Automated Seal Cap Installation for Fastener Alignment
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Solution Overview
Problem
The manual installation of pre-molded seal caps onto fasteners is cumbersome and time-consuming, negatively impacting manufacturing cycle time and cost in assembly processes such as those in aircraft construction.
Innovation Solution
An apparatus comprising a plunger mechanism, a feed system, and a take-up mechanism that automates the sequential removal and installation of pre-molded seal caps from a carrier strip onto fasteners, ensuring proper alignment and spacing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual installation of pre-molded seal caps is performed, then flexibility and simplicity are maintained, but productivity and manufacturing cycle time are reduced
Solution Approach 1:
The automated installation system performs the seal cap installation task autonomously without requiring manual intervention. The plunger mechanism automatically positions and installs seal caps onto fasteners, while the feed system continuously supplies seal caps from a carrier strip, enabling the system to serve itself in completing the installation process efficiently
Solution Approach 2:
The patent replaces the manual mechanical operation with an automated mechanical system. The plunger mechanism uses controlled mechanical motion to install seal caps, and the feed system uses automated mechanisms to transport seal caps from the carrier strip, substituting human manual labor with programmed mechanical systems that improve productivity
2Manufacturing precision
If manual installation of pre-molded seal caps is performed, then equipment simplicity is maintained, but manufacturing precision and alignment consistency deteriorate
Solution Approach 1:
The automated installation system incorporates feedback mechanisms that monitor and control the positioning and installation of seal caps. The system can detect alignment status and adjust the plunger mechanism accordingly to ensure consistent precision, maintaining high manufacturing precision through closed-loop control rather than relying solely on operator skill
Solution Approach 2:
The feed system performs preliminary actions by pre-positioning seal caps on the carrier strip and automatically transporting them to the correct location before installation. The plunger mechanism is pre-configured with the proper installation trajectory and force parameters, ensuring that each seal cap is installed with consistent alignment precision before the actual installation occurs
3Loss of time
If manual installation of pre-molded seal caps is performed, then operational simplicity is maintained, but loss of time and labor costs increase
Solution Approach 1:
The feed system enables continuous operation by continuously supplying seal caps from the carrier strip to the plunger mechanism without interruption. The automated system maintains continuous useful action throughout the installation process, eliminating the intermittent pauses and setup time associated with manual installation, thereby significantly reducing total installation time
Data Source
AI summary
A method of installing pre-molded seal caps onto fasteners that extend from a surface comprises sequentially delivering the pre-molded seal caps, arranged on a carrier strip, to a plunger mechanism via a feed system. The method also comprises sequentially removing the pre-molded seal caps from the carrier strip using the plunger mechanism, operating in concert with the feed system. The method further comprises individually installing the pre-molded seal caps onto selected ones of the fasteners using the plunger mechanism.