Ultrasonic Transducer Bonding Tooling for Fastener Orientation Flexibility
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Solution Overview
Problem
The existing methods for bonding ultrasonic transducers to fasteners are inefficient and unreliable, requiring skilled technicians and precision equipment, leading to inaccuracies and slow production rates, especially when fasteners cannot be oriented for optimal bonding.
Innovation Solution
A low-cost transducer bonding tooling system that includes a self-centering vise and pressure pin mechanism, combined with temporary adhesive layers and protective caps, allows for precise positioning and bonding of ultrasonic transducers to fasteners, enabling reliable and quick attachment regardless of fastener orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual transducer bonding by skilled technicians is used, then placement precision can be achieved, but the process is very slow and tedious
Solution Approach 1:
The patent introduces a bonding tool as an intermediary device that includes a positioning mechanism with a flat surface and positioning features, along with a pressure applying mechanism. This tool mediates between the technician and the transducer-fastener system, automatically achieving precise placement and consistent bonding pressure without requiring skilled manual manipulation, thus resolving the contradiction between precision and speed.
Solution Approach 2:
The positioning mechanism in the bonding tool is designed with positioning features that automatically align and center the transducer on the fastener when the fastener is placed on the flat surface. The system serves itself by using the fastener's own geometry and the tool's positioning features to achieve precise placement without requiring skilled technician intervention, thereby increasing productivity while maintaining precision.
2Manufacturing precision
If manual transducer bonding is used, then some placement accuracy can be achieved, but bond line repeatability is poor
Solution Approach 1:
The bonding tool acts as an intermediary that standardizes the bonding process through its positioning mechanism and pressure applying mechanism. The tool ensures repeatable bond line thickness and quality by automatically controlling pressure distribution and maintaining proper alignment throughout the bonding process, eliminating the variability introduced by manual manipulation while keeping the operation simple.
Solution Approach 2:
The bonding tool controls critical bonding parameters such as pressure magnitude, pressure distribution, and alignment position through its mechanical design. By standardizing these parameters through the tool's structure rather than relying on technician skill, the process achieves repeatable bond lines while remaining easy to operate - the technician simply needs to place the fastener and activate the pressure mechanism.
3Adaptability or versatility
If traditional bonding methods are used, then transducers can be attached, but the fastener must be oriented with bonding surface facing up
Solution Approach 1:
The bonding tool is designed with universal adaptability to accommodate fasteners in various orientations. The positioning mechanism can be configured to support fasteners whether the bonding surface is facing up, down, or at an angle, making the tool versatile for different installation scenarios without requiring multiple specialized tools, thus achieving adaptability without excessive complexity.
4Manufacturing precision
If factory production methods are used, then high precision and reliability are achieved, but the cost and complexity are very high
Solution Approach 1:
The bonding tool serves as a simplified intermediary device that captures the essential functions of complex factory production systems - positioning, alignment, and pressure application - in a single, relatively simple tool. This allows field technicians to achieve factory-level precision without requiring the entire factory production system, thereby reducing complexity while maintaining precision.
Solution Approach 2:
The tool incorporates self-aligning positioning features that automatically compensate for minor variations in fastener placement, eliminating the need for complex adjustment mechanisms or highly skilled operators. This self-service capability maintains high precision while keeping the device relatively simple and easy to use in field conditions.
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 solution enables users to produce load indicating fasteners with precision and reliability similar to factory-produced ones, allowing for rapid and accurate load measurements, and can be applied to various small objects like identification labels, even on already installed fasteners.
Implementation Method 1
ultrasonic transducer to transmit and receive the acoustic waves effectively
Implementation Method 2
pulse-echo technique to determine the time-of-flight or acoustic length of the fastener
Implementation Method 3
the adhesive acts as an acoustic couplant and an electrical capacitive coupling to the bolt surface
Data Source
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AI summary
Low cost transducer bonding tooling and techniques are provided which can be used to duplicate the quality of factory manufactured load indicating members, and to allow transducers to be attached to fasteners irrespective of their orientation. The bonding tooling and techniques can also be used to bond other small objects requiring precise placement and reliable bonding such as, for example, the bonding of identification labels to manufactured components or structures.