Offset Collar Installation for Fasteners Under Aircraft Overhangs
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Solution Overview
Problem
Automated fastener installation systems face challenges in aircraft manufacturing due to the large number of fasteners required, complex geometries, and lateral deviations of fastener holes, which limit their ability to accurately and efficiently install collars under overhangs and in areas with angled holes.
Innovation Solution
A method and apparatus using an offset collar installer connected to a platform, which rotates about a central axis to position a collar offset from the axis, allowing for accurate installation of fasteners in holes under overhangs and those deviating from normal orientations by positioning the collar before pin insertion and swaging it to engage the pin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated fastener installation equipment is used, then productivity increases, but manufacturing precision deteriorates due to lateral deviation of fastener holes from normal orientation
Solution Approach 1:
The collar is positioned on the fastener hole before the pin is inserted, rather than after. This preliminary positioning allows the automated equipment to place the collar accurately even when the hole is angled, compensating for lateral deviation before the pin insertion process begins
Solution Approach 2:
The collar serves as an intermediary component that bridges the gap between the angled fastener hole and the pin. By positioning the collar first, it creates a reference surface that accommodates the lateral deviation, allowing subsequent pin insertion to proceed with maintained precision
2Loss of time
If automated equipment is used for fastener installation, then loss of time is reduced, but ease of operation deteriorates due to limited access under overhangs
Solution Approach 1:
The fastener installation process is segmented into distinct sequential steps: collar positioning first, then pin insertion. This segmentation allows the automated equipment to access the work area in stages, with the collar positioning step occurring before the pin insertion equipment needs to access the same confined space under the overhang
Solution Approach 2:
The collar is positioned as a preliminary action before pin insertion. This preliminary positioning of the collar creates space and establishes a reference that facilitates subsequent pin insertion, allowing automated equipment to operate effectively in areas with limited access under overhangs
3Productivity
If automated fastener installation is performed, then productivity increases, but manufacturing precision deteriorates due to lateral deviation of fastener holes
Solution Approach 1:
The collar is positioned on the fastener hole before the pin is inserted. This preliminary action allows the system to compensate for lateral deviations in hole orientation by establishing the collar position first, then accommodating the angled pin insertion without compromising overall assembly precision
Solution Approach 2:
The system accepts and accommodates variations in hole orientation parameters (angularity from normal) by allowing the collar to be positioned first, then inserting the pin at the actual measured angle rather than requiring perfect normal orientation. This parameter flexibility maintains precision despite manufacturing variations
Data Source
AI summary
A method for installing a fastener system. A position on a structure relative to an overhang on the structure is automatically sensed for installing a fastener system in a hole using an offset collar installer. The offset collar installer is moved about a rotation axis to the position such that a collar in the fastener system is held in the position over the hole. The offset collar installer is connected to a platform and rotatable about the rotation axis. The collar is fastened to an engagement feature for a bolt in the hole.