Offset Collar Delivery for Low-Clearance Swage Tool Alignment

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Solution Overview

Problem

Automated fastener installation systems face challenges in aligning collars with lockbolts, particularly in low clearance environments and when holes are not optimally positioned, leading to mis-alignment and inefficiencies in the swaging process.

Innovation Solution

A collar delivery system for offset swage tools that aligns and places collars flush against the Inner Mold Line (IML) of a part before the lockbolt is inserted, using a pair of fingers with an inclined ramp and arcuate cut-out to ensure precise alignment and placement without air gaps, enabling swaging in low clearance areas.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a swage tool attempts to align and place a collar onto a lockbolt after the lockbolt is driven through the hole, then the collar placement can be performed, but mis-alignment occurs particularly in low clearance environments or when holes are not optimally positioned

Engineering Contradiction:

Improvecollar alignment precisionVSAvoidoperation difficulty in low clearance environments

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The collar is delivered and positioned on the lockbolt shaft before the lockbolt is driven through the hole. The collar delivery system places the collar on the shaft in advance, ensuring proper alignment is established before the locking operation begins, thereby preventing mis-alignment issues during the swaging process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

A collar delivery system with fingers acts as an intermediary mechanism between the collar and the lockbolt. The fingers hold and position the collar on the shaft, providing controlled alignment and placement that eliminates the mis-alignment problems encountered when attempting to align the collar after lockbolt insertion

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the collar is placed after the lockbolt is driven through the hole, then the locking operation can proceed, but the process requires re-attempts due to mis-alignment

Engineering Contradiction:

Improvefastener installation efficiencyVSAvoidcollar placement accuracy

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The collar is delivered and positioned on the lockbolt shaft before the lockbolt is driven through the hole. This preliminary placement ensures proper alignment is established before the locking operation begins, thereby preventing mis-alignment issues during the swaging process and eliminating the need for re-attempts

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The collar delivery system provides visual or sensor-based feedback to verify proper collar alignment and placement on the shaft before the lockbolt is driven. This feedback mechanism ensures that the collar is correctly positioned, preventing mis-alignment and reducing the need for re-attempts, thereby improving both reliability and productivity

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS11358211B2Offset collar delivery for swage tools

Publication Date: 2022.06.14 THE BOEING CO

AI summary

Systems and methods are provided for fastening via a swage tool. One embodiment is a method for fastening via a swage tool. The method includes steps of selecting a hole located at a part, aligning an axis of a lockbolt collar with a center of the hole, placing the lockbolt collar flush against the part at a first end of the hole, and swaging the lockbolt collar onto a lockbolt that has been driven through the hole. This securely fastens the lockbolt collar to the lockbolt.