Laser Projection Fastener Installation Automation
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Solution Overview
Problem
Existing methods for installing fasteners in manufacturing, such as in aircraft assembly, are time-consuming, unreliable, and costly due to manual entry and checking of installation requirements, which often result in lost information if not recorded properly.
Innovation Solution
A system using a laser projection apparatus to project instruction sets onto structures, captured by a camera, which determines the identifier and retrieves the corresponding installation instructions for torque, swage force, or preload, programming a tool for precise fastener installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual methods are used to check tables and enter fastener installation requirements, then the process is simple to implement, but it is time-consuming and unreliable with high risk of information loss
Solution Approach 1:
The patent uses optical scanning to create digital copies of fastener collar identifiers (part numbers, lot numbers) directly from the physical fastener collars. This automated copying process eliminates manual data entry and ensures accurate capture of installation requirements, resolving the contradiction between reliability and complexity by using technology to improve reliability while the systematic approach keeps complexity manageable
Solution Approach 2:
The patent replaces manual mechanical processes (hand-checking tables, manual data entry) with an automated optical scanning and image processing system. The camera-based system captures identifiers, and software automatically processes the images to extract installation parameters, substituting human labor with automated technological systems to improve reliability
2Productivity
If manual tables are used to track and monitor fasteners, then the method is easy to implement, but it is expensive and time-consuming
Solution Approach 1:
The fastener collar identifiers are designed to be self-identifying through optical scanning. The system automatically captures, processes, and extracts installation parameters from the fastener collars themselves without requiring external manual intervention. This self-service capability eliminates time-consuming manual data entry and verification steps, directly addressing the productivity-time loss contradiction
Solution Approach 2:
The system performs preliminary automated capture and processing of fastener identifier information before the actual installation process. By pre-capturing part numbers, lot numbers, and installation parameters through optical scanning and image processing, the system eliminates the need for time-consuming manual data entry during installation, improving productivity while reducing time loss
3Loss of information
If package information is not entered into a data system, then storage space is saved, but installation information is lost when the package is opened
Solution Approach 1:
The system creates digital copies of fastener installation information by optically scanning and capturing identifiers directly from the fastener collars themselves, rather than relying on package labels. This direct copying ensures information is captured at the source and stored in a digital system, preventing information loss while maintaining appropriate automation levels
Solution Approach 2:
The patent introduces an intermediary optical scanning and image processing system that bridges the physical fastener collar and the digital data system. This intermediary captures identifier information from the fastener itself and translates it into digital format for storage and retrieval, ensuring information retention without requiring manual intervention
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 method automates the fastener installation process, reducing human error, increasing efficiency, and ensuring accurate adherence to installation parameters, thereby improving the reliability and cost-effectiveness of the fastening process.
Implementation Method 1
projecting, by means of a laser projection apparatus, an identifier of an instruction set
Implementation Method 2
capturing, by means of a fastener installation apparatus which includes a camera, an image of the projected identifier from the structure
Data Source
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AI summary
A system (102) is provided that includes a laser projection apparatus (206) and a fastener insallation apparatus (114). The laser projection apparatus is configured to project an identifier (110) of an instruction set including one ore more instructions for installing a fastener or fastener collar on a structure (106), with the laser projection apparatus being configured to project the identifier onto the structure about a location at which the respective fastener or fastener collar is to be installed. The fastener installation apparatus (114) is configured to capture an image of the projected identifier (110) from the structure, determine the identifier from the captured image, and retrieve the instruction set based on the determined identifier. The fastener insallation apparatus (114) includes a tool (114) for installing the respective fastener or fastener collar, and the fastener installation apparatus is configured to program the tool according to the retrieved instruction set.