Abstract: Self-retaining shim apparatus and methods for providing an offset surface for supporting a template above a contoured workpiece such as the frame of an aircraft are disclosed. In one embodiment, an apparatus includes a shim portion of substantially uniform thickness, and one or more biasing members secured to the distal end thereof and extending toward the proximal end. A work piece is positioned between the biasing member and shim portion such that the biasing members are elastically deformed, resulting in a restoring force exerted on the workpiece serving to retain the shim in engagement with the workpiece. Contact pads secure to the free ends of the biasing members and have a contact portion offset from the free end. The contact portion is rounded to facilitate mounting and retention of the self-retaining shim.

Abstract: A portable, air powered drill has an automated feed system and an adjustable dwell for producing countersunk holes in a workpiece. The feed system uses hydraulic cylinders and pneumatic control logic to control the feed rate, and the dwell time of a countersink drill bit at the end of the drill stroke. A movable mechanical stop permits an operator user to adjust countersink depth. The control logic provides fully automatic feed of the drill bit, and adjustment of the dwell time to consistently produce identical countersunk holes in a variety of workpiece materials.

Abstract: A drill clamp comprising a clamp mechanism and a hole-locating pin. The clamp mechanism has a first clamp portion and a second clamp portion. The second clamp portion includes a drill-receiving opening sized for receiving a drill bit. The hole-locating pin is operatively connected to the first clamp portion. The clamp mechanism is adapted and configured for movement of the first and second clamp portions relative to each other between clamped and unclamped positions. The hole-locating pin is farther from the drill-receiving opening when the clamp mechanism is in the unclamped position than when the clamp mechanism is in the clamped position. The hole-locating pin and the drill-receiving opening are aligned with one another when the clamp mechanism is in the clamped position.

Abstract: A pneumatic motor trigger actuator includes a trigger housing adapted to engage a pneumatic motor trigger of a pneumatic tool. A top plate is coupled to the trigger housing. A primary valve is coupled to the top plate and has an open configuration and a closed configuration. The primary valve is pneumatically coupled to the trigger housing such that air flow through the primary valve, when the primary valve is in the open configuration, enters the trigger housing and causes a plug to physically engage the motor trigger with sufficient force to move it to is fully engaged position. The primary valve includes a primary switch and an automatic stop switch. The primary switch is engagable by an operator to configure the primary valve in the open configuration. The automatic switch is engagable by an object to move the primary valve to the closed configuration when a predetermined condition is met.

Abstract: An apparatus for forming features in a workpiece is provided. The apparatus includes a nosepiece that engages a boss of a template and guides a tool member therethrough. The nosepiece includes a housing and an adjustable member positioned at least partially in an interior space of the housing. The adjustable member defines radial apertures that hold locking members such as spherical bearings. The locking members are configured to contact a tapered portion of the inner surface of the housing so that as the adjustable member is adjusted from an unlocked position to a locked position, the locking members contact the tapered portion of the housing and are urged radially inward to retain the boss.

Abstract: An apparatus for forming features in a workpiece is provided. The apparatus includes a nosepiece that engages a boss of a template and guides a tool member therethrough. The nosepiece includes a housing and an adjustable member positioned at least partially in an interior space of the housing. The adjustable member defines radial apertures that hold locking members such as spherical bearings. The locking members are configured to contact a tapered portion of the inner surface of the housing so that as the adjustable member is adjusted from an unlocked position to a locked position, the locking members contact the tapered portion of the housing and are urged radially inward to retain the boss.

Abstract: A power feed attachment that has a coupling structure to couple it to a hand held drill. A double-acting cylinder, which has a piston and a rod, and is fixedly coupled to the coupling structure. A two-position valve assembly is configured for directing a pressurized fluid to the double-acting cylinder. When the two-position valve assembly is in a first position is directs a fluid to a first side of the piston moving the piston to a first position. When the two-position valve assembly is in the second position it directs the pressurized fluid to a second side of the piston to move the piston to a second position. An arm is coupled to the piston. A control mechanism having a housing and a control rod, wherein the control rod is movable within the housing of the control mechanism between an extended position and a retracted position.

Abstract: A power feed attachment that has a coupling structure to couple it to a hand held drill. A double-acting cylinder, which has a piston and a rod, and is fixedly coupled to the coupling structure. A two-position valve assembly is configured for directing a pressurized fluid to the double-acting cylinder. When the two-position valve assembly is in a first position is directs a fluid to a first side of the piston moving the piston to a first position. When the two-position valve assembly is in the second position it directs the pressurized fluid to a second side of the piston to move the piston to a second position. An arm is coupled to the piston. A control mechanism having a housing and a control rod, wherein the control rod is movable within the housing of the control mechanism between an extended position and a retracted position.

Abstract: An apparatus having a controllable dwell for drilling and or countersinking a hole in a workpiece is provided which generally comprises a feed mechanism, a retraction mechanism, and a dwell mechanism. The feed mechanism is configured to feed a spindle from a starting position to a predetermined feed limit during a feed cycle. The retraction mechanism is configured to retract the spindle from the feed limit to the starting position to complete the feed cycle. The dwell mechanism is in communication with the retraction mechanism and comprises a mechanical bias member that stores energy during at least a portion of the feed cycle, wherein the mechanical bias member releases at least a portion of the energy once the spindle reaches the feed limit. The retraction mechanism is only actuated once the spindle reaches the feed limit and the mechanical bias member releases at least a portion of the energy.

Abstract: An axial feed apparatus having an adjustable feed stop is provided. The axial feed apparatus generally comprises a power feed module having an adjustable stop mechanism engaged therewith, wherein the adjustable stop mechanism may comprise a spindle threadedly engaging the power feed module. An adjustable depth-controlling device is further included intermediate the spindle and the power feed module, which uses a series of calibrated graduations in communication with the spindle such that a rotational change in the engagement of the graduations moves the spindle by a predetermined axial distance and thereby adjust the position of the feed stop for the power feed module. Such a power feed module may be combined with a drill motor to produce a device capable of drilling/countersinking holes in a workpiece.

Abstract: The drill/countersink nosepiece assembly of the present invention permits the fabrication of a precise hole and countersink in a structural assembly workpiece in a single operation with the aid of a drill plate or other hole template. The small size of the nosepiece tip enables multiple holes to be closely spaced without interference between drill plate engagement slots. A close fit between the shaft of the rotating drill/countersink bit and the inner surface of the sleeve prevents the bit from wandering upon repeated or heavy use. The drill/countersink nosepiece comprises a combination drill/countersink bit to be received by a drill motor chuck, a bushing to be received by a fixed housing portion of the drill motor, a sleeve telescopically mounted within the bushing, a spring within the bushing to bias the sleeve forward, and fingers or other features at the end of the sleeve for engaging an alignment slot in a drill plate.

Abstract: The wedgelock of the present invention prevents the separation of structural members during drilling or other fabrication operations on structural assemblies with curved surfaces or thickness variations and precludes the formation of burrs and delaminations which might result from such separation. The wedgelock also permits more precise and repeatable hole and other feature fabrication by more precisely locating an alignment fixture, such as a drill plate, relative to a structural assembly upon which fabrication operations are to be performed. The bushed spring loaded wedgelock comprises a standard, commercially-available wedgelock modified by attaching a bushing within which a spring loaded spacer is telescopically mounted. Like a standard wedgelock, the bushed spring loaded wedgelock is inserted through collinear holes in a drill plate or other alignment fixture and a structural assembly to clamp the assembly to the fixture.