Abstract: An electromagnetic coil assembly particularly suited for use in high-acceleration impact devices includes an inner hub having a flat metal and dielectric strip wound thereabout to form a coil, and an outer body mounted about the inner hub against one side of the coil. Inner and outer coil leads are formed by flat 90° bends of the inner and outer ends of the coil strip, such that the coil leads extend axially away from the coil toward one end of the coil assembly. Recesses are formed in the end faces of the inner hub and outer body at this end of the assembly, and the coil leads are folded into these recesses and attached by lug connectors to a pair of electrical conductors that lead out the side of the coil assembly. The coil leads and conductors are secured in the recesses, preferably by potting them in place.

Abstract: An apparatus for assembling panel-shaped workpieces such as aircraft wing panels includes a traveling gantry that supports a tool-holding frame on which are supported a plurality of tools such as drills, riveters, rivet shavers, inspection tools, and the like. The frame is movable along a plurality of axes and is rotatable about at least one axis for positioning the tools in relation to the workpiece. The apparatus also includes a fixture for holding a workpiece, the fixture comprising a plurality of slidable holders that can be extended or retracted along a horizontal direction generally perpendicular to the surfaces of a wing panel or the like. The holders have clamps and/or vacuum cups for engaging the workpiece to hold the workpiece in a desired position. The holders are retractable to create a clearance between the workpiece and the holders to allow the frame to be passed through the clearance.

Abstract: The present invention relates to a pressure foot that applies a clamping pressure to an area undergoing drilling or fastening operations on a joint formed by a first panel and a second panel. The pressure foot includes a front clamp for pressing against a front side of the area undergoing the drilling or fastening operations, and a carriage for moving the front clamp along a length and width of the joint formed by the first panel and the second panel.

Abstract: The present invention relates to a tool position detection assembly that aligns a tool relative to a feature within a lap joint of a first panel and a second panel. The detection assembly includes an indexing device engageable to the feature. The indexing device includes a reflecting member having a width. The assembly also includes an end-effector movable along at least one axis parallel to the lap joint for positioning the tool. The end-effector has a dual laser device for detecting when the device is aligned with the reflecting member.

Abstract: The present invention relates to vacuum fastened guide that supports and facilitates movements of a machining device along at least one component to be operated upon. The guide includes a primary rail that is vacuum coupled to the component. The primary rail includes a primary tube portion for slideable engagement with the machining device, and a primary contact platform coupled to the primary tube portion for forming a vacuum between the primary rail and the component.

Abstract: The present invention relates to a bucking bar that upsets a shank of a rivet. The bucking bar includes an L-shaped bucking die having a wide section and a thin angular section capable of sliding between an obstacle and the shank. The L-shaped bucking bar consists of Tungsten Carbide. The bucking bar also includes a bucking bar arm coupled to the wide section of the L-shaped bucking die for positioning the thin angular section of the bucking die between the obstacle and the shank of the rivet.

Abstract: The present invention relates to a bucking bar assembly that positions a bucking bar for clamping a first panel and a second panel along a lap joint and upsets a rivet to fasten the first panel to the second panel at the lap joint. The assembly includes a lateral carriage system for moving the bucking bar along a length of the lap joint, and a rotational carriage system for rotating the bucking bar relative to the lateral carriage.

Abstract: The present invention relates to a portable process for automated fastening of aircraft structures. The invention will employ two primary elements for locating and installing through-the-skin fasteners. Inside and outside units are attached onto an airframe and indexed to each other through coordination holes that have been pre-drilled through the structure. The aircraft structure is assembled with the pre-drilled coordination holes by aligning adjacent airframe parts and inserting alignment pins. The alignment pins will provide a degree of clamping to pull the parts together and provide indexing for inside and outside vacuum attachment track systems. The invention is equipped to traverse along the track system, accurately position itself, and drill only or countersink a hole, insert a fastener, and fasten, i.e., upset a rivet, or run down a threaded nut, then reposition itself to the next fastener location and repeat the process.

Abstract: The present invention relates to a protrusion sensor that determines the acceptability of a rivet within a component. The sensor includes a baseline detector which remains stationary, a movable detector which moves with a bucking bar module and produces a first signal proportionate to a distance between the baseline detector and the movable detector, and a CPU electronically connected to the movable detector and receiving the first signal.

Abstract: A process for seating a tight-fitting headed fastener in a hole in a workpiece so that the head of the fastener contacts the surface of the workpiece. The process includes inserting a distal end of the fastener, opposite its headed end, into the hole so that the distal end is tightly wedged into the hole and the headed end of the fastener is spaced from the workpiece surface. A driver of an electromagnetic impulse actuator is extended into contact with the fastener head, and the position of the driver when it is in contact with the fastener head is sensed and recorded to determine how far the fastener must be driven into the hole to seat the fastener head against the workpiece surface. A desired off-set distance of the driver from the fastener head is calculated which will result in seating of the fastener when the electromagnet impulse actuator is actuated, but will not cause excessive impact of the fastener head with the workpiece surface.

Abstract: An automated hole inspection system for measuring, on a plurality of planes, the diameter of a hole in a workpiece includes a hole gauge for measurement of a hole diameter in one plane, and a remote centering compliance device connected to the proximal end of the probe for allowing the probe to move laterally, perpendicularly to the probe axis, to self-center in the hole. A center locking device locks the remote centering compliance device on the axis of the probe after the probe has self-centered in the hole. A rotary actuator rotates the remote centering compliance device to rotate the probe to a new desired plane for making an additional diameter measurement in the hole.

Abstract: An automated assembly machine for fabricating large mechanical structures including a floor assembly jig for receiving and holding parts in a desired orientation, a pair of carriages, a first drive mechanism for independently driving the carriages longitudinally, a second drive mechanism for moving the carriages vertically, a tool tray mounted on the carriages, and a plurality of tools, including a drill, a hole diameter measurement probe, a nut runner, and an electromagnetic riveter, mounted on the tool tray for lateral movement toward and away from a workpiece clamp-up position. The tools are positioned at the workpiece clamp-up position by moving one of the carriages longitudinally along the floor assembly jig and raising the other carriage to elevate the tool tray to a desired elevation.

Abstract: An automatic liquid lubricant application device for applying a liquid lubricant to the inside of a hole in a workpiece includes an applicator for insertion into the hole for application of the lubricant. The applicator includes a perforated tube surrounded by a sleeve of wicking material. A shoulder surrounding the applicator is sized to engage the workpiece on the marginal portions around the hole. The shoulder is mounted for limited axial movement when pressed against the workpiece. A fluid flow channel connected at one end to a source of lubricant is connected at the other end to the perforated tube. A flow control device for controlling the flow of lubricant in the channel is actuated by axial movement of the shoulder when engaging the workpiece.