Laser Cleaning Head for Consistent Aircraft Nutplate Bonding
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Solution Overview
Problem
Manual surface preparation methods for removing coatings around nutplate installation areas on aircraft panels result in variations in bonding strength, leading to disbonded nutplates, affecting the efficiency and reliability of the assembly process.
Innovation Solution
An automated laser system is used to accurately remove coatings around predrilled holes on aircraft panels, employing a robotic arm, laser scanner, and vacuum connector to ensure precise coating removal and surface preparation, reducing manual intervention and variability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual surface preparation methods are used to remove coatings around nutplate installation areas, then the process is simple and flexible, but bonding strength consistency deteriorates leading to disbonded nutplates
Solution Approach 1:
The patent replaces manual mechanical surface preparation methods with an automated laser-based system. The laser cleaning apparatus uses optical energy to remove coatings from the understructure surface, eliminating human variability and achieving consistent bonding strength. The system includes a laser source, scanning mechanism, and automated positioning system that precisely control the cleaning process.
Solution Approach 2:
The patent changes the physical state and parameters of the coating removal process by using laser energy instead of manual mechanical methods. The laser parameters (power, pulse duration, scanning speed) are precisely controlled to achieve optimal coating removal while maintaining surface integrity for consistent adhesive bonding.
2Reliability
If automated laser system is used to remove coatings, then bonding strength consistency is improved, but device complexity increases
Solution Approach 1:
The automated laser system is designed to perform multiple functions: coating removal, surface preparation, and quality inspection. The same laser apparatus can be applied to different understructure geometries and coating types, reducing the need for multiple specialized tools and justifying the initial complexity through versatile application.
3Productivity
If automated laser system is used for coating removal, then installation time is reduced, but initial setup time and complexity increase
Solution Approach 1:
The system performs preliminary surface preparation automatically before nutplate installation, ensuring the surface is ready for immediate adhesive application. The laser cleaning process prepares multiple surfaces in sequence without manual intervention, reducing overall installation time despite the sophisticated setup required.
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 automated system enhances bonding strength consistency, reduces scrap, rework, and installation time by providing precise coating removal, thereby improving the efficiency and reliability of nutplate installation.
Implementation Method 1
produce and direct a laser onto a surface of one or more sections of understructure to remove at least a portion of a coating disposed on the surface
Data Source
AI summary
In one embodiment, systems and methods include using an automated laser system to remove a portion of a coating for nutplate installation. An automated laser system comprises a laser scanner and a laser head, wherein the laser head is coupled to the laser scanner. The laser head comprises a containment unit and a vacuum connector wherein the vacuum connector is disposed on a first side of the containment unit. The laser head further comprises a camera system, a light source, a first actuator, and a second actuator all disposed on a top surface of the containment unit. The laser head further comprises an end piece, wherein the second actuator is configured to displace the end piece.