Split Tool Head Fastener Installation to Reduce Operator Fatigue
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Solution Overview
Problem
Existing fastener installation tools require operators to lift and support the weight of the actuation base during multiple fastener installations, leading to fatigue and reduced efficiency.
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 handle only the tool head during installation, thereby eliminating the need to lift the base.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the actuation base is integrated with the tool head as a single unit, then structural stability is improved, but operator fatigue increases due to having to lift and support the entire base structure during multiple fastener installations
Solution Approach 1:
The fastener installation device is divided into two separate components: a stationary actuation base containing the air cylinder and hydraulic system, and a mobile tool head containing the nose assembly. These components are connected via flexible hydraulic hoses and air lines, allowing the operator to handle only the lightweight tool head while the heavier base remains stationary on the work surface, thereby eliminating operator fatigue from lifting the base during multiple installations.
2Ease of operation
If the tool head and actuation base are separated and connected by flexible hoses, then operator fatigue is reduced, but device complexity increases due to additional connection components
Solution Approach 1:
The separation between the actuation base and tool head is bridged using flexible hydraulic hoses and pneumatic air lines. The air cylinder in the base generates pneumatic pressure that actuates a hydraulic piston, which in turn pressurizes hydraulic fluid transmitted through hoses to the tool head. This pneumatic-hydraulic linkage enables force transmission over flexible connections, maintaining system functionality while allowing physical separation of components.
3Adaptability or versatility
If the base structure is lifted and moved with the tool head, then positioning flexibility is improved, but installation speed decreases due to the time required to lift and reposition the heavy base for each fastener
Solution Approach 1:
By segmenting the device into a stationary base and mobile tool head, the system allows the tool head to be quickly repositioned to different fastener locations without moving the heavy base. The flexible hoses and air lines accommodate the movement of the tool head, enabling rapid repositioning and improving installation speed while maintaining positioning flexibility.
Solution Approach 2:
Flexible hydraulic hoses and pneumatic air lines serve as intermediaries between the stationary base and mobile tool head. These flexible connections transmit force and control signals while accommodating the movement and repositioning of the tool head, enabling rapid repositioning without requiring the base to be moved, thereby improving installation speed.
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 enhances installation speed and efficiency by allowing the operator to focus on handling the lighter tool head during multiple fastener installations.
Implementation Method 1
air to be applied under pressure to the top of the air piston in the base while air below the piston is exhausted. This in turn moves the hydraulic piston downward
Implementation Method 2
hydraulic lines connect the hydraulic oil in the base housing to the tool head where it acts on a puller piston
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.