Seal Cap End Effector for Automated Fastener Installation
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Solution Overview
Problem
Automating the installation of pre-molded seal caps onto fasteners extending from a surface is challenging due to complex movements involved in retrieving, positioning, and installing the caps, especially when the caps are filled with sealant, which increases the complexity of the process.
Innovation Solution
An end effector system comprising a frame, cap-dispenser assembly, and cap-placement assembly with a plunger mechanism and gripper fingers that are rotatable and translatable to grasp, position, and release pre-molded seal caps, allowing for automated installation on fasteners, supported by a robot for sequential operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual installation of pre-molded seal caps is performed, then installation flexibility and adaptability are maintained, but labor intensity increases and productivity decreases
Solution Approach 1:
The end effector is divided into distinct functional modules: a cap-dispenser assembly for cap supply, a cap-placement assembly for positioning, and a plunger mechanism for installation. Each module performs a specific function, allowing the system to achieve automation while maintaining manageable complexity through functional segmentation.
Solution Approach 2:
The end effector is designed as a multi-functional device that can retrieve caps from the dispenser, position them over fasteners, and install them using the plunger mechanism. This universal design consolidates multiple operations into a single automated tool, improving productivity without requiring separate systems for each function.
2Extent of automation
If complex movements are implemented for retrieving and positioning seal caps, then automated installation capability is achieved, but device complexity and difficulty of operation increase
Solution Approach 1:
The cap-dispenser assembly and cap-placement assembly are merged into a single integrated end effector structure. The dispenser and placement mechanisms work in coordinated sequence, reducing the number of separate operations and simplifying the overall automated process while maintaining full automation capability.
Solution Approach 2:
The end effector acts as an intermediary device between the cap supply source and the fastener installation point. It retrieves caps from the dispenser, holds them temporarily, positions them over the fastener, and installs them using the plunger. This intermediary function simplifies the automation by providing a buffer and coordination point in the process.
3Reliability
If sealant filling is performed in pre-molded end caps, then sealing functionality is improved, but installation complexity and automation difficulty increase
Solution Approach 1:
The seal caps are pre-filled with sealant before being supplied to the end effector. This preliminary action ensures proper sealing functionality is already in place, eliminating the need for complex sealant dispensing mechanisms during the automated installation process. The end effector simply installs the pre-prepared caps, maintaining reliability while reducing installation complexity.
Data Source
AI summary
An end effector for installing pre-molded seal caps onto fasteners comprises a cap-dispenser assembly and a cap-placement assembly. The cap-placement assembly comprises a main housing and a plunger mechanism, comprising an outer plunger housing and an inner gripper. The inner gripper is rotatable relative to the outer plunger housing between a cap-retaining configuration and a cap-releasing configuration. The plunger mechanism is selectively translatable from an extended position to a retracted position and from the retracted position to the extended position. The main housing is selectively rotatable from a cap-receiving position, in which the plunger mechanism is aligned with the seal-cap-delivery-sleeve central axis, to a cap-installing position, in which the main housing is angularly displaced from the cap-receiving position, and from the cap-installing position to the cap-receiving position.