Rivet Fastening System with Real-Time Height Feedback Control
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Solution Overview
Problem
The conventional method of driving rivets is inefficient in consistently achieving optimal tolerance, leading to under-driven or over-driven rivets, which can result in reduced material strength, costly rework, and potential damage to the airframe.
Innovation Solution
A system and method utilizing sensors and a feedback control system to measure the rivet's driven head height in real-time, communicating the rivet driving stage to operators through light indicators, and automatically controlling the rivet gun operation to prevent under-driving or over-driving.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manual rivet driving method is used, then operators can complete rivet installation quickly, but it is difficult to consistently achieve optimal tolerance and avoid under-driving or over-driving
Solution Approach 1:
The patent implements a feedback control system that uses sensors to measure rivet head height in real-time during the rivet driving process. The measured height is compared against target specifications, and the system automatically adjusts the rivet gun operation to maintain the rivet within tolerance limits, preventing both under-driving and over-driving while ensuring consistent quality.
Solution Approach 2:
The patent replaces the manual mechanical judgment and control by operators with an automated sensor-based measurement and control system. Optical or contact sensors automatically measure rivet head height, eliminating the need for operators to visually estimate or manually measure, thereby ensuring precise tolerance control without sacrificing installation speed.
2Reliability
If operators rely on visual inspection and manual control, then the equipment remains simple, but under-driven or over-driven rivets occur frequently
Solution Approach 1:
The system incorporates sensors that continuously monitor rivet head height during installation and provide real-time feedback to the control system. This automated feedback loop ensures consistent rivet quality by automatically detecting and correcting deviations from target specifications, eliminating reliance on operator skill and visual inspection while maintaining system simplicity through automated control.
Solution Approach 2:
The rivet driving system performs self-adjustment based on sensor feedback, automatically controlling the rivet gun to maintain proper rivet head height. The system monitors its own output and corrects deviations without external intervention, ensuring reliable quality consistency while adding minimal complexity through integrated sensor and control components.
3Object-affected harmful factors
If rivet driving is performed without real-time measurement, then the process is simple and fast, but material fatigue and airframe damage risks increase
Solution Approach 1:
The system uses sensors to provide real-time feedback on rivet head height during installation, enabling automatic adjustment of the rivet gun to prevent over-driving that could damage the airframe or cause material fatigue. The feedback control ensures rivets are driven to the correct specification without exceeding safe limits, eliminating the need for post-installation inspection while protecting the airframe.
Solution Approach 2:
The system performs preliminary measurement and control during the rivet installation process itself, detecting rivet head height in real-time and adjusting the driving process before damage can occur. This preventsive approach eliminates the need for complex post-installation inspection equipment while protecting the airframe from harmful over-driving effects.
Data Source
AI summary
A system and method for rivet setting comprising an anvil having an anvil face, a plunger having a sensor coupled to a control system that measures the distance between the anvil face and the work surface during the rivet setting process and stops the rivet driver when the driven rivet head achieves a desired head height above the work surface. In preferred embodiments, the control system also communicates the stage of the rivet driving cycle to the operators to expedite the rivet driving process.