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 and potential errors.
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 or unsuccessful installations, thereby reducing overall installation time and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the automated installation tool waits for the expected maximum installation time to complete, then all fasteners are installed, but the installation process takes longer than necessary
Solution Approach 1:
The system continuously monitors hydraulic pressure during the swaging operation and uses this feedback to detect when the fastener installation is actually complete. When the pressure stabilizes or drops below a threshold, the system immediately terminates the operation, eliminating the need to wait for the predetermined maximum time to elapse.
Solution Approach 2:
The hydraulic pressure monitoring system automatically detects completion of the swaging operation and triggers termination without requiring external intervention or timing mechanisms. The system serves itself by using its own operational parameters (pressure) to control its own termination.
2Productivity
If the automated installation tool operates quickly without monitoring, then installation time is reduced, but detection of successful or unsuccessful installations becomes difficult
Solution Approach 1:
The hydraulic pressure monitoring provides continuous feedback during the swaging operation, enabling the system to detect whether the fastener installation was successful. By analyzing pressure patterns (stabilization indicating success, unexpected drops indicating failure), the system reliably determines installation outcome without slowing down the process.
Solution Approach 2:
The patent replaces manual inspection methods with automated hydraulic pressure monitoring to detect installation completion and success. This substitution enables rapid automated detection of fastener installation states without requiring physical inspection of each fastener.
3Reliability
If manual inspection of fasteners is performed, then installation quality is ensured, but labor intensity and time consumption increase significantly
Solution Approach 1:
The patent replaces manual visual inspection with automated hydraulic pressure monitoring and analysis. The system uses pressure data to automatically determine whether each fastener installation was successful, eliminating the need for technicians to manually inspect each fastener while maintaining reliable detection of installation quality.
Solution Approach 2:
The system performs self-inspection by monitoring its own hydraulic pressure parameters during operation. Instead of requiring external manual inspection, the installation tool automatically evaluates its own performance by analyzing pressure patterns that indicate successful or unsuccessful fastener installation.
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 preventing unnecessary waiting for maximum installation time and provides accurate detection of installation states, enhancing the efficiency and reliability of the automated fastener 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.