Swage Tool Pressure Sensing for Fastener Completion Detection
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Solution Overview
Problem
Automated fastener installation in aircraft assembly is inefficient due to varying completion times and the need for labor-intensive inspection of millions of fasteners, leading to prolonged processing times.
Innovation Solution
A system that uses pressure measurements from a hydraulic system to determine the completion of fastener installation, allowing the automated tool to halt operations early and facilitating the detection and reporting of successful and unsuccessful installations, thereby optimizing the installation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the automated installation tool waits for the expected maximum installation time to complete, then the installation process is ensured to finish, but the overall installation speed decreases
Solution Approach 1:
The system continuously monitors hydraulic pressure during the installation process and uses this feedback to determine when the fastener installation is actually complete. When the pressure stabilizes or drops below a threshold, the system automatically stops the installation cycle, rather than waiting for a predetermined maximum time. This real-time feedback mechanism allows the system to adapt to actual installation conditions and terminate operations as soon as completion is detected, resolving the contradiction between ensuring reliable completion and maintaining high installation speed.
2Reliability
If technician inspection of all fasteners is performed manually, then installation quality is ensured, but labor intensity and time consumption increase
Solution Approach 1:
The system performs self-inspection by automatically monitoring hydraulic pressure during each installation cycle and determining whether the fastener was successfully installed. The controller analyzes pressure data to identify successful installations versus failures, eliminating the need for manual technician inspection of every fastener. This self-service capability maintains installation quality through automated quality control while dramatically reducing labor intensity and inspection time.
3Force
If hydraulic pressure is maintained at high levels throughout the installation cycle, then the installation force is sufficient, but energy consumption increases and unnecessary pressure application occurs
Solution Approach 1:
The system dynamically adjusts hydraulic pressure based on real-time detection of installation completion. Rather than maintaining constant high pressure throughout the entire installation cycle, the system monitors pressure feedback and reduces or stops pressure application as soon as the fastener installation is detected as complete. This dynamic pressure adjustment ensures sufficient installation force is applied when needed while minimizing energy consumption by eliminating unnecessary pressure application after installation completion.
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
The system enables faster installation of large numbers of fasteners by avoiding wait times for maximum installation times and provides efficient detection and reporting of installation outcomes, enhancing the overall efficiency of the automated installation process.
Implementation Method 1
a sensor that detects pressure changes over time in the hydraulic system
Data Source
AI summary
Systems and methods are provided for inspecting installation of a fastener. One method includes monitoring hydraulic pressure of a tool that is installing the fastener, detecting that the hydraulic pressure has dropped by more than a threshold amount within a period of time, determining that a pintail of the fastener has snapped in response to the detecting, and reducing the hydraulic pressure in response to the determining.