Abstract: A method of of fabricating an electromagnet is provided in which a core having a flux return backplate on one end and a cover plate on the other end of the core is provided. For example, the flux return backplate may be fixed to one end of the core and the cover plate may be fixed to the other end of the core. A plurality of layers of wire may then be wound about the core between the flux return backplate and the cover plate, prior to fixing a flux return ring to the cover plate to at least partially enclose the wire.

Abstract: A method for inserting fasteners fastener in a hole defined by a workpiece is provided. The method aligns an opening defined by an insertion tube with the hole defined by the workpiece, generates air flow through the insertion tube in a direction toward the workpiece, places the fastener into the insertion tube and carries the fastener into the hole defined by the workpiece as a result of the air flow through the tube. In order to prevent the fastener from inhibiting the air flow when the fastener is placed in the tub, air flow is permitted through openings about a circumferential surface of the tube.

Abstract: The method and apparatus for drilling holes and optionally inserting fasteners of the present invention provide for efficiently drilling holes through a multiple-layer structure because the layers are securely held together during the drilling by an electromagnet and a clamp, each on opposite sides of the structure. The electromagnet and clamp hold the layers together so tightly that burrs do not form within the holes and debris does not accumulate between the layers and, therefore the layers do not have to be disassembled after drilling. In addition, the apparatus and method of the present invention provide for initially drilling the hole with a countersink and for inserting a fastener into the hole, through the electromagnet, immediately after drilling the hole, such that the hole does not have to be revisited after reassembly and drying of the sealant in order to drill a countersink and/or insert a fastener.

Abstract: The method and apparatus for drilling holes and optionally inserting fasteners of the present invention provide for efficiently drilling holes through a multiple-layer structure because the layers are securely held together during the drilling by an electromagnet and a clamp, each on opposite sides of the structure. The electromagnet and clamp hold the layers together so tightly that burrs do not form within the holes and debris does not accumulate between the layers and, therefore the layers do not have to be disassembled after drilling. In addition, the apparatus and method of the present invention provide for initially drilling the hole with a countersink and for inserting a fastener into the hole, through the electromagnet, immediately after drilling the hole, such that the hole does not have to be revisited after reassembly and drying of the sealant in order to drill a countersink and/or insert a fastener.

Abstract: The electromagnetic clamp and method includes an electromagnet and a clamping piece located on opposite sides of a structure to clamp the structure. The electromagnet attracts the clamping piece through the structure when the electromagnet is energized, such that the electromagnet and clamping piece exert force on the structure, and an operation, such as drilling and/or fastener installation, may be performed on the structure. The configuration of the electromagnet creates the force necessary to securely clamp the structure. The electromagnet includes a coil and a core, and the core of the electromagnet is located within a longitudinal aperture that extends through the coil. The smallest lateral dimension of the core is chosen to maximize the flux density between the core and the clamping piece. As such, the smallest lateral dimension of the electromagnet may be greater than the distance between the clamping piece and the electromagnet.

Abstract: The method and apparatus for drilling holes and optionally inserting fasteners of the present invention provide for efficiently drilling holes through a multiple-layer structure because the layers are securely held together during the drilling by an electromagnet and a clamp, each on opposite sides of the structure. The electromagnet and clamp hold the layers together so tightly that burrs do not form within the holes and debris does not accumulate between the layers and, therefore the layers do not have to be disassembled after drilling. In addition, the apparatus and method of the present invention provide for initially drilling the hole with a countersink and for inserting a fastener into the hole, through the electromagnet, immediately after drilling the hole, such that the hole does not have to be revisited after reassembly and drying of the sealant in order to drill a countersink and/or insert a fastener.

Abstract: The electromagnetic clamp and method includes an electromagnet and a clamping piece located on opposite sides of a structure to clamp the structure. The electromagnet attracts the clamping piece through the structure when the electromagnet is energized, such that the electromagnet and clamping piece exert force on the structure, and an operation, such as drilling and/or fastener installation, may be performed on the structure. The configuration of the electromagnet creates the force necessary to securely clamp the structure. The electromagnet includes a coil and a core, and the core of the electromagnet is located within a longitudinal aperture that extends through the coil. The smallest lateral dimension of the core is chosen to maximize the flux density between the core and the clamping piece. As such, the smallest lateral dimension of the electromagnet may be greater than the distance between the clamping piece and the electromagnet.

Abstract: The method and apparatus for drilling holes and optionally inserting fasteners of the present invention provide for efficiently drilling holes through a multiple-layer structure because the layers are securely held together during the drilling by an electromagnet and a clamp, each on opposite sides of the structure. The electromagnet and clamp hold the layers together so tightly that burrs do not form within the holes and debris does not accumulate between the layers and, therefore the layers do not have to be disassembled after drilling. In addition, the apparatus and method of the present invention provide for initially drilling the hole with a countersink and for inserting a fastener into the hole, through the electromagnet, immediately after drilling the hole, such that the hole does not have to be revisited after reassembly and drying of the sealant in order to drill a countersink and/or insert a fastener.

Abstract: The method and apparatus for drilling holes and optionally inserting fasteners of the present invention provide for efficiently drilling holes through a multiple-layer structure because the layers are securely held together during the drilling by an electromagnet and a clamp, each on opposite sides of the structure. The electromagnet and clamp hold the layers together so tightly that burrs do not form within the holes and debris does not accumulate between the layers and, therefore the layers do not have to be disassembled after drilling. In addition, the apparatus and method of the present invention provide for initially drilling the hole with a countersink and for inserting a fastener into the hole, through the electromagnet, immediately after drilling the hole, such that the hole does not have to be revisited after reassembly and drying of the sealant in order to drill a countersink and/or insert a fastener.

Abstract: The method and apparatus for drilling holes and optionally inserting fasteners of the present invention provide for efficiently drilling holes through a multiple-layer structure because the layers are securely held together during the drilling by an electromagnet and a clamp, each on opposite sides of the structure. The electromagnet and clamp hold the layers together so tightly that burrs do not form within the holes and debris does not accumulate between the layers and, therefore the layers do not have to be disassembled after drilling. In addition, the apparatus and method of the present invention provide for initially drilling the hole with a countersink and for inserting a fastener into the hole, through the electromagnet, immediately after drilling the hole, such that the hole does not have to be revisited after reassembly and drying of the sealant in order to drill a countersink and/or insert a fastener.