Multi-Drilling Electromagnet for Simultaneous Rivet Assembly
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Solution Overview
Problem
Current manufacturing techniques for assembling airplane fuselage sections are inefficient, requiring manual operation by multiple individuals and lacking the ability to perform tasks simultaneously, which hampers speed and efficiency in the assembly process.
Innovation Solution
The method involves using an electromagnet and magnetically attractive backing plates to clamp and secure components, with robotic end effectors for simultaneous drilling, fastener insertion, and driving, allowing for the simultaneous operation of multiple fasteners across overlapping fastener receiving zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operations are used for drilling, fastener insertion, and securing, then ease of operation is maintained, but productivity is low and assembly speed is slow
Solution Approach 1:
The patent combines multiple separate manual operations (drilling, fastener insertion, and securing) into a single automated apparatus that performs all three functions simultaneously. The electromagnet assembly integrates the drilling mechanism, fastener delivery system, and securing mechanism into one unified device that can process multiple fasteners in parallel, thereby dramatically increasing productivity while managing complexity through functional integration.
Solution Approach 2:
The apparatus is divided into distinct functional modules: an electromagnet assembly for drilling, a fastener delivery system, and a securing mechanism. Each module can be independently controlled and optimized, allowing the system to perform multiple operations simultaneously while maintaining ease of operation through modular design.
2Loss of time
If multiple individuals work manually to accomplish fastening operations, then ease of operation is maintained, but loss of time increases due to sequential operations
Solution Approach 1:
The automated apparatus enables continuous operation by performing drilling, fastener insertion, and securing in an uninterrupted sequence without the transitions and coordination delays inherent in manual multi-person operations. The system maintains continuous productive action across all fastening operations, eliminating idle time between steps.
Solution Approach 2:
The electromagnet is positioned and clamped onto the workpiece before drilling begins, and the apparatus is pre-configured with all necessary fasteners. This preliminary positioning and preparation eliminate setup time during the actual fastening process, allowing immediate commencement of simultaneous multi-point operations.
3Manufacturing precision
If electromagnet and backing plate are used to clamp components, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces traditional mechanical clamping systems with an electromagnet-based clamping mechanism. The electromagnet uses magnetic fields instead of mechanical linkages, levers, or screws to achieve precise positioning and secure clamping of the workpiece. This substitution maintains manufacturing precision while reducing mechanical complexity.
Solution Approach 2:
The electromagnet allows for precise control of clamping force through electrical parameter adjustment. By varying the electrical current to the electromagnet, the system can precisely control the magnetic attraction force, thereby achieving accurate positioning and appropriate clamping pressure without complex mechanical adjustment mechanisms.
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 approach significantly increases the speed and efficiency of the assembly process by enabling simultaneous drilling, insertion, and securing of multiple fasteners, reducing the need for manual labor and enhancing the overall manufacturing speed while maintaining safety and security.
Implementation Method 1
The electromagnet is activated for thereby being attracted to the aligned and magnetically attractive backing plate member in the interior or inboard side of the airplane fuselage for thereby substantially clamping the two components together
Data Source
AI summary
Method and apparatus for assembling, with fasteners, components of a structure having an outboard side, an inboard side, and a supporting frame. The components are placed together on the frame. An electromagnet having a core with multiple openings is positioned on the outboard side. A magnetically attractive member is placed against the inboard side opposite and aligned with the electromagnet. When activated, the electromagnet is attracted towards the magnetically attractive member and the two hold the components together. Multiple drill members pass through the openings in the core of the electromagnet and multiple openings are drilled simultaneously through the components. Subsequently, multiple rivets or huck bolts are simultaneously inserted into the drilled openings.