Vacuum Alignment Tool for Fastener Collar Positioning
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Solution Overview
Problem
Existing fastening systems require a multi-step process with manual alignment and positioning, leading to inefficiencies and increased time due to narrow tolerances, which can result in incorrect fastening if components are not aligned properly.
Innovation Solution
A vacuum alignment tool coupled with a fastening system that uses a suction force to automatically align and position a collar on a bolt, eliminating the need for separate alignment of the collar and swaging tool with the bolt by holding the collar within a bore and applying suction through a vacuum channel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment and positioning is used to meet narrow tolerances, then manufacturing precision is improved, but productivity deteriorates due to time-consuming multi-step processes
Solution Approach 1:
The patent combines the collar feeding system and swaging tool alignment into a single integrated tool that performs both functions simultaneously. The collar is fed and positioned onto the bolt while the swaging tool is aligned in the same operation, eliminating the need for separate manual alignment steps and thereby improving productivity without sacrificing precision.
Solution Approach 2:
The tool incorporates automatic collar feeding and positioning mechanisms that eliminate the need for technician intervention. The system self-aligns the collar with the bolt and positions it within narrow tolerances through automated mechanical guides and positioning features, maintaining precision while dramatically reducing cycle time.
2Manufacturing precision
If manual positioning is used to achieve narrow tolerances, then manufacturing precision is improved, but loss of time increases due to repeated adjustments and rework
Solution Approach 1:
The collar feeding system pre-positions the collar onto the bolt with precise alignment before the swaging operation begins. The tool is designed with built-in alignment features that automatically establish correct positioning in advance, eliminating the need for time-consuming manual adjustments and reducing the risk of misalignment that would require rework.
3Productivity
If automated vacuum alignment is used, then productivity is improved through single-step operation, but device complexity increases due to additional vacuum system components
Solution Approach 1:
The vacuum alignment tool is designed as a multi-functional device that combines collar feeding, positioning, and swaging operations in a single integrated tool. This universal tool performs multiple functions that would otherwise require separate devices, improving productivity while the vacuum mechanism serves as a compact alignment aid rather than adding significant complexity.
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 simplifies the fastening process to a single step, reduces cycle time, increases repeatability, decreases defects, and lowers costs by automating the alignment and positioning of fasteners.
Implementation Method 1
a vacuum source coupled to the vacuum receiving portion and configured to apply a suction force through the vacuum channel to hold at least the portion of the first fastener within the aperture
Data Source
AI summary
In one aspect, a vacuum alignment tool for holding and aligning a first fastener with a second fastener is provided. The vacuum alignment tool includes a main body including an end wall having an aperture disposed therein configured to receive at least a portion of the first fastener. The vacuum alignment tool also includes a vacuum receiving portion coupled to the main body. The vacuum receiving portion including a vacuum bore disposed therein, wherein a vacuum channel extends within the main body and within the vacuum receiving portion between the aperture and the vacuum bore.