Multi-Function End Effector for Automated Fastener Continuity Testing

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Solution Overview

Problem

Current methods for verifying the electrical grounding of fasteners in aircraft are manual, time-consuming, and prone to errors, making it impractical to check the electrical resistance of each fastener in large structural assemblies.

Innovation Solution

A multi-function end effector mounted to a movable platform that integrates a continuity tester to automatically verify the electrical path between fasteners and the structure during installation, ensuring accurate and consistent resistance measurements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual resistance meter measurement is used to verify electrical grounding of fasteners, then measurement capability is achieved, but productivity is severely reduced and human error increases

Engineering Contradiction:

Improvemeasurement accuracyVSAvoidverification speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the manual mechanical resistance meter measurement system with an automated electrical testing system. The continuity tester automatically performs electrical continuity testing between fasteners and the structure, eliminating manual operations while maintaining measurement accuracy. This substitution enables high-speed automated verification without the human error associated with manual measurements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The testing system performs self-verification through automated continuity testing. The system automatically positions test leads, executes measurements, and records results without requiring manual intervention for each fastener. This self-service capability dramatically increases productivity while maintaining consistent measurement accuracy across all fasteners.

Inventive Principle:

Principle #25Self-service

2Measurement precision

If manual resistance meter measurement is used for each fastener, then individual verification is possible, but loss of time increases due to the large quantity of fasteners

Engineering Contradiction:

Improveelectrical resistance measurementVSAvoidverification time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The automated continuity tester enables continuous verification of electrical grounding across all fasteners without interruption. The system systematically moves from one fastener to the next, performing measurements in continuous sequence rather than discrete manual operations. This continuous action maintains measurement precision while dramatically reducing the total time required to verify all fasteners in large assemblies.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system performs preliminary positioning and setup of test leads and equipment before beginning the verification process. Once configured, the automated system executes the complete measurement sequence without requiring repeated manual setup for each fastener. This preliminary action eliminates time-consuming repetitive setup while maintaining measurement precision throughout the verification process.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If automated end effector with continuity tester is used, then productivity and accuracy are improved, but device complexity increases

Engineering Contradiction:

Improveverification efficiencyVSAvoidtesting system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The end effector is designed as a multi-functional device that combines fastener installation capabilities with integrated continuity testing. The same automated positioning and control system used for fastener installation also manages the continuity testing operation. This multi-functionality increases productivity by combining operations while managing device complexity through shared control architecture rather than separate independent systems.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Enables automated and accurate verification of electrical continuity in fasteners, reducing human error and increasing efficiency in large-scale structural assemblies.

Implementation Method 1

a standalone ohmmeter module mounted to the end effector frame adjacent to the process tools and configured to measure a magnitude of electrical resistance of an electrical path between each fastener and the structure

Methodology Applied

Scientific EffectElectrical Resistance: Electrical Resistance

Implementation Method 2

a continuity tester configured to determine the existence of an uninterrupted electrical path between a fastener and the structure after installation of the fastener

Methodology Applied

Scientific EffectElectrical Conduction: Conduction (electrical)

Data Source

PatentUS12461170B2Multi-function end effector and method for testing the electrical continuity between a structure and a fastener

Publication Date: 2025.11.04 THE BOEING CO

AI summary

An end effector has an end effector frame configured to be mounted to a movable platform capable of positioning the end effector relative to a structure. In addition, the end effector has a plurality of process tools mounted to the end effector frame and having different functional capabilities associated with hole formation and fastener installation in the structure. Furthermore, the end effector has a continuity tester configured to determine the existence of an uninterrupted electrical path between a fastener and the structure after installation of the fastener.