Automated Frangible Collar Installation with Debris Capture
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Solution Overview
Problem
Current methods for installing frangible collars in manufacturing environments are labor-intensive and generate foreign object debris, as the nut portion often breaks off uncontrollably, posing risks and inefficiencies, especially in automated manufacturing settings where robotic integration is desired.
Innovation Solution
An automated system comprising an end effector with an attachment system, element loader, element installer, and removal system, which loads and installs frangible collars onto threaded fasteners, applies torque to break off the nut portion at a selected threshold, and captures the nut portion for disposal, reducing manual labor and debris.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual installation of frangible collars is performed, then the process allows flexibility and control, but it is labor-intensive and time-consuming
Solution Approach 1:
The patent replaces manual mechanical installation with an automated end effector system that uses a motorized rotatable member to apply torque to the frangible collar. This substitution maintains control through automated torque application while eliminating manual labor and increasing installation speed.
Solution Approach 2:
The frangible collar's nut portion automatically breaks off when the predetermined torque threshold is reached during the automated installation process. This self-service mechanism eliminates the need for manual intervention to separate the collar from the fastener, improving productivity while maintaining controlled torque application.
2Productivity
If automated installation of frangible collars is implemented, then productivity increases and labor is reduced, but the nut portion may break off in an uncontrolled manner creating foreign object debris
Solution Approach 1:
The patent introduces a retaining member as an intermediary component that captures the nut portion when it breaks off during automated installation. This mediator prevents the nut portion from becoming uncontrolled foreign object debris while allowing the automated installation process to proceed at high speed.
Solution Approach 2:
The patent converts the potentially harmful uncontrolled breakoff of the nut portion into a beneficial controlled process. By using a retaining member to capture the broken nut, the system transforms what would be harmful debris into a contained byproduct, allowing automated high-speed installation without creating safety hazards.
3Manufacturing precision
If torque control is applied during frangible collar installation, then precise control is achieved, but it requires manual operation and reduces productivity
Solution Approach 1:
The patent replaces manual torque control with an automated motorized system that applies precise torque through a rotatable member. This substitution maintains manufacturing precision in torque application while eliminating the need for manual operation, thereby increasing productivity.
Solution Approach 2:
The frangible collar is designed with a predetermined torque threshold that causes automatic separation when reached. This self-service feature eliminates the need for continuous manual torque monitoring and adjustment, allowing automated high-speed installation while maintaining precise torque control through the motorized system.
Data Source
AI summary
A method and an end effector for installing an element over a member associated with an object. An end effector may be attached to the object. The element may be loaded onto an element installer by an element loader of the end effector. The element may be installed onto the member associated with the object by the element installer.