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.