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: 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: 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: An assembly comprising first and second structural elements having aligned holes, a fastener that occupies at least respective portions of the holes without a surrounding sleeve, and a mating part that is coupled to the fastener. The fastener comprises: a head; a circular cylindrical shank extending from the head; a mating portion comprising external projections; and a transition portion disposed between the shank and the mating portion. The transition portion comprises a tapered lead-in section that meets the shank at a shank/lead-in intersection and a radiused lead-in section that meets the tapered lead-in section. The tapered lead-in section tapers gradually in a first axial direction toward the mating portion and has a first profile that is linear and a taper angle equal to or less than 20 degrees, while the radiused lead-in section curves abruptly in the first axial direction and has a second profile that is a circular arc having a radius.

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, 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: A method and apparatus for preventing damage to a metal component that is susceptible to damage by electro-magnetic effects or reduce manufacturing assembly steps. An initial channel is formed through the metal component and is defined by an inner surface. A bushing is placed into the initial channel. An interference fit is created between the outer surface of the bushing and the inner surface of the initial channel through the metal component. A final channel is formed through the bushing. A fastener is placed into the final channel to attach the metal component to a second component, wherein electrical magnetic effects occur between the fastener and the bushing.

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 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 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: An assembly comprising first and second structural elements having aligned holes, a fastener that occupies at least respective portions of the holes without a surrounding sleeve, and a mating part that is coupled to the fastener. The fastener comprises: a head; a circular cylindrical shank extending from the head; a mating portion comprising external projections; and a transition portion disposed between the shank and the mating portion. The transition portion comprises a tapered lead-in section that meets the shank at a shank/lead-in intersection and a radiused lead-in section that meets the tapered lead-in section. The tapered lead-in section tapers gradually in a first axial direction toward the mating portion and has a first profile that is linear and a taper angle equal to or less than 20 degrees, while the radiused lead-in section curves abruptly in the first axial direction and has a second profile that is a circular arc having a radius.

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 assembly comprising first and second structural elements having aligned holes, an fastener that occupies at least respective portions of the holes without a surrounding sleeve, and a mating part that is coupled to the fastener. The fastener comprises: a head; a circular cylindrical shank extending from the head; a mating portion comprising external projections; and a transition portion disposed between the shank and the mating portion. The transition portion comprises a first radiused lead-in section that meets the shank at a shank/lead-in intersection and a second radiused lead-in section that meets the first radiused lead-in section. The first radiused lead-in section curves gradually in a first axial direction toward the mating portion and has a first profile that is a circular arc having a first radius, while the second radiused lead-in section curves abruptly in the first axial direction and has a second profile that is a circular arc having a second radius which is much smaller than the first radius.

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.

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 method (2000) of aligning a first body (302) and a second body (304) of a structure (300) comprises: preparing indexing pins (100); orienting the second body (304) so that second openings (308) extend vertically; orienting the first body (302) so that first openings (306) extend vertically; and aligning the first openings (306) with the second openings (308) so that a circumferentially closed contour (342), formed by each one of the first openings (306) and a corresponding one of the second openings (308) is large enough to receive a threaded portion (126) of any one of the indexing pins (100) with a clearance fit. The method (2000) further comprises: moving the first body (302) and the second body (304) toward each other; inserting the indexing pins (100) into the first openings (306); and applying a downward force on the indexing pins (100), while allowing the first body (302) and the second body (304) to move relative to each other.

Abstract: An indexing pin (100) comprises a central axis (154). The indexing pin (100) further comprises a threaded portion (126), extending along the central axis (154). The indexing pin (100) also comprises a stem (148), extending along the central axis (154) opposite the threaded portion (126). The indexing pin (100) further comprises a cylindrical surface (104), extending along the central axis (154) between the threaded portion (126) and the stem (148). The indexing pin (100) further comprises a tapered surface (112), extending between the threaded portion (126) and the cylindrical surface (104). The indexing pin (100) further comprises a flange (136), located between the stem (148) and the cylindrical surface (104).

Abstract: Systems and methods are provided for inspecting installation of a fastener. One method includes monitoring hydraulic pressure of a tool that is installing the fastener, detecting that the hydraulic pressure has dropped by more than a threshold amount within a period of time, determining that a pintail of the fastener has snapped in response to the detecting, and reducing the hydraulic pressure in response to the determining.