Abstract: A method for installing a fastener system. A position on a structure relative to an overhang on the structure is automatically sensed for installing a fastener system in a hole using an offset collar installer. The offset collar installer is moved about a rotation axis to the position such that a collar in the fastener system is held in the position over the hole. The offset collar installer is connected to a platform and rotatable about the rotation axis. The collar is fastened to an engagement feature for a bolt in the hole.

Abstract: A plug gauge including a probe housing defining an internal volume and a longitudinal axis, the probe housing includes a first and second openings, a first contact element having a portion extending through the first opening, a first cam member defining a first axis of rotation, the first cam member being in camming engagement with the first contact element such that movement of the first contact element relative to the probe housing causes corresponding rotation of the first cam member about the first axis of rotation, a second contact element having a portion extending through the second opening, and a second cam member defining a second axis of rotation, the second cam member being in camming engagement with the second contact element such that movement of the second contact element relative to the probe housing causes corresponding rotation of the second cam member about the second axis of rotation.

Abstract: A plug gauge includes a housing, defining an internal volume, first openings, and second openings. The plug gauge includes first contact elements, each at least partially received in a respective one of the first openings. The plug gauge includes a first plunger in the internal volume and movable relative to the housing. The first plunger is biased to urge the first contact elements radially outward through the first openings. The plug gauge includes a first sensor sensing movement of the first plunger. The plug gauge includes second contact elements, each at least partially received in a respective one of the second openings. The plug gauge includes a second plunger in the internal volume and movable relative to the housing. The second plunger is biased to urge the second contact elements radially outward through the second openings. The plug gauge includes a second sensor sensing movement of the second plunger.

Abstract: An electromagnetic effect suppressing termination part for a fastener formed of a metallic material, the fastener having a head, a shank, and a male threaded portion opposite the head, has a metallic core coated by a layer of dielectric material. An internal bore of the termination part includes an inner wall, a counterbore hole, and a cavity disposed therebetween. An outer surface includes an outer wall, and a frustoconical wall positioned proximally relative to the outer wall, the frustoconical wall extending radially outwardly from the outer wall and having an included angle of less than approximately 90 degrees. A seal is disposed in the counterbore hole, and the frustoconical wall is configured so that a compressive force applied to the frustoconical wall deforms the inner wall to conform to the male threaded portion of the fastener and deforms the seal to fill the cavity.

Abstract: A method and system for installing a fastener system. A collar in the fastener system is automatically positioned on a hole on a first side of a structure prior to an insertion of a pin in the fastener system into the hole from a second side of the structure in which the pin has a pin tail. The pin with the pin tail is inserted through the collar in which the pin extends through the hole and the collar. A force is applied on at least one of the collar or the pin tail along a centerline extending centrally though the collar until the pin tail becomes separated from the pin such that the collar engages an engagement feature on the pin when the pin with pin tail is inserted into the hole from the second side.

Abstract: Systems and methods are provided for inspecting fastener installation. One embodiment is a method for inspecting installation of a fastener. The method includes determining an initial distance between a nose of a swage tool and an Inner Mold Line (IML) of a part, operating the swage tool to swage a collar onto a fastener that protrudes through the IML of the part, determining a terminal distance of the nose to the IML during swaging, prior to a pintail of the fastener breaking, and arriving at a conclusion indicating a state of a fastener installation, based on the terminal distance.

Abstract: An example end mill includes a shaft, a cutting head positioned on one end of the shaft, and an edge relief cutting head positioned on the shaft spaced apart from the cutting head. The portion of the shaft between the cutting head and the edge relief cutting head has a diameter that is less than the diameters of the cutting head and the edge relief cutting head. The end mill is rotated around a longitudinal axis of the end mill and revolved around a central axis of a hole to be cut, with the longitudinal axis radially offset from the central axis, to cut the hole with the cutting head and cut an edge relief in a leading edge of the hole with the edge relief cutting head.

Abstract: Provided is cutting tool. The tool, in certain examples, includes a drill body that defines a drill axis, and a tool window formed in the drill body. The tool also includes a drill bit extending from the drill body, and a material reworking attachment (“MRA”) coupled to the drill body and storable within the tool window. The MRA is extendable from a stored position into either a surface-finishing position or a material-removal position. The MRA includes a first chamfering blade, a second chamfering blade, and a finishing surface interposed between the chamfering blades. The tool also includes a position manager to detect a position of the cutting tool with reference to a workpiece, and an actuator to transition the MRA from the stored position to the material-removal position, followed by a transition to the surface-finishing position, and followed by a transition to material-removal position.

Abstract: A method for installing a fastener system. A position on a structure relative to an overhang on the structure is automatically sensed for installing a fastener system in a hole using an offset collar installer. The offset collar installer is moved about a rotation axis to the position such that a collar in the fastener system is held in the position over the hole. The offset collar installer is connected to a platform and rotatable about the rotation axis. The collar is fastened to an engagement feature for a bolt in the hole.

Abstract: A method for evaluating a surface of a bore formed in a structure, where the bore defines a bore axis. The method includes moving a probe at least partially through the bore in a first lineal direction about the bore axis while simultaneously rotating the probe about the bore axis. The probe includes a contact element contacting the surface of the bore at a plurality of first contact points as the probe moves in the first lineal direction.

Abstract: A compound contour vacuum track, and an automated fastening machine using the track, for automation of final assembly inside an aircraft fuselage. The track is mounted at an angle to a surface, such as an inside surface of the fuselage, wherein the surface has one or more holes through which fasteners are inserted. The automated fastening machine is mounted on the track to traverse the track while performing fastening functions and steps. The automated fastening machine includes a carriage, arm, and end effector, wherein the arm is mounted on the carriage and the end effector is mounted on the arm. The carriage is attached to the track for positioning the arm and end effector, the arm is attached to the carriage for positioning the end effector, and the end effector is attached to the arm for installing the fasteners into the holes of the surface.

Abstract: A method for installing a flexible track system is presented. At least one of a number of heights or a number of angles is selected for a variable height base system that connects a base attaching system and flexible tracks in the flexible track system to each other, wherein at least one of the number of heights or the number of angles for the variable height base system maintains at least one of a desired distance between the flexible tracks and a surface of a structure to which the base attaching system is attached to the flexible tracks in the flexible track system matching a contour of the surface of the structure. The flexible track system is attached to the surface of the structure.

Abstract: A plug gauge includes a housing defining an internal volume and a longitudinal axis AH. The housing includes an opening into the internal volume. The plug gauge also includes a contact element at least partially received in the opening. The plug gauge further includes a plunger at least partially received in the internal volume. The plunger is biased into engagement with the contact element to urge the contact element radially outward from the housing through the opening. The plug gauge additionally includes a sealing member between the contact element and the housing.

Abstract: A plug gauge includes a housing, defining an internal volume, first openings, and second openings. The plug gauge includes first contact elements, each at least partially received in a respective one of the first openings. The plug gauge includes a first plunger in the internal volume and movable relative to the housing. The first plunger is biased to urge the first contact elements radially outward through the first openings. The plug gauge includes a first sensor sensing movement of the first plunger. The plug gauge includes second contact elements, each at least partially received in a respective one of the second openings. The plug gauge includes a second plunger in the internal volume and movable relative to the housing. The second plunger is biased to urge the second contact elements radially outward through the second openings. The plug gauge includes a second sensor sensing movement of the second plunger.

Abstract: Systems and methods are provided for assembling a magazine for a swage tool. The method includes selecting a cartridge that comprises a first serpentine channel dimensioned for conveying collars, and further comprises an entrance and an exit of the first serpentine channel. The method also includes disposing the cartridge at a swage tool.

Abstract: A compound contour vacuum track, and an automated fastening machine using the track, for automation of final assembly inside an aircraft fuselage. The track is mounted at an angle to a surface, such as an inside surface of the fuselage, wherein the surface has one or more holes through which fasteners are inserted. The automated fastening machine is mounted on the track to traverse the track while performing fastening functions and steps. The automated fastening machine includes a carriage, arm, and end effector, wherein the arm is mounted on the carriage and the end effector is mounted on the arm. The carriage is attached to the track for positioning the arm and end effector, the arm is attached to the carriage for positioning the end effector, and the end effector is attached to the arm for installing the fasteners into the holes of the surface.

Abstract: A compound contour vacuum track, and an automated fastening machine using the track, for automation of final assembly inside an aircraft fuselage. The track is mounted at an angle to a surface, such as an inside surface of the fuselage, wherein the surface has one or more holes through which fasteners are inserted. The automated fastening machine is mounted on the track to traverse the track while performing fastening functions and steps. The automated fastening machine includes a carriage, arm, and end effector, wherein the arm is mounted on the carriage and the end effector is mounted on the arm. The carriage is attached to the track for positioning the arm and end effector, the arm is attached to the carriage for positioning the end effector, and the end effector is attached to the arm for installing the fasteners into the holes of the surface.

Abstract: A method of aligning a first body and a second body of a structure comprises orienting the first body so that first openings extend vertically and inserting indexing pins into the first openings. The method comprises orienting the second body so that the second openings extend vertically and aligning the second openings with the indexing pins. The method comprises moving the first body and the second body toward each other, while: allowing the first body and the second body to move relative to each other and applying a downward force to the indexing pins. The method comprises moving the first body and the second body toward each other until a first-body second surface contacts a second-body first surface, while applying the downward force to the indexing pins.

Abstract: A method of aligning a first body and a second body of a structure comprises orienting the second body so that second openings extend vertically and orienting the first body so that first openings extend vertically. The method comprises aligning the first openings with the second openings so that a circumferentially closed contour, formed by each one of the first openings and a corresponding one of the second openings is large enough to receive a threaded portion of any one of the indexing pins with a clearance fit. The method comprises moving the first body and the second body toward each other and inserting the indexing pins into the first openings. The method comprises applying a downward force on the indexing pins, while allowing the first body and the second body to move relative to each other.

Abstract: An electromagnetic effect suppressing termination part is provided for a fastener formed of a metallic material, the fastener having a head, a shank, and a threaded portion opposite the head. The termination part includes a main body defining an internally threaded portion configured to threadably receive the threaded portion of the fastener, the internally threaded portion defining a thread major diameter. A collar is coupled to a distal end of the main body by a frangible web, wherein the main body, collar, and frangible web are formed of a metallic core coated by a layer of dielectric material. The frangible web, when broken, presents an exposed portion of the metallic core, wherein the frangible web includes an inner surface radially outwardly offset from the thread major diameter of the internally threaded portion by a setback distance.