One-Sided Fastener Assembly Verification Without Backside Inspection
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Solution Overview
Problem
Manual installation of fastener assemblies, particularly those requiring sealant, is time-consuming, costly, and prone to errors due to the need for backside inspection, which is not accessible in all structures and is not suited for automated machines.
Innovation Solution
A predictive verification model using a processor to determine if fastener assembly hole characteristics and installation values are within predetermined ranges, allowing for one-sided fastener installation and verification, reducing the need for blind backside inspection by using a fastening system with a grip gage, nutrunner, and processor to measure and verify installation parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual installation techniques are used for fastener assemblies requiring sealant, then the fastener can be installed correctly, but the installation is time-consuming and prone to errors due to backside inspection requirements
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated verification system that uses sensors and processors to detect fastener installation parameters (such as torque, angle, and depth) automatically, eliminating the need for time-consuming manual backside inspection while maintaining installation accuracy
Solution Approach 2:
The system implements real-time feedback by monitoring installation parameters during the fastening process and providing immediate verification, allowing operators to confirm correct installation without waiting for backside inspection, thus improving both reliability and productivity
2Reliability
If backside inspection is performed to verify fastener installation, then installation correctness can be confirmed, but large equipment is required which is not accessible to all parts of a structure
Solution Approach 1:
Instead of inspecting from the back side (traditional approach), the patent inverts the verification approach by using sensors and detection devices on the accessible front side to measure installation parameters and verify fastener correctness, eliminating the need for large inspection equipment
Solution Approach 2:
The patent introduces intermediary sensing elements and verification devices that can be positioned on the accessible side of the structure to indirectly verify fastener installation quality without requiring direct access to the back side, thus avoiding the need for large complex inspection equipment
3Reliability
If backside inspection is required to verify fastener installation, then installation correctness can be confirmed, but the inspection is costly and time-consuming
Solution Approach 1:
The patent performs verification actions during or immediately after the installation process itself, rather than requiring a separate subsequent inspection step. The system captures and analyzes installation parameters in real-time, providing immediate verification and eliminating the need for separate time-consuming backside inspection procedures
Data Source
AI summary
Methods and systems for installing and verifying installation of a fastener assembly using predictive verification. A method includes receiving, at a processor, at least one fastener assembly hole characteristic of a fastener assembly hole. The method further includes determining, via the processor, whether the at least one fastener assembly hole characteristic is within a predetermined range of fastener assembly hole variable and, upon determining the at least one fastener assembly hole characteristic is within the predetermined range of fastener assembly hole variables, transmitting instructions, via the processor, to a fastening device to initiate installation of a fastener assembly in the fastener assembly hole. The processor then receives at least one installation value of the fastener assembly and determines via the processor, whether the installation value is within a predetermined range of fastener installation variables.