Offset Collar Installer for Angled Fasteners Under Overhangs
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Solution Overview
Problem
The challenge in aircraft manufacturing is the inefficiency and inaccuracy in automating the installation of fastener systems, particularly in areas with overhangs and non-normal hole orientations, which limits the effectiveness of current fastener installation systems and requires human intervention or increased time.
Innovation Solution
A fastener installation system comprising a platform with an offset collar installer that is rotatable and movable around a rotation axis, equipped with a bearing assembly, gear ring, and drive assembly, allowing it to position and fasten collars to bolts in holes under overhangs and accommodate angled bolt insertions, using a flexible track system for mobility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated fastener installation equipment is used, then productivity increases, but the equipment cannot accommodate holes deviating from normal orientation and requires manual intervention
Solution Approach 1:
The collar installer is designed with rotational capability about an axis, allowing it to dynamically adjust its orientation to accommodate bolts at various angles. The system can rotate the installer to different positions to match the specific orientation of each hole, enabling automated installation across diverse geometries without manual intervention.
Solution Approach 2:
The offset collar installer is designed as a universal device that can handle multiple types of fastener installations. By combining rotational movement with offset positioning capability, a single automated device can accommodate various hole orientations and positions, replacing multiple specialized tools or manual operations.
2Extent of automation
If automated collar installation equipment is used, then labor costs decrease, but the equipment cannot position collars accurately for angled bolts due to lateral deviation
Solution Approach 1:
The system employs dynamic rotational adjustment of the collar installer to compensate for lateral deviation caused by angled bolts. By rotating the installer to the correct orientation before collar installation, the system maintains high positioning accuracy regardless of the bolt's angle relative to the surface normal.
Solution Approach 2:
The patent replaces manual measurement and adjustment mechanisms with an automated rotational positioning system. The automated system uses rotational movement about an axis to calculate and achieve the correct collar position, eliminating the need for manual intervention while maintaining precision.
3Device complexity
If traditional fastener installation methods are used, then equipment simplicity is maintained, but cycle time increases due to manual intervention requirements
Solution Approach 1:
The collar installer incorporates rotational movement capability, allowing it to automatically adapt to different hole orientations. This dynamic adjustment eliminates the need for manual repositioning between fasteners, significantly reducing cycle time while maintaining relatively simple equipment architecture.
Solution Approach 2:
The automated collar installer performs its own positioning and orientation adjustment through rotational movement. The system automatically orients itself to match the bolt angle and positions the collar accurately without requiring external manual intervention, thereby reducing cycle time while keeping the equipment design straightforward.
4Reliability
If automated equipment is used for fastener installation, then consistency and quality improve, but the equipment cannot access areas with overhangs and limited space
Solution Approach 1:
The collar installer is designed with rotational capability that enables it to access and operate in restricted areas with overhangs. By rotating to appropriate angles, the installer can reach holes that are not accessible from a fixed position, maintaining consistent installation quality in previously difficult-to-reach areas.
Solution Approach 2:
The system adds a rotational dimension to the collar installer's degrees of freedom. This additional dimensional movement allows the equipment to access holes located in three-dimensional space, including areas with overhangs and limited clearance, while maintaining automated installation consistency.
Data Source
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AI summary
A system and 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 (310) is moved about a rotation axis (324) 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 (308) and rotatable about the rotation axis. The collar is fastened to an engagement feature for a bolt in the hole.