity is specifically designed with a curved surface that guides the mandrel to bend gradually during deformation, transforming the instantaneous high-energy breaking event into a progressive low-energy bending process, thereby significantly reducing acoustic energy release while maintaining installation security
Solution Approach 2:
The patent converts the harmful effect of mandrel breaking into a beneficial bending deformation. By designing the anvil cavity with a curved guide surface, the mandrel is intentionally guided to bend in a controlled manner during installation, transforming the harmful acoustic energy release from breaking into a beneficial controlled deformation process that achieves secure collar installation without excessive noise
2Reliability
If the mandrel is broken to install the fastening collar, then the collar can be securely installed, but the installation process becomes time-consuming
Solution Approach 1:
The anvil cavity is pre-designed with a specific curved geometry that anticipates and guides the mandrel deformation path. This preliminary design of the deformation path allows the mandrel to bend smoothly and predictably during installation, eliminating the need for complex real-time control or multiple adjustment steps, thereby reducing installation time while ensuring secure collar installation
3Reliability
If the mandrel is broken to install the fastening collar, then the collar can be securely installed, but the overall length and weight of the fastener system increase
Solution Approach 1:
The patent changes the mandrel end configuration from a broken state with protruding fragments to a bent state that tapers smoothly. The anvil cavity geometry is specifically designed to create a bent mandrel end that conforms to the collar inner surface, eliminating the need for additional length to accommodate broken pieces while achieving secure installation
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 apparatus simplifies the installation process, reduces installation time, and minimizes acoustic noise by bending the mandrel instead of breaking it, thereby reducing the overall length and weight of the fastener system.
Implementation Method 1
the first anvil end of the anvil is forcibly contacted with the fastening collar while the lever is in the first lever position, thereby deforming the fastening collar onto the mandrel
Implementation Method 2
The lever is moved to the second lever position, thereby misaligning the first and second axis and bending the mandrel
Data Source
AI summary
Fastening collar installation apparatus and methods of installing a fastener system are provided. The fastening collar installation apparatus comprises an anvil, a sleeve, and a lever. The sleeve comprises a first section comprising a first sleeve end and a second sleeve end, a sleeve cavity, and a slot. The first sleeve end is intermediate the anvil and the second sleeve end. The slot extends a first distance from the first sleeve end. The lever is slidably received by the slot of the sleeve and configured to move between a first lever position in the slot and a second lever position in the slot. The lever comprises a second distance from a first lever end to a second lever end. The second distance is less than the first distance.