Split-Head Fastener Installation with Remote Actuation Base
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Solution Overview
Problem
Existing fastener installation tools require operators to lift and support the weight of the actuation base during lockbolt installation, leading to fatigue and inefficiency, especially during multiple fastener installations.
Innovation Solution
A fastener installation device with a separate tool head and pneumatic/hydraulic actuation base connected only by flexible hoses, allowing the operator to lift only the tool head, thereby relieving the burden of the base structure, utilizing a system where air lines control a reverse-acting pneumatic cylinder and hydraulic lines operate a puller-type tool head.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the actuation base is integrated with the tool head, then structural stability is improved, but operator fatigue increases due to having to lift and support the base weight during installation
Solution Approach 1:
The fastener installation device is divided into two separate components: a tool head and an actuation base. The tool head contains the fastener installation mechanism while the actuation base houses the pneumatic motor and drive system. These components are connected via a drive shaft and coupling mechanism, allowing the operator to hold only the lightweight tool head while the heavier actuation base remains stationary on the work surface, thereby eliminating operator fatigue from supporting base weight.
Solution Approach 2:
A drive shaft and coupling mechanism serve as intermediaries between the actuation base and tool head. The drive shaft transmits rotational force from the pneumatic motor in the base to the fastener installation mechanism in the tool head, while the coupling ensures reliable power transmission. This intermediary system allows the components to function together as a unified tool while remaining physically separable, resolving the contradiction between structural stability and ease of operation.
2Reliability
If the base structure is made robust to house pneumatic and hydraulic systems, then system reliability is improved, but device weight increases making it difficult for operators to handle
Solution Approach 1:
The heavy actuation base containing the pneumatic motor and control systems is separated from the tool head. The base remains stationary and provides reliable power, while the tool head weighs only a fraction of the total system. This segmentation allows the robust base structure to maintain system reliability without requiring the operator to handle its full weight, as the operator only manipulates the lightweight tool head portion.
3Strength
If the tool head and base are connected by rigid linkages, then mechanical strength is improved, but flexibility and ease of positioning are reduced
Solution Approach 1:
A drive shaft with coupling mechanisms serves as the intermediary connection between the actuation base and tool head. This intermediate power transmission system provides sufficient mechanical strength to transmit torque from the pneumatic motor while allowing the tool head to be positioned flexibly at various orientations and distances from the base. The coupling mechanism ensures reliable power transmission without requiring rigid fixed positioning, thus maintaining both strength and flexibility.
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
This design significantly reduces operator fatigue and speeds up the installation process by allowing the base to be supported separately, enabling faster and less tiring multiple fastener installations.
Implementation Method 1
air to be applied under pressure to the top of the air piston in the base
Implementation Method 2
hydraulic fluid in the hydraulic line attached to the tool head causing a piston in the tool head to move
Data Source
AI summary
A fastener application device comprising an hydraulically-operated tool head held by an operator and having an actuator trigger, a base structure having an air-operated power cylinder operatively attached to an hydraulic cylinder to supply hydraulic pressure to the tool head in response to operation of the actuator trigger. The tool head and base structure are connected only by air and oil lines that are long enough to allow the base structure to be supported on, for example, a workbench, requiring the tool operator to support only the weight of the tool head during a fastener installation sequence.