Instrumented Fastener Light Beacon for 3D Assembly Alignment
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Solution Overview
Problem
Existing methods for aligning and positioning assembly systems in aircraft airframe structures are imprecise, providing only two-dimensional guidance and lacking the ability to identify specific structural locations, which hinders precise assembly and testing operations.
Innovation Solution
The use of intelligent fasteners equipped with light sources that produce encoded light beacons to guide both internal and external assembly systems into precise alignment, providing three-dimensional positioning information and enabling autonomous assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional vision system cameras and magnet centroid finders are used for alignment, then the assembly system can be positioned and aligned, but the precision is limited to two-dimensional guidance and cannot identify specific structural locations
Solution Approach 1:
The patent introduces an optical target as an intermediary element that is attached to the structural component. This optical target serves as a mediator between the assembly system and the structure, providing encoded three-dimensional positioning information that enables precise alignment while identifying specific structural locations. The optical target reflects or emits light signals that contain positional data, allowing the vision system to accurately determine both the location and orientation of the structure.
2Stability of the object's composition
If passive tacks are used for stabilization during assembly, then components can be stabilized, but they cannot identify the specific structural location in which they are placed
Solution Approach 1:
The patent merges the stabilization function of passive tacks with the positioning function of optical targets. The optical target is integrated with or attached to the tack fastener, combining two previously separate functions into a single component. This allows the fastener to both stabilize the component during assembly and provide encoded information about its specific structural location through the optical target's position and orientation data.
3Productivity
If automated assembly systems are used, then assembly productivity is improved, but precise positioning and alignment information is difficult to obtain and maintain
Solution Approach 1:
The patent applies preliminary action by pre-attaching optical targets to the structural components before the automated assembly process begins. These optical targets are positioned at known, precise locations on the structure, establishing a reference framework in advance. When the automated assembly system approaches, the vision system can immediately detect these pre-positioned targets and calculate accurate three-dimensional positioning and alignment information, enabling the automated system to operate with high precision without requiring complex real-time measurement systems.
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
This solution enhances the precision and accuracy of assembly operations by allowing both assembly systems to align correctly based on the encoded light beacons, facilitating precise installation of fasteners and improving the overall assembly process.
Implementation Method 1
one or more light sources (e.g., light-emitting diodes) configured to produce a light beacon
Data Source
Figure 1
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AI summary
An instrumented fastener (e.g., a "tack" fastener (130,130A-130E)) includes one or more light sources (e.g., light-emitting diodes (210,212)) configured to produce a light beacon (132,132A,132B) that includes encoded information regarding the instrumented fastener (e.g., part number), wherein the direction of the light beacon can be used to align external and/or internal assembly systems (110) to the instrumented fasteners (130). The light beacon (132) may be activated automatically, or via an instruction received from an external system. Once aligned, the assembly system may, for example, proceed with installing permanent fasteners between neighboring tack fasteners.