General Electro-mechanical Corporation

Gemcor Engineering Corp.

Robert J Kellner

Mark J Andrews

Bradley M Roberts

Kurt R Kubanek

Thomas H Speller, Jr

Bernhard Kittelberger

Jeffrey P Weaver

David Michalewski

Mark F Cassidy, Jr

Thomas H Rummell

Mark J Catania

Steven Gross

James L Birke

James J Birke

Bradly M Roberts

Thomas E Burns

Riveting apparatus wherein a planetary roller screw delivers the high forces required for actuating the fastener upset tooling. In order that precise control of the entire upset operation may be obtained, a servo-controlled electric motor operates the actuator. In order that different machining operations may be performed on a workpiece without having to provide an actuator for each tool, the tools are engaged in turn by the actuator for performing riveting and other machining in succession.

Method and apparatus for actuating riveting tooling

A control system and method for automatic fastening machines wherein a multi-axes motion controller is utilized in place of the conventional PLC or CNC control to provide for virtually an immediate change in system response when the systems feedback devices indicate the need for variance. The major advantage of the process control approach of the present invention is that all system feedback information is controlled via a single on board processor thus eliminating any communication lag associated with multi controller applications. This also provides for an improvement in fastener installation cycle time. An additional advantage to the approach of the present invention is the elimination of many mechanical hard stops and their respective electrical position switch indicators, which in turn reduces the chance for machine breakdowns resulting in a greater increase in productivity. The new control architecture of the present invention is utilized to control an &ldquo;anti-wink&rdquo; automatic slug riveting process which improves fastening accuracy, reliability and cycle time. This technique of fastening provides for virtually no work piece movement during the forming process allowing for the use of rigid fixturing.

Method for automatic fastening machines

Apparatus for actuating tooling

An automatic fastening machine and method which reduces fastener installation cycle time by virtue of unique tool movements, pressure foot operation and other features. The pressure foot plate is coupled to actuators for moving the same in a manner allowing tilting of the plate relative to the plane of the workpiece during movement from one fastener installation location to another. The actuators are independently operated by a servo control arrangement in conjunction with the machine control. As a result, it is not necessary for the system to seek a new down position thereby saving machine cycle time. Sensors operatively associated with the actuators in conjunction with the machine control cause movement of the pressure foot plate in reaction to force applied to the workpiece during fastener installation to maintain the workline established by the position of the workpiece prior to application of force. The clamp of the lower ram is driven positively during both upward and downward strokes so as to save cycle time. The lower ram tool is rotated in a manner which does not interfere with other components on the lower ram assembly. A new and improved slug riveting process also is provided by the machine and method.

Automatic fastening machine and method

Control system and method for automatic fastening machines

The present invention relates to a system control for directing and monitoring the operation of an automatic fastening machine, such as automatic drilling and riveting machine, by gathering, recording, and processing relevant data from each drilling and riveting cycle. The cycle data then becomes part of a master record that is useful for logging maintenance schedules, for establishing real-time cycle trends and for historical purposes. Real-time cycle trends are particularly beneficial to effect corrections in subsequent cycles.

Statistical process control for an automatic fastening machine

In an automatic fastening machine for installing fasteners in a workpiece provided with a hole for receiving a fastener having a longitudinal axis, wherein a work axis extends through the hole and wherein the fastener is held in a holding position prior to installation in the hole so that the fastener is oriented with the longitudinal axis thereof parallel to the work axis, a method and apparatus for detecting tipped or mis-oriented fasteners while in the holding position and prior to being upset in the workpiece, the method and apparatus utilizing at least one beam of energy which is influenced by the fastener orientation. Energy is radiated along at least one path intersecting the fastener when in the holding position and the radiated energy is received and a response is given to the amount of energy interrupted by the fastener in a manner providing an indiction if the fastener longitudinal axis is not parallel to the work axis. Preferably, the energy is radiated along two paths disposed at angles to each other and intersecting in a manner such that when the fastener longitudinal axis is parallel to the work axis, equal amounts of energy are interrupted, and when the fastener is mis-oriented unequal amounts of energy are interrupted thereby providing an indication of fastener mis-orientation. The energy comprises a laser beam in the form of a band having a width extending between longitudinally extending edges of the band. Two laser beam bands are disposed at angles and with an edge of each band intersecting the longitudinal axis of the fastener whereby in any mis-oriented disposition of the fastener, unequal amounts of the beams are interrupted thereby providing an indication of the mis-oriented fastener. The indication of a tipped or mis-oriented fastener is immediately signaled to the machine control to stop the machine or take whatever corrective action is appropriate to avoid damage to the workpiece. The accuracy and effectiveness of the method and apparatus of the present invention provides a level of confidence in tipped fastener detection thereby avoiding any need to slow the fastnener insertion cycle and even allowing an increase in fastener insertion speed so as to increase the overall production rate.

Apparatus and method for detecting mis-oriented fasteners

Apparatus and method for actuating tooling

The present invention provides a method and apparatus for positioning tooling with respect to a curvilinear workpiece which is curved in a first direction extending along a plane substantially perpendicular to the longitudinal axis of the workpiece and which is curved in a second direction extending along a plane to the workpiece longitudinal axis, the degree of curvature in the first direction being greater than the degree of curvature in the second direction. An illustrative example is automatic drilling, inserting and upsetting one or two piece fasteners such as exterior skin rivets on an airplane fuselage. Inner and outer positioning systems carry or support inner and outer tooling, respectively, which engage the workpiece from opposite sides thereof during tooling operations thereon. Each of the inner and outer positioning systems move the respective tooling through a large number of axes, for example six axes of movement provided by the outer positioning system and seven axes of movement provided by the inner positioning system. Movements of the inner and outer positioning systems are controlled and co-ordinated by an adaptive, master-slave control system. A lateral trasfer system enables the appratus to operate successively on a plurality of workpieces.

Method for positioning tooling

Automatic fastening machine with statistical process control

Apparatus for positioning tooling

A method and apparatus (10) for fastening upper and lower workpieces (20, 22) without movement of the workpieces. The apparatus is provided with a frame having upper and lower portions (24.1, 24.2) carrying upper and lower riveting ram assemblies (26, 28), respectively. Each riveting ram assembly includes a buck ram (30 or 32), a buck ram moving assembly (62 or 90, 92), a pressure foot (34 or 36), a pressure foot moving assembly (38 or 40), a buck ram position measuring device (74 or 104), and a pressure foot position measuring device (78 or 108). The upper pressure foot moving assembly (38) further includes an upper pressure foot compensation cylinder assembly (42). The apparatus also includes a load cell (112) carried by one of the buck rams for sending a force signal in response to the force being applied to the fastener during upset and thereafter. A programmable process controller (82) is provided which is capable of having programmed into it the length of a fastener, and a deflection compensation table which sets forth the deflection of a portion of the frame during upset. The controller modulates sequential operation of the various moving assemblies during operation to move the buck rams and the pressure feet in response to signals received from the position measuring devices and the load cell in such a manner that the fastener may be upset while maintaining the upper surface (122) of the upper workpiece (20) in a desired workplane (124) even though one portion of the frame may deflect more than another portion of the frame.

Method and apparatus for fastening

A method and apparatus for riveting two workpieces (20, 22) together by simultaneously upsetting both ends of a slug rivet (12). The present apparatus includes a frame portion (44) which may deflect during the rivet upsetting operation and a frame compensation booster assembly (164) which is provided to ensure that movement of the upper riveting ram relative to the frame portion (44) is increased an amount equal to the frame deflection so that the workpieces will be maintained in a substantially fixed work plane during the upsetting operation. Before the slug rivet is upset and after the slug rivet has been snugly engaged by the riveting rams (50, 60) the pressure behind the riveting rams is equalized by introducing fluid into the cylinder (48) until the pressure within the cylinder (48) equals the pressure within the cylinder (56). This is to prevent movement of the workpiece at the commencement of the upsetting operation.

Slug riveting method and apparatus with C-frame deflection compensation

A method and apparatus for positioning tooling and riveting the apparatus including a frame provided with opposed riveting rams (96, 86) and clamps (34, 36). The first clamp (34) is extended above the work plane established by the outer surface of one workpiece (10) with the lower ram retracted. Next, the frame (26) is moved downwardly until the first clamp touches the workpiece. An encoder (140) measured the amount of first clamp collapse during overtravel of the frame after the first touch is sensed. The frame is now backed off this distance to establish a work line coextensive with the work plane. The lower clamp (36) is then raised to clamp the workpieces (10, 12) and drill carried by a sub-frame (66) will now drill aligned apertures through the workpieces. The subframe is indexed to another position to place rams (96, 86) is alignment with the apertures. The upper riveting ram (96) is then advanced to its full down position to set an upper cavity and is locked under high pressure. The lower ram (86) then rises under low pressure to a snug up position. Squeeze forming is now accomplished by simultaneously controlled motion of the frame down and the lower ram up until an upset complete signal is received. During this operation the upper clamp (34) is in a resilient condition. When the rivet is completely upset pressure is dumped from the upper clamp and simultaneously the frame is driven to its start position and the lower ram is retracted. As soon as the lower ram reaches its back away position the upper riveting ram is fully retracted.

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Orchard Park, NY, United States of America

Robert J Kellner