Swage Tool Pressure Feedback for Fastener Completion Detection

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Solution Overview

Problem

Automated fastener installation processes in aircraft assembly are inefficient due to varying completion times, requiring manual inspection and prolonged operation based on worst-case scenarios, which increases labor and time consumption.

Innovation Solution

A pressure-based control system that monitors hydraulic pressure changes during fastener installation, allowing the swage tool to halt operations when a predetermined pressure drop indicates completion, thereby enabling immediate progression to the next operation and reducing overall installation time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the automated installation tool operates based on worst-case scenario timing, then all fastener installations can be accounted for, but the installation process becomes slower and less efficient

Engineering Contradiction:

Improveaccounting for all fastener installationsVSAvoidinstallation speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system continuously monitors hydraulic pressure during fastener installation and uses this feedback to determine when installation is complete. The pressure sensor provides real-time data to the controller, which adjusts the operation timing based on actual installation status rather than predetermined worst-case scenarios, thereby improving both reliability and productivity

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces mechanical timing mechanisms with a sensor-based detection system. Instead of relying on mechanical timers or fixed cycle times, the system uses hydraulic pressure sensors to detect installation completion, substituting mechanical time-based control with sensor-based condition monitoring

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If manual inspection is performed on all installed fasteners, then installation quality can be verified, but labor time and costs increase significantly

Engineering Contradiction:

Improveinstallation quality verificationVSAvoidinspection time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The fastener installation system performs self-verification through automated sensor monitoring. The hydraulic pressure sensor and controller work together to automatically detect and record installation completion, allowing the system to verify its own work without requiring external manual inspection, thus maintaining quality assurance while eliminating time loss

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual visual inspection with automated sensor-based detection. The hydraulic pressure sensor system automatically monitors and records installation parameters, substituting the manual inspection process with an automated electronic detection system that provides equivalent or superior verification capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If the swage tool waits for maximum installation time before proceeding, then all installations are completed properly, but the overall process time increases

Engineering Contradiction:

Improveproper fastener installationVSAvoidwait time between operations

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system dynamically adjusts the installation timing based on real-time hydraulic pressure readings. Rather than using fixed wait times, the controller continuously monitors pressure changes and determines the optimal moment to proceed to the next operation, making the timing flexible and adaptive to actual installation conditions, thereby reducing unnecessary wait time while ensuring proper installation

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The hydraulic pressure sensor provides continuous feedback to the controller during the installation process. This feedback allows the system to detect when installation is complete based on pressure drop patterns, enabling the tool to proceed immediately after completion rather than waiting for a predetermined maximum time, thus eliminating unnecessary delays

Inventive Principle:

Principle #23Feedback

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 approach enhances the efficiency of fastener installation by allowing the swage tool to move on to the next operation promptly upon detecting completion, thus saving time and reducing labor-intensive inspections.

Implementation Method 1

described herein provide systems and methods which are capable of determining whether or not installation of a fastener has completed, based on pressure measurements for a hydraulic system that drives an automated installation tool

Methodology Applied

Scientific EffectPressure detection:

Data Source

PatentEP3626361B1Sensor based control of swage tools

Publication Date: 2023.01.18 THE BOEING CO

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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.