U.S. patent application number 13/751966 was filed with the patent office on 2013-08-01 for installation/processing systems, methods, and components.
This patent application is currently assigned to FATIGUE TECHNOLOGY, INC.. The applicant listed for this patent is Doug Bakken, Kevin J. Dooley, Scott Harlow Gulick, Timothy Howard Johnson, James Ryunoshin Ross. Invention is credited to Doug Bakken, Kevin J. Dooley, Scott Harlow Gulick, Timothy Howard Johnson, James Ryunoshin Ross.
Application Number | 20130192331 13/751966 |
Document ID | / |
Family ID | 48869091 |
Filed Date | 2013-08-01 |
United States Patent
Application |
20130192331 |
Kind Code |
A1 |
Ross; James Ryunoshin ; et
al. |
August 1, 2013 |
INSTALLATION/PROCESSING SYSTEMS, METHODS, AND COMPONENTS
Abstract
A processing tool to process workpieces, for example cold
working holes and/or installing expandable members into holes
includes an expansion assembly with a plurality of elongated
expansion segments. A first band and a second band couple the
expansion segments into an array with the expansion segments
circumferentially distributed about a longitudinal axis, with a
passageway extending between the arrayed segments. The processing
tool may include a tuning assembly that allows a radial expansion
amount of the expansion assembly to be adjusted without altering a
stroke length of a drive member of the processing tool. Sensors may
sense various aspects of the processing performed by the processing
tool to enable analysis and storage of information regarding
performance of the process and/or materials processed by the
processing tool.
Inventors: |
Ross; James Ryunoshin;
(Seattle, WA) ; Johnson; Timothy Howard; (Seattle,
WA) ; Bakken; Doug; (Seattle, WA) ; Dooley;
Kevin J.; (Issaquah, WA) ; Gulick; Scott Harlow;
(Seattle, WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ross; James Ryunoshin
Johnson; Timothy Howard
Bakken; Doug
Dooley; Kevin J.
Gulick; Scott Harlow |
Seattle
Seattle
Seattle
Issaquah
Seattle |
WA
WA
WA
WA
WA |
US
US
US
US
US |
|
|
Assignee: |
FATIGUE TECHNOLOGY, INC.
Seattle
WA
|
Family ID: |
48869091 |
Appl. No.: |
13/751966 |
Filed: |
January 28, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61592419 |
Jan 30, 2012 |
|
|
|
Current U.S.
Class: |
72/391.2 ;
72/393 |
Current CPC
Class: |
B23P 9/025 20130101;
B21D 41/028 20130101; B21D 39/20 20130101 |
Class at
Publication: |
72/391.2 ;
72/393 |
International
Class: |
B21D 39/20 20060101
B21D039/20; B21D 41/02 20060101 B21D041/02 |
Claims
1. An expansion assembly, comprising: a plurality of elongated
expansion segments, each of the expansion segments having a contact
surface and a drive surface; and a first band and a second band
coupling the expansion segments into an array with the expansion
segments circumferentially distributed about a longitudinal axis,
with a passageway extending between the arrayed segments.
2. The expansion assembly of claim 1, wherein the first band and
the second band are located on proximate ends of the expansion
segments with respect to a length of the array.
3. The expansion assembly of claim 1, wherein the first band and
the second band are located on opposite sides of a center of a
length of the array.
4. The expansion assembly of claim 1, further comprising a core
element that is movable within the passageway along the
longitudinal axis from a first position to a second position to
drive each respective one of the plurality of expansion segments in
a respective radial direction substantially transverse to the
longitudinal axis.
5. The expansion assembly of claim 1, further comprising a core
element that is movable within the passageway along the
longitudinal axis to expand the expansion segments without pivoting
by physical interaction between the core element and the drive
surfaces of the plurality of expansion segments.
6. The expansion assembly of claim 4, wherein the passageway
includes a first taper that is defined by the bearing surfaces of
the plurality of expansion segments, and the core element includes
a second taper.
7. The expansion assembly of claim 6, wherein the first taper and
the second taper are non-conical tapers.
8. The expansion assembly of claim 6, wherein the drive surface of
each of the plurality of expansion segments defines a portion of
the first taper, and the second taper of the drive member includes
a plurality of planar bearing surfaces that each respectively
corresponds to one of the drive surfaces of one of the plurality of
complementary segments and which define a portion of the second
taper.
9. The expansion assembly of claim 6, wherein the core has a
polygonal cross section with respect to a central axis of the
core.
10. The expansion assembly of claim 1, wherein each of the
plurality of expansion segments includes a portion of linearly
decreasing thickness along the longitudinal axis.
11. The expansion assembly of claim 1, wherein the drive surface of
each of the plurality of expansion segments is a bevel that extends
in a plane oblique to the longitudinal axis.
12. The expansion assembly of claim 1, wherein the expansion
segments each include a respective first and second retainer, and,
in use, the first band and the second band are located in
respective ones of the first and second retainers.
13. The expansion assembly of claim 12, wherein at least one of the
first and second retainers is a groove in an outer surface of at
least one of the plurality of expansion segments.
14. The expansion assembly of claim 1, wherein the each of the
plurality of expansion elements includes a flange that extends
radially outward with respect to the contact surface, and the
flange is located between the first band and the second band.
15. The expansion assembly of 1, further comprising: a nose cap
including an interior face and through hole; and a retaining member
seated within the adjustment cap so that the flange of each of the
plurality of expansion elements is secured between the retaining
member and the interior face of the nose cap.
16. The expansion assembly of 1, wherein each of the expansion
segments includes a portion on one end of the contact surface with
respect to the longitudinal axis that, when the expansion segments
are assembled together, forms a ring portion with a first diameter
that is larger than a second diameter of the contact surface
proximate to a center of the expansion segments with respect to the
longitudinal axis.
17. The expansion assembly of 1, wherein at least one of the
expansion segments includes a longitudinally extending ridge on the
contact surface.
18. The expansion assembly of claim 1, wherein the expansion
assembly includes four of the expansion segments.
19. A tuning assembly for use in a processing system that includes
an expansion assembly including a plurality of expansion elements,
and a drive member that is movable in a longitudinal direction to
actuate each respective one of the plurality of expansion segments
of the expansion assembly in a respective radial direction
substantially transverse to a longitudinal axis of the expansion
assembly, the longitudinal direction being substantially parallel
to the longitudinal axis, the tuning assembly comprising: a
mechanism configured to selectively adjust a maximum radial
expansion amount of the expansion assembly without altering a
stroke length of the drive member.
20. The tuning assembly of claim 19, wherein the expansion segments
of the expansion system are arranged circumferentially in an array
distributed about the longitudinal axis, with a passageway
extending between the arrayed expansion segments, the expansion
assembly includes a core element movable in the passageway in the
longitudinal direction to drive each respective one of the
plurality of expansion segments in the respective radial direction
by physical interaction between the core element and drive surfaces
of the plurality of expansion segments, and the tuning mechanism is
configured to translate the expansion segments relative to the core
element along the longitudinal axis.
21. The tuning assembly of claim 20, wherein the processing system
includes a housing that houses the drive member, the tuning
assembly is coupled to the housing for selective movement with
respect to the housing in the longitudinal direction, and the
plurality of expansion segments are coupled to the housing so as to
be fixed with respect to the housing in the longitudinal
direction.
22. The tuning assembly of claim 21, wherein the tuning assembly is
rotatable about the longitudinal axis relative to the housing
between a plurality of fixed positions, each fixed position
corresponding to a different maximum radial expansion amount of the
expansion assembly.
23. The tuning assembly of claim 19, wherein the tuning assembly is
rotatable about the longitudinal axis relative to a housing that
houses the drive member between a plurality of fixed positions,
each fixed position corresponding to a different maximum radial
expansion amount of the expansion assembly.
24. The tuning assembly of claim 19, wherein the tuning assembly
includes a tuning cylinder that is fixed relative to the plurality
of expansion segments in the longitudinal direction, and the tuning
cylinder is selectively movable relative to a housing that houses
the drive member in the longitudinal direction.
25. The tuning assembly of claim 24, wherein the tuning assembly
includes an index ring that is coupled to the tuning cylinder, the
index ring fixed relative to the tuning cylinder with respect to a
rotational direction about the longitudinal axis, the index ring
selectively engageable with the housing at plurality of fixed
positions in the rotational direction, each fixed position
corresponding to a different maximum radial expansion amount of the
expansion assembly.
26. The tuning assembly of claim 19, wherein the expansion segments
are circumferentially distributed in an array about a longitudinal
axis, with a passageway extending between the arrayed segments, the
expansion assembly includes a core element movable in the
passageway in the longitudinal direction to drive each respective
one of the plurality of expansion segments in the respective radial
direction by physical interaction between the core element and
drive surfaces of the plurality of expansion segments, and the
tuning assembly is configured to adjust a depth of penetration in
the longitudinal direction of the core element into the passageway.
Description
BACKGROUND
[0001] 1. Field
[0002] This disclosure generally relates to installation/processing
systems for installing expandable members into holes in workpieces
and/or cold expanding holes in workpieces.
[0003] 2. Description of the Related Art
[0004] Conventional installation tools are used to install bushings
in holes within workpieces. These installation tools often have an
expansion mandrel with an enlarged tapered portion used to expand
the bushing. To radially expand the bushing, the expansion mandrel
is inserted into an opening in the bushing. The bushing and mandrel
are simultaneously inserted into a hole in a workpiece. When the
bushing is positioned in the hole of the workpiece, the enlarged
tapered portion of the mandrel extends outwardly from the backside
of the workpiece. These types of installation tools thus require an
adequate amount of backside clearance and are unsuitable for
installing bushings in non-through holes, blind holes, or other
holes having limited backside clearance.
[0005] To expand the bushing, the enlarged tapered portion of the
mandrel is forcibly pulled axially through the opening of the
bushing until an interference fit is formed between the bushing and
workpiece. Unfortunately, relatively high frictional forces can be
generated as the mandrel is moved through the bushing. These forces
may cause the bushing to move relative to the workpiece, thus
resulting in improper positioning of the installed bushing.
Additionally, as the mandrel is pulled through the bushing, the
outer surface of the mandrel can abrade the sidewall of the
bushing's opening, thereby reducing the quality of the installed
bushing.
[0006] Other installation tools use a threaded installation member
to install a partially collapsible fastener element. The partially
collapsible fastener element is inserted into a through hole in a
workpiece until a first flange at a trailing end of the fastener
element is in contact with a front face of the workpiece.
Unfortunately, a collapsible portion of the fastener element has to
extend outwardly from the backside of the workpiece, thus requiring
a through hole having sufficient backside clearance.
[0007] Once the fastener element is positioned in the workpiece, an
externally threaded end of the threaded installation member is
inserted into an opening in the fastener element from the front
side of the workpiece. The installation member is threadably mated
with internal threads of the fastener element such that both the
installation member and fastener element extend beyond the backside
of the workpiece.
[0008] A tubular mandrel surrounding the installation member is
moved into contact with an entrance of the opening in the fastener
element. An actuator (e.g., pusher, puller) device retracts the
installation member through the tubular mandrel to cause the
collapsible portion (e.g., a reduced thickness wall portion) of the
fastener element to collapse and form a second flange on the
backside of the workpiece. The workpiece is thus sandwiched between
the first and second flanges of the fastener element.
Unfortunately, during this process, the actuator device is pulled
against the front surface of the workpiece and may deform, mar, or
otherwise degrade the front surface of the workpiece.
[0009] The tubular mandrel is moved axially into the opening of the
fastener element causing radial expansion of a portion of the
fastener element. The portion of the fastener element is radially
expanded against the sidewall of the opening to form an
interference fit. During this expansion process, the mandrel
directly contacts and slides against the fastener element and,
consequently, can undesirably abrade and damage the surface of the
fastener element.
[0010] Consequently, conventional installation tools may not
adequately meet certain quality and installation needs.
BRIEF SUMMARY
[0011] As noted above, it has been observed that the longitudinal
motion of a mandrel passing through an opening has several
disadvantages relating to space requirements as well as abrasion of
the workpiece and/or an element that is to be installed. In
addition, it has been observed that the mandrel can drag or push
material, depending on the actuation direction, to either end of an
installed component or workpiece as the mandrel is moved
longitudinally through an opening. It may require addition steps to
remove such material.
[0012] One solution has been to employ expandable structures that
are inserted into holes and then expanded while in the hole. Such
expandable structures typically include a plurality of elements or
jaws that are arranged around an expansion mandrel, secured to each
other at a proximal end, and free at a distal end. Moving the
expansion mandrel longitudinally causes the expandable structures
to separate from each other and expand.
[0013] It has been observed that conventional expandable structures
are caused to pivot during expansion about the fixed, proximal end.
Such pivoting results in non-uniform expansion in a radial
direction along a longitudinal direction of the hole in which the
expandable structure is inserted.
[0014] It has been further observed that an expansion assembly that
includes a plurality of elongated expansion segments in which a
first band and a second band couple the expansion segments into an
array with the expansion segments circumferentially distributed
about a longitudinal axis can achieve uniform radial expansion
along the longitudinal direction of the hole in which the expansion
assembly is installed. Further, such a configuration avoids the
problems associated with expansion by dragging or pulling a mandrel
through the hole.
[0015] In effect, it has been observed that a two band
configuration may advantageously allow the outer surfaces of the
expansion segments to expandable equally along the entire length of
the expansion segments (i.e., move radially without pivoting).
[0016] Further, it has been observed that the inclusion of the
bands on either side of a center point of a length of the
individual expansion segments may allow for easier retention of the
segments to a core element up to and during expansion. In
particular, it has been observed that if only a single band is used
on one end of the expansion segments, the opposite, non-banded end
of the expansion elements may skew relative to the core element,
resulting in non-uniform expansion forces. For example, such
skewing may result in a spiral expansion.
[0017] It has further been observed that more uniform expansion in
the radial direction results in less growth or more controlled
growth of expandable members (e.g., tubular bushings, grommets,
fittings, sleeves, etc.) installed in an opening of a workpiece.
Such control may reduce or eliminate the need to install expandable
members "flush to over flush," and may reduce or eliminate the need
to trim the installed product after installation.
[0018] In some embodiments, an expansion assembly includes a
plurality of elongated expansion segments. Each of the expansion
segments have a contact surface and a drive surface. A first band
and a second band couple the expansion segments into an array with
the expansion segments circumferentially distributed about a
longitudinal axis, with a passageway extending between the arrayed
segments.
[0019] The first band and the second band may be located on
proximate ends of the expansion segments with respect to a length
of the array. The first band and the second band may be located on
opposite sides of a center of a length of the array. The expansion
may further include a core element that is movable within the
passageway along the longitudinal axis from a first position to a
second position to drive each respective one of the plurality of
expansion segments in a respective radial direction substantially
transverse to the longitudinal axis. The passageway may include a
first taper that is defined by the bearing surfaces of the
plurality of expansion segments, and the core element may include a
second taper. The first taper and the second taper may be
non-conical tapers. The drive surface of each of the plurality of
expansion segments may define a portion of the first taper, and the
second taper of the drive member may include a plurality of planar
bearing surfaces that each respectively corresponds to one of the
drive surfaces of one of the plurality of complementary segments
and which define a portion of the second taper. The core may have a
polygonal cross section with respect to a central axis of the
core.
[0020] In some embodiments, the expansion assembly may further
include a core element that is movable within the passageway along
the longitudinal axis to expand the expansion segments without
pivoting by physical interaction between the core element and the
drive surfaces of the plurality of expansion segments. Each of the
plurality of expansion segments may include a portion of linearly
decreasing thickness along the longitudinal axis. The drive surface
of each of the plurality of expansion segments may be a bevel that
extends in a plane oblique to the longitudinal axis. The expansion
segments may each include a respective first and second retainer,
and, in use, the first band and the second band are located in
respective ones of the first and second retainers. At least one of
the first and second retainers may be groove in an outer surface of
at least one of the plurality of expansion segments. Each of the
plurality of expansion elements may include a flange that extends
radially outward with respect to the contact surface, and the
flange is located between the first band and the second band. The
expansion assembly may further include a nose cap including an
interior face and through hole. A retaining member may be seated
within the adjustment cap so that the flange of each of the
plurality of expansion elements is secured between the retaining
member and the interior face of the nose cap. The expansion
assembly may include four of the expansion segments.
[0021] Observation has been made that an operator may be required
to change a tooling setup to accommodate a variety of scenarios
that arise during a single project. A single job may require
expanding different holes with different materials. Different
materials may have differing mechanical strengths or may be more or
less crack prone. In another example, if a workpiece has a large
hole tolerance, there may be a wide range of hole sizes that need
to be worked. Likewise, there may be a varied range of material
thicknesses across a workpiece that is to be cold-worked. It has
been observed that each of these scenarios may require an operator
to apply a different expansion amount to different holes on the
same job, which may necessitate the operator to change the setup in
order to achieve the desired expansion. Further, it has been
observed that if mixed materials are used in a stack-up that is to
be cold-worked, it may be necessary to perform at least two work
steps using separate tooling for each step to accommodate different
expansion amounts for each material. Such changes in setup are not
only time consuming, but also require the operator to have access
to multiple tooling setups, which can be costly.
[0022] A tuning assembly that allows an operator to adjust a radial
expansion amount without altering a stroke amount of a drive system
of a processing tool would be advantageous for many reasons. For
example, the same setup can be used for a variety of scenarios.
Likewise, once the expansions system is properly tuned, an operator
can simply fully stroke the drive system, thus ensuring that the
appropriate amount of force is applied to work the workpiece at the
appropriate expansion amount. In effect, such a tuning assembly
would allow a drive system to be fully stroked while nevertheless
achieving different amounts of selected radial expansion using the
same tool.
[0023] A tuning assembly for use in a processing system that
includes an expansion assembly including a plurality of expansion
elements, and a drive member that is movable in a longitudinal
direction to actuate each respective one of the plurality of
expansion segments of the expansion assembly in a respective radial
direction substantially transverse to a longitudinal axis of the
expansion assembly, the longitudinal direction being substantially
parallel to the longitudinal axis, may be summarized as including a
mechanism configured to selectively adjust a maximum radial
expansion amount of the expansion assembly without altering a
stroke length of the drive member.
[0024] The expansion segments of the expansion system are arranged
circumferentially in an array distributed about the longitudinal
axis, with a passageway extending between the arrayed expansion
segments. The expansion assembly may include a core element movable
in the passageway in the longitudinal direction to drive each
respective one of the plurality of expansion segments in the
respective radial direction by physical interaction between the
core element and drive surfaces of the plurality of expansion
segments, and the tuning mechanism may be configured to translate
the expansion segments relative to the core element along the
longitudinal axis. The processing system may further include a
housing that houses the drive member. The tuning assembly may be
coupled to the housing for selective movement with respect to the
housing in the longitudinal direction, and the plurality of
expansion segments are coupled to the housing so as to be fixed
with respect to the housing in the longitudinal direction. The
tuning assembly may be rotatable about the longitudinal axis
relative to the housing between a plurality of fixed positions,
each fixed position corresponding to a different maximum radial
expansion amount of the expansion assembly. The tuning assembly may
include a tuning cylinder that is fixed relative to the plurality
of expansion segments in the longitudinal direction, and the tuning
cylinder may be selectively movable relative to a housing that
houses the drive member in the longitudinal direction. The tuning
assembly may further include an index ring that is coupled to the
tuning cylinder, the index ring fixed relative to the tuning
cylinder with respect to a rotational direction about the
longitudinal axis. The index ring may be selectively engageable
with the housing at plurality of fixed positions in the rotational
direction, each fixed position corresponding to a different maximum
radial expansion amount of the expansion assembly. The expansion
segments may be circumferentially distributed in an array about a
longitudinal axis, with a passageway extending between the arrayed
segments, the expansion assembly may include a core element movable
in the passageway in the longitudinal direction to drive each
respective one of the plurality of expansion segments in the
respective radial direction by physical interaction between the
core element and drive surfaces of the plurality of expansion
segments, and the tuning assembly may be configured to adjust a
depth of penetration in the longitudinal direction of the core
element into the passageway.
[0025] A processing system to process at least a workpiece can be
summarized as including an expansion assembly including a plurality
of expansion elements; a drive member that is movable in a
longitudinal direction to actuate each respective one of the
plurality of expansion segments of the expansion assembly in a
respective radial direction substantially transverse to a
longitudinal axis of the expansion assembly, the longitudinal
direction being substantially parallel to the longitudinal axis;
and a tuning assembly configured to selectively adjust a maximum
radial expansion amount of the expansion assembly without altering
a stroke length of the drive member.
[0026] A processing system to process at least a workpiece can be
summarized as including a plurality of elongated expansion segments
distributed about a longitudinal axis; a core element sized and
shaped to move the expansion segments away from each other as the
core element is moved along the longitudinal axis; and at least one
sensor responsive to at least one of a position of the core
element, a distance of travel of the core element, a pressure, an
applied force, or a reaction force resulting from an applied force
applied directly or indirectly by the expanding of the expansion
segments to the interior surface of the hole of a workpiece.
[0027] Each of the expansion segments may have a contact surface
and a drive surface, and the expansion segments may contact an
interior surface of a hole of a workpiece as the core element is
moved along the longitudinal axis and bears against the drive
surface of the expansion segments. At least one sensor may include
a pressure sensor mounted to the expansion tool. At least one
sensor may include a linear variable differential transducer.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0028] In the drawings, identical reference numbers identify
similar elements or acts. The sizes and relative positions of
elements in the drawings are not necessarily drawn to scale. For
example, the shapes of various elements and angles are not drawn to
scale, and some of these elements are arbitrarily enlarged and
positioned to improve drawing legibility. Further, the particular
shapes of the elements as drawn, are not intended to convey any
information regarding the actual shape of the particular elements,
and have been solely selected for ease of recognition in the
drawings.
[0029] FIG. 1 is an isometric view of a processing tool which is
coupled to an expansion assembly, and a tuning assembly, according
to one illustrated embodiment.
[0030] FIG. 2 is a partial cross-sectional view of the processing
tool, expansion assembly, and tuning assembly of FIG. 1 taken along
2-2 of FIG. 1, in an expanded state.
[0031] FIG. 3 is a partial cross-sectional view of the processing
tool, expansion assembly, and tuning assembly of FIG. 1 taken along
2-2 of FIG. 1, in a retracted state.
[0032] FIG. 4A is an exploded isometric view of the processing
tool, expansion assembly, and tuning assembly of FIG. 1.
[0033] FIG. 4B is reverse isometric view of an index ring of the
tuning assembly.
[0034] FIG. 5 is an exploded cross-sectional view of the processing
tool, expansion assembly, and tuning assembly of FIG. 1.
[0035] FIG. 6 is an isometric view of a pressure transducer that
can be coupled to the processing tool, according to one illustrated
embodiment.
[0036] FIG. 7 is an isometric view of a linear variable
differential transformer that can be coupled to the processing
tool, according to one illustrated embodiment.
[0037] FIG. 8A is a partial cross-sectional view of portions of the
processing tool and expansion assembly, and workpiece of FIG. 1
taken along 2-2 of FIG. 1, in a retracted state.
[0038] FIG. 8B is a partial cross-sectional view of portions of the
processing tool and expansion assembly, and workpiece of FIG. 1
taken along 2-2 of FIG. 1, in an expanded state.
DETAILED DESCRIPTION OF THE INVENTION
[0039] In the following description, certain specific details are
set forth in order to provide a thorough understanding of various
embodiments of the invention. However, one skilled in the art will
understand that the invention may be practiced without these
details.
[0040] Unless the context requires otherwise, throughout the
specification and claims which follow, the word "comprise" and
variations thereof, such as, "comprises" and "comprising" are to be
construed in an open, inclusive sense, that is as "including, but
not limited to."
[0041] The headings provided herein are for convenience only and do
not interpret the scope of meaning of the claimed invention. The
following description relates to installation/processing systems
used to install expandable members (e.g., tubular bushings,
grommets, fittings, sleeves, etc.) in openings, such as non-through
holes in workpieces. The systems can also be used to process
workpieces, such as cold working holes in workpieces. For purposes
of this discussion and for clarity, a processing system for
installing an expandable member will be described, and then a
description of its components will follow. The term "processing
system" is a broad term and includes, without limitation, a system
that can be used to expand an expandable member, material
surrounding a hole in a workpiece, or other suitable expandable
structures. In some embodiments, processing systems are
installation systems that install bushings in workpieces. The
processing systems can also be in the form of cold expansion
systems used to cold expand holes in workpieces with, or without,
installing an expandable member. The terms "proximal" and "distal"
are used to describe the illustrated embodiments and are used
consistently with a description of non-limiting exemplary
applications. The terms "proximal" and "distal" are used in
reference to the user's body when the user operates a processing
system, unless the context clearly indicates otherwise. It will be
appreciated, however, that the illustrated embodiments can be
located or oriented in a variety of desired positions.
[0042] The term processing system should not be confused with the
term "processor-based system" which is used herein to denominate
systems that include a processor such as a microprocessor,
microcontroller, digital signal processors (DSPs), application
specific integrated circuit (ASIC), programmed logic controller
(PCL), programmable gate array (PGA) for instance a field
programmable gate array (FPGA) or other controllers. Notably, in
many implementations a processing system may be a processor-based
system.
[0043] I. Overview
[0044] FIGS. 1-4 shows a processing tool 100, an expansion assembly
200 physically coupled to the processing tool 100, and a tuning
assembly 300 coupled between the processing tool 100 and the
expansion assembly 200. Generally, the illustrated processing tool
100 may be used for one-sided or two-sided installation of an
expandable member (not depicted) such as a bushing or rivetless nut
plate (generically expandable member) in a hole (not depicted) in a
primary workpiece (not depicted). A plurality of expansion segments
220 of the expansion assembly 200 can be controllably expanded in
order to expand and install the expandable member. After
installation, the expansion segments 220 can be controllably
contracted to separate the expansion assembly 200 from the
installed expandable member. The expandable member is sometimes
referred to herein as a secondary workpiece, since processing may
be performed in the expandable member in installing the expandable
member at least partially in the hole of the primary workpiece.
[0045] As noted above, the processing system can be used in
procedures involving workpieces. As used herein, the term "primary
workpiece" or sometimes just "workpiece" is broadly construed to
include, without limitation, a parent structure having at least one
hole or opening suitable for processing (e.g., receiving an
expandable member, undergoing cold expansion, etc.). The hole can
be, for example, a through hole, non-through hole, blind hole,
counter bore, or other types of holes that may or may not have
backside access. In some embodiments, the primary workpiece is a
bulkhead, fuselage, engine or other structural member of an
aircraft, even if there is limited or no backside access. In some
embodiments, the primary workpiece itself may be suitable for
expansion (e.g., cold expansion) and may or may not be suitable for
receiving an expandable member.
[0046] In the present example, the processing tool 100 is driven
hydraulically. For example, the processing tool 100 may be fluidly
communicatively coupled to a pressurization system (not depicted)
which includes a source of pressurized fluid (not depicted), for
instance one or more hydraulic reservoirs (not depicted) and/or
pumps (not depicted) via a distribution system such as a hydraulic
distribution system including one or more fluid carrying conduits,
valves, and/or manifolds. The pressurization system may be of any
conventional design, thus is not described in detail in the
interest of brevity. Notably, other sources of power or drive
capable of producing the required or desired forces may be
employed. Further, the present disclosure is not limited to
hydraulically driven processing tools, and is also applicable to
processing tools that are driven electrically, pneumatically, or by
any other suitable drive structures, mechanisms or engines.
[0047] The illustrated processing tool 100 includes a cylinder 120
that is coupled to a grip 110. A rear housing element 140 and an
end cap are mounted on a rear end of the cylinder 120, and a front
housing cap 160 is mounted on a front end of the cylinder 120. The
user can manually grasp the grip 110 to controllably hold and
accurately position the processing tool 100 with respect to a
primary workpiece. The grip 110 is illustrated as a pistol grip,
however, other types of grips can be utilized. The processing tool
100 may include a trigger 112 or other switch to activate the
processing tool 100. For example, the trigger 112 can be a rocker
switch that controls forward or rearward motion of a drive system
of the processing tool 100. The trigger 112 can also be a button,
momentary contact switch, or other switch that only requires one
touch for activation. In a system that does not include electronic
controls, the forward and back motion of the drive system of the
process tool 100 can be controlled by air logic. In an
electronically controlled system, motion of the drive system
following activation of the switch can be controlled by a
controller and software in a manner described in U.S. provisional
patent application Ser. No. 61/592,500, entitled "SMART
INSTALLATION/PROCESSING SYSTEMS, COMPONENTS, AND METHODS OF
OPERATING THE SAME," and U.S. non-provisional patent application
Ser. Nos. 13/750,604 and 13/750,607, the contents of each of which
are incorporated by reference herein in their entirety.
[0048] The cylinder 120 houses a drive system that can drive a
mandrel or core element 210 of the expansion assembly 200 with
respect to the expansion segments 220 of the expansion assembly
200. The drive system can have a push/pull piston arrangement and
may comprise a double acting piston 130 in combination with the
hydraulic cylinder 120. Other cylinder arrangements are also
possible.
[0049] A pair of fluid conduits or lines 114 (only one is visible)
can provide pressurized fluid (e.g., pressurized gas, liquid, or
combinations thereof) to the drive system and/or relieve
pressurized fluid from the drive system via the fluid paths 116 in
the grip. In the present example, the fluid lines 114 can provide
pressurized hydraulic fluid.
[0050] The drive system can be activated to drive the core element
210 along a predetermined path. The predetermined path can be a
generally linear path (e.g., a line of action) extending in a
proximal and a distal direction.
[0051] As illustrated in FIGS. 1-4, the expansion assembly 200 may
include a core element 210 and a plurality of expansion segments
220. The expansion segments 220 include elongated bodies and a
flange 226. As best understood from a review of FIGS. 2, 5, 8A and
8B, the expansion segments 220 are seated in a nose cap 170 such
that the flanges 226 are secured between an inner surface 174 of
the nose cap 170 and a retention devices 230 that is also seated in
the nose cap 170. The elongated portion of the expansion segments
220 extends through a hole 172 in the front of the nose cap 170.
The core element 210 is positioned to be driven by the drive
system, and to physically interact with the expansion segments 220
to expand and the retract the expansion segments 220 in response to
the core element 210 being driven by the drive system (in this
case, the piston 130). In this example, the core element 210
includes a threaded portion 216 that engages a rod of the piston
130.
[0052] As used herein, the terms "core element" and "mandrel" are
broad terms that include, but are not limited to, an elongated
member configured to expand a plurality of expansion segments 220.
The core element 210 can have a one-piece or multi-piece
construction. In some embodiments, the core element has one or more
surfaces (e.g., enlarged and/or tapered portions) which can
interact with the expansion segments 220 so as to cause expansion
of at least a portion of the expansion segments 220.
[0053] As illustrated, the expansion segments 220, with a
passageway 240 defined therebetween to engagingly receive the core
element 210. The expansion segments 220 may each form a portion of
a cylinder or annulus, for example each forming approximately a
quarter section of a cylinder. When viewed from either a proximate
or distal end, or longitudinally, the arrangement or array of
expansion segments 220 may have an approximately circular or oval
outer perimeter. The inner perimeter may be polygonal.
[0054] In operation, the outer perimeter of the expansion segments
220 engage an expandable member (not depicted), or a primary
workpiece 500 (FIGS. 8A and 8B) if no expandable member is to be
used. There may be small gaps between adjacent edges of neighboring
expansion segments 220 prior to expansion, which gaps increase as
the expansion segments 220 are radially expanded outwardly in
response to translation of the core element 210 outwardly with
respect to the processing tool 100. Alternatively, the adjacent
edges may be in contact with one another prior to radial expansion,
essentially eliminating any gaps.
[0055] In the implementation illustrated in the figures, an inner
surface 222 of the expansion segments 220 may be beveled or angled
along at least a portion of a length of the expansion segment 220
(e.g., from proximate end to distal end thereof). The bevel or
angle may, for example, complement a bevel or angle of the outer
surfaces 212 of the core element 130. Such causes the inner surface
222 of the expansion segments 220 to interact with the outer
surfaces 212 of the core element 210 to cause the expansion
segments 220 to radially expand outwardly without pivoting of the
expansion segments 220. Such may also cause the expansion segments
220 to radially withdraw or retract inwardly without pivoting of
the expansion segments 220. Thus, each expansion segment 220 may
move perpendicularly or transversely with respect to a centerline,
longitudinal axis or center or a body or revolution of the
expansion segments 220.
[0056] The expansion segments 220 may be expandably coupled to one
another, for example via one or more bands 250a, 250b (FIGS. 8A and
8B) mounted in retainers 228a and 228b. Two expandable members may
couple the expansion segments 220 together at two points along a
length of the expandable assembly 200. The expandable members can
take the form of, for example a spring retaining clip made from,
for example, steel; an o-ring made from, for example, an
elastomeric material; or any other suitable expandable, elastic
element made of any suitable material as will be readily apparent
to one having ordinary skill in the art upon review of this entire
disclosure. This may advantageously allow the outer surfaces of the
expansion segments 220 to expandable equally along the entire
length of the expansion segments 220 (i.e., move radially without
pivoting). This may advantageously eliminate or at least reduce any
pivoting that would occur, such as pivoting that would occur were
the expansion segments defined in a unitary structure. Further, the
inclusion of the bands on either side of a center point of a length
of the individual expansion segments may allow for easier retention
of the segments to the core element up to and during expansion. In
particular, if only a single band is used on one end of the
expansion segments, the opposite, non-banded end of the expansion
elements may skew relative to the core element, resulting in
non-uniform expansion forces. For example, such skewing may result
in a spiral expansion.
[0057] The core element 210 can be moved distally along a path from
an initial position (shown in FIGS. 3 and 8A) to an extended
position (shown in FIGS. 2 and 8B) to expand the expansion segments
220 from a first configuration to a second configuration. For
example, the core element 210 can drive the expansion segments 220
from a radially retracted, withdrawn or collapsed configuration to
a radially expanded configuration.
[0058] The partially or fully extended core element 210 can also be
retracted. When the extended core element 210 moves proximally
towards its initial position, the expansion segments 220 retract,
withdraw or collapses inwardly. The bands may bias or urge the
expansion segments 220 of the expandable assembly 200 toward the
radially retracted, withdrawn or collapsed configuration. Once the
core element 210 is pulled out of the expansion segments 220, the
expansion segments 220 may return to their fully retracted,
withdrawn or collapsed configuration. In this manner, the expansion
segments 220 can be repeatedly moved between the expanded and the
retracted, withdrawn or collapsed configurations.
[0059] The process tool 100 may also include an indicator to alert
the operator that the actuator has reached the full forward
position for which it was calibrated. For example, an electronic
control system may include one or more visual indications which may
indicate when a drive member or actuator has reached a full forward
position, which may be a position calibrated using an optional
tuning assembly. Alternatively, where pressure is employed to
supply control signals to a processing tool, an indicator may take
a mechanical form, for example a popup indicator that has a signal
member which pops up in response to full travel of the drive member
being achieved.
[0060] Optionally, a sleeve (not shown) may be positioned in the
passageway 240 defined by the expansion segments 220, which may
form a protective liner between the core element 210 and at least a
portion of the expansion segments 210. Optionally, a lubricant may
be provided between the core element 210 and/or the expansion
segments 220. Optionally, a surface of either or both of the core
element 210 and/or the expansion segments 220 of the expansion
segments 220 may be coated or treated to be lubricious for example
treated with a tungsten based coating such as the commercially
available under the trademark ULTRALUBE.RTM..
[0061] FIGS. 1-4 further depict a tuning assembly 300 disposed
between the processing tool 100 and the expansion assembly 200. The
tuning assembly 300 advantageously allows an operator to adjust a
radial expansion amount of the expansion assembly 200 without
altering a stroke amount of the drive system of the processing tool
100. For example, the tuning assembly 300 can adjust a penetration
depth of the core element 210 into the expansion segments 220 by
linearly translating the expansion segments 220 relative to the
core element 210. This arrangement allows the piston 130 to be
fully stroked while nevertheless achieving different amounts of
selected radial expansion using the same tool.
[0062] Advantageously, the tuning assembly 300 gives operators the
ability to adjust to multiple scenarios without needing to switch
to new tooling. For example, if a single job requires different
materials to be worked, which may have differing mechanical
strengths or may be more or less crack prone, the tuning assembly
300 allows the operator to adjust the expansion amount accordingly
without require multiple setups. Likewise, the tuning assembly 300
has a tuning range, discussed in detail below, that allows a single
setup to process workpieces with a wider range of tolerances than
existing devices. In another example, if mixed materials are used
in a stack-up (e.g., two or more pieces) that is to be cold-worked,
the tuning assembly 300 can be used to tailor a common ground
expansion amount or enables an operator to use two separate
expansion amounts in two separate operations without needing to
change tools.
[0063] In a further aspect, the processing tool 100 can also
include a number of sensors or transducers to sense, measure or
detect various operational conditions or parameters. Such are
illustrated and/or discussed with reference to FIGS. 6 and 7.
[0064] Each of these aspects will now be described in greater
detail.
[0065] II. Expansion Assembly
[0066] As illustrated in FIGS. 1-4, the expansion assembly 200
includes a mandrel or core element 210 and a plurality (e.g., four)
expansion segments 220.
[0067] The core element 210 may be a generally elongated member,
and has one or more bearing surfaces 212. The bearing surfaces 212
of the core element 210 may be beveled, tapered or otherwise
contoured. This taper may be in the range of 1.5.degree. to
2.5.degree.. Such a taper angle has been found to not have problems
with binding. As illustrated, the core element 210 has four bearing
surfaces. In other embodiments, the core element 210 may have a
greater number of bearing surfaces (e.g., five, six, eight, or
more) or fewer contact surfaces (e.g., three, two, one). The core
element 210 may take the form of a shaft, rod, link, shank,
elongate member, or other member suitable for driving the expansion
segments.
[0068] The expansion segments 220 each have a contact surface 224
(e.g., outer surface) that in use contacts either an expandable
member, or an interior surface of a hole in the primary workpiece.
The expansion segments 220 each have a driven surface (e.g., inner
surface) 222, which in use is contacted by the bearing surfaces 212
of the core element. The driven surfaces 222 of the expansion
segments 220 may be beveled, tapered or otherwise contoured. For
example, driven surfaces 222 of the expansion segments 220 may be
beveled, tapered or otherwise contoured to be complementary bevel,
taper or contour of the second surfaces 212 of the expansion
segments 220.
[0069] The expansion segments 220 may be arrayed in a generally
annular arrangement. The expansion segments 220 may be retained,
and optionally biased, by one or more retainment members (not
shown), for instance a pair of bands. The bands may bias or urge
the expansion segments 220 toward a first, radially contracted or
unexpanded configuration.
[0070] The expansion segments 220 could be cut from a cylindrical
stock piece machined to a larger outside diameter than required.
When cutting the individual segments, the cut width could be
enlarged. When the expansion segments 220 are assembled, the
resulting combined shape of the expansion segments 220 would be an
"out of round" (non-round) mandrel. This shape could advantageously
create enhance resistance to torque during expansion. The cost of
manufacturing conventional mandrels is greatly increased if they
are made non-round. By contrast, the combined structure of the
expansion segments 220 could be made non-round with a marginal
increase in manufacturing cost.
[0071] The mandrel or core element 210 is received in a central
passageway 240 formed between the expansion segments 220, for
translation therethrough. When the core element 210 is in a first
position (not depicted), the expansion segments 220 are in first,
radially contracted or unexpanded configuration. As the core
element 210 is translated to a second position, as shown in, for
example, FIG. 2, the bearing surfaces 212 of the mandrel or core
element 210 contact the driven surfaces 222 of the expansion
segments 220, driving the expansion segments 220 radially outward,
toward a second, radially expanded configuration.
[0072] Thus, the expansion assembly 200 can be resiliently and
controllably expanded and contracted. As used herein, the term
"resilient" is a broad term and includes, without limitation, being
capable of withstanding working loads or movements without
appreciable permanent or plastic deformation. In some embodiments,
the expansion segments 220 of the resilient expansion assembly 200
can be moved from the first configuration to the second
configuration repeatedly without appreciable permanent or plastic
deformation. Of course, there may be a minimal degree of localized
plastic yielding even though the expansion assembly generally
experiences elastic deformation. In some embodiments, visual
inspection can be used to determine whether there is appreciable
plastic deformation. After the expansion segments 220 are actuated,
any plastic deformation in the expansion assembly 200 may not be
recognizable upon visual inspection with the naked eye. In some
preferred embodiments, the deformation of the expansion assembly
200 is substantially elastic deformation during operation.
Accordingly, the resilient expansion assembly 200 can be actuated
any desired number of times.
[0073] Additionally or alternatively, the expansion assembly 200,
or a portion thereof, can contain a liner, lubricant, combinations
thereof, or other structure that reduces or increases the
frictional interaction between the core element 210 and expansion
segments 220. In some embodiments, a friction reducer in the form
of a lubricant is applied to the bearing surfaces of the expansion
assembly 200, expansion segments 220, and/or core element 210. For
example, the inner surfaces 222 of the expansion segments 220 can
be coated with a lubricant for minimizing frictional interaction
between the core element 210 and expansion segments 220. A coating
(e.g., polymer, such as synthetic resins like
polytetrafluoroethylene (PTFE), TEFLON.RTM., nylon, NEDOX.RTM. CR+,
blends, mixtures, etc.) can be used to reduce frictional forces.
Other surface treatments can be used to achieve the desired
frictional interaction between moving components of the processing
tool 100.
[0074] The expansion assembly 200 may be used to install an
expandable member in a hole in a primary workpiece. The expansion
assembly 200 (preferably in the fully collapsed configuration or
partially expanded configuration) can be sized to tightly receive
the expandable member to form, for example, an interference fit
(e.g., a slight interference fit). In other embodiments, the
expansion assembly 200 is sized to allow some play between the
expandable member and the expansion segments 220. Alternatively,
the expansion assembly 200 may be used to radial expand and/or cold
work an opening or hole without installation of an expandable
member therein or thereto.
[0075] The processing tool 100 can be used to expand the expandable
member even though there is limited or no backside access. To
position the expandable member in the hole of the workpiece, the
unexpanded expansion portion and associated expandable member are
inserted into the hole. In some embodiments, the hole can be sized
to closely receive the expandable member to form a slight
interference fit.
[0076] During the expansion process, the elongate expansion
segments 220 are generally expanded radially outward. In the
illustrated embodiment, the expansion segments 220 radially expand
without pivoting. As such, the portions of the expansion segments
220 contacting the expandable member can be generally expanded
uniformly along their lengths, thereby ensuring proper placement of
the expandable member in the hole. This uniform expansion can
minimize, limit, or substantially prevent axial displacement of the
expandable member relative to the hole. The expandable member, for
example, can be generally axially fixed relative to the
longitudinal axis of the hole during the expansion process.
[0077] Advantageously, the expansion segments 220 can protect the
expandable member from the linear movement of the core element 210.
As the expansion portion expands outwardly, the expansion segments
220 can be axially stationary relative to the hole, thus
minimizing, limiting, or preventing frictional interaction and wear
between the expansion assembly and the expandable member.
[0078] The processing system can be used with one or more clamps or
other positioning devices. If the installer has backside access, a
clamp (e.g., a C-clamp) can help position the processing tool 100
relative to the primary workpiece. The processing tool 100 can also
be used without a positioning device, unlike traditional mandrel
installation systems. Traditional mandrel installation systems
react relatively large axial reactive forces to the installer
requiring clamping devices for proper installation. These axial
forces may cause undesirable movement between a bushing and
workpiece, thus requiring a clamp for proper installation.
[0079] Because the expansion segments 220 expands generally
radially outward (not linearly through the expandable member), the
expansion assembly 200 can be easily held within the expandable
member without using a clamp. The reactive forces from the core
element 210 are transferred to the processing tool 100 via the cap
170. The installer can conveniently position the expansion assembly
200 and an expandable member within the hole of the primary
workpiece with minimal insertion forces, thereby eliminating the
need for any clamps. The installer can therefore manually hold the
processing tool 100 in proper position during the expansion process
without the need of clamps or other holding devices.
[0080] To facilitate removal from an installed expandable member, a
clearance fit can be formed between the collapsed expansion
segments 220 and expandable member. Accordingly, the expansion
assembly 200 can be easily removed from the expandable member and
used again to install another expandable member.
[0081] The processing tool 100 of FIG. 1 can also be used to treat
one or more features of a primary workpiece, without installing an
expandable member. The processing tool 100, for example, can be
used to expand a hole in a similar manner as the expandable member
described above. For example, FIGS. 8A and 8B illustrate the
expansion assembly 200 treating a hole 510 in a primary workpiece
500. In FIG. 8A, a portion of the expansion assembly 200 is
inserted into the hole 510. The processing tool 100 can be
activated to drive the core element 210 longitudinally, thereby
expanding the expansion segments 220 and associated hole 510, as
shown in FIG. 8B. As can be seen in FIGS. 8A and 8B, the inclusion
of the bands 250a and 250b ensures a uniform radial expansion of
the expansion segments 220 along the length of the hole 510. For
cold expansion, the expansion assembly can be expanded to cold work
the hole to produce residual stresses in the material forming the
hole. Of course, the expansion assembly 200 can also be used to
perform other types of expansion processes.
[0082] As noted above, there may be small gaps between adjacent
edges of neighboring expansion segments 220 prior to expansion,
which gaps increase as the expansion segments 220 are radially
expanded outwardly in response to translation of the core element
210 outwardly with respect to the processing tool 100.
Alternatively, the adjacent edges may be in contact with one
another prior to radial expansion, essentially eliminating any
gaps. The expansion process may leave longitudinally extending
ridges, corresponding to the gaps between adjacent segments 220, in
the material of the workpiece or expandable element that is
contacted by the contact surfaces 224 of the expansion segments
220. These ridges can be removed by reaming or other
processing.
[0083] In another example, the expansion assembly can be used to
eliminate the ridges created by the gaps between the expansion
elements 220. After a first expansion, which creates the ridges,
the expansion assembly could be retracted, rotated by, for example,
45.degree. (in the case of an assembly 200 with four segments), and
expanded a second time. The second expansion would flatten the
ridges, and possibly avoid the need to ream the hole post
installation, or at least reduce the amount of reaming or further
processing that is necessary. In another example, the expansion
segments 220 could include surface features that create
longitudinally extending grooves for the passage of lubricant in,
for example, an installed bushing. This could advantageously reduce
the machining costs associated with machining lubrication grooves
as a separate step. In some cases, creating the lubrication grooves
with the expansion segments 220 could allow the creation of grooves
that could not be machine practically.
[0084] In other examples, the expansion segments 220 can be used to
create other functional features in a work piece and/or expandable
member. For example, the contact surface 224 of the expansion
segments 220 could include a ring portion with a slightly larger
diameter on one or both opposite ends in a longitudinal direction.
This ring portion (or portions) could be used to provide extra
expansion to one or both ends of an expandable member, such as a
bushing. This extra expansion could provide a mechanical lock
increasing the pushout resistance. The indentation created in the
expandable member would be cleaned up by a final reaming step. In
this example, the expansion elements 220 are made to a particular
length for specific applications. The amount the diameter of the
ring portion can be increased is limited by the amount of clearance
needed to allow the expansion segments 220 to access the hole and
still maintain a clearance. The larger the ring portions are made,
the more the segments 220 would need to be able to collapse prior
to expansion. As a result, the gaps between the adjacent segments
220 would be larger in the expanded state. It has been found that
it does not require a great variation in the amount of difference
in the diameter of the ring portion and the diameter of the other
portions of the of the expansion segments 220 to create much higher
retention of an installed expandable element.
[0085] In another example, one end of the expansion segments 220
could include the ring portion to provide extra expansion at
portion of an expandable member that extends beyond one end of a
workpiece in order to retain a washer against that one end of the
workpiece. In effect, the additional expansion in the area that
includes the washer would create a captured flange. In conventional
systems, it is sometimes difficult to achieve enough retention, as
the flange and the bushing are typically the same material. Using
the ring configuration on the expansion segments 220 may reduce
this difficulty. The captured flange could be put on either end,
maybe even both.
[0086] In another example, a ridge on at least one of the expansion
segments 220 could be used to create a longitudinal groove for the
purpose of, for example, bushing rotational resistance. The groove
would create a mechanical lock and a final reaming step could be
used to clean up the inner diameter.
[0087] In another example, at least one of the expansion segments
220 includes a longitudinally extending ridge that creates a
longitudinal groove to create a key way within an expandable
member, such as a bushing, during installation. The key way could
accommodate a spherical bearing that is slid into the bushing after
installation. The key way provides rotational resistance for the
bearing.
[0088] The expansion assembly 200 could also be used with a sleeve.
Such a sleeve could be arranged between the contact surfaces 224 of
the expansion segments 220 and the surface to be contacted by the
expansion assembly 200 during expansion. The inclusion of the
sleeve could reduce the size of the longitudinally extending ridges
created by the expansion segments 220 during expansion. The sleeve
could also help the expansion segments 220 release from an
expandable member that is being installed in the workpiece. For
example, if the size of the gap between adjacent segments 220 were
to be increased to allow the segments 220 to collapse to a smaller
size in a retracted state, the inclusion of a sleeve may be useful
to reduce the size of the resulting longitudinal ridges and release
the expansion segments 220 from a workpiece or expandable
member.
[0089] It may be advantageous to use sleeves with difference
thickness for different applications. For example, a thicker sleeve
might be used if the size of the gap between adjacent segments 220
were to be increased. The sleeve could include a single,
longitudinally extending slot or the sleeve might be matched
segments with a combined diameter very close to the hole diameter
of the workpiece or expandable element, to help minimize the
resultant longitudinally extending ridge.
[0090] While a specific expansion assembly 200 has been illustrated
and described, many of the structures and acts described herein can
be employed with other expansion assemblies. For example, the
processing tool 100 may operate using an expansion assembly
including an expansion jaw having plurality of elongate members
that pivot radially outward. Such may not realize as uniform
expansion as the expansion assembly 100 described herein, yet may
still produce desired results. The tuning assembly 300, discussed
below, may be employed with such an expansion jaw. The sensing
discussed below may also be employed with such an expansion jaw.
Also, the processing tool 100 may operate with more traditional
mandrels, which are drawn through either an expandable member to be
secured in a hole or through a hole without an expandable member.
The various control systems and method described herein, as well as
the storage systems and methods may be employed with such
conventional mandrels.
[0091] III. Tuning Assembly
[0092] As discussed above, the tuning assembly 300 gives operators
the ability to adjust to multiple scenarios without needing to
switch to new tooling. FIGS. 1-4 illustrate an example that
includes a tuning assembly 300. However, the expansion assembly 200
need not be used with tuning assembly 300, and can be coupled to a
processing tool 100 that does not include a tuning assembly
300.
[0093] The tuning assembly 300 includes a tuning cylinder 310 and
an index ring 320. The nose cap 170 is mounted to a portion 314 of
the tuning cylinder 310. A threaded portion 316 of the tuning
cylinder 310 is screwed into a threaded portion 164 of the front
housing 160 of the processing tool 100. A spring 330 biases the
tuning cylinder 310 and the front housing 160 apart. By adjusting
the relative position of the tuning cylinder 310 and the front
housing 160 in a longitudinal direction, the penetration depth of
the core element 210 into the expansion segments 220 can be
adjusted. In particular, as discussed above, the flanges 226 of the
expansion segments 220 are seated in the nose cap 170 between the
retention device 230 and an interior surface 174 of the nose cap
170. As the nose cap 170 is fixed relative to the tuning cylinder
310 in the direction of linear travel of the core element 210,
translating the tuning cylinder 310 relative to the processing tool
100 also causes the expansion segments 220 seated within the nose
cap 170 to translate relative to the processing tool 100. On the
other hand, the core element 210 is fixed to the piston 130 of the
processing tool 100. Thus, the expansion segments 220 are caused to
translate relative to the core element 210 when the tuning cylinder
310 translates relative to the front housing 160.
[0094] The relative position of tuning cylinder 310 and the front
housing 160 is adjusted with an index ring 320. The index ring 320
is fixed with respect to the tuning cylinder 310 in a rotational
direction about the longitudinal axis of the processing tool by way
of pins 340 that are seated in blind holes 312 in the tuning
cylinder 310 and extend through slots 322 in the index ring. The
index ring 320 can translate in the longitudinal direction relative
to the tuning cylinder 310 for a distance defined by the length of
the slots 322. The index ring 320 includes a plurality of discrete
positions (in this example 16) that can be selected by aligning any
one of the holes 326 (FIG. 4B) drilled in an array on the back side
of the index ring 320 with the pin 345 that is seated in the blind
hole 162 of the front housing element 160 of the processing tool
100. The index ring 320 further includes a plurality of indicia 324
that assist an operator in recognizing which position has been
selected.
[0095] Rotating the index ring 320 between selected positions also
causes the tuning cylinder 310 to rotate. As the threaded portion
316 of the tuning cylinder 310 is screwed into the threaded portion
164 of the front housing 160, rotating the tuning cylinder 310
relative to the front housing 160 causes the tuning cylinder 310 to
translate relative to the front housing 160 by an amount determined
by the thread pitch of the threaded portions 316 and 164. As noted
above, this relative motion of the front housing 160 and the tuning
cylinder 310 also changes a penetration amount of the core element
210 into the expansion segments 220. The radial expansion amount of
the expansion segments 220 is then changed by an amount that
depends on both the amount of reduction or addition of penetration
depth in the longitudinal direction and the taper angles of the
surfaces 222 of the expansion segments 220 and the taper angles of
the surfaces 212 of the core element 210.
[0096] Thus, the expansion amount of the expansion segments 220 can
be finely tuned by adjusting a combination of the taper angles of
the surfaces 222 and 212, the thread pitch of the threaded portions
316 and 164, and the spacing and amount of selected positions on
the index ring as defined by the holes 326. These variables
determine a tuning range of the tuning assembly 300.
[0097] In this manner, the tuning assembly 300 gives operators the
ability to adapt to various work requirements without needing to
undergo extensive changes in tooling or setup. Instead, an operator
can merely rotate the index ring 320 to a desired setting depending
on the scenario. For example, if a single job requires workpieces
having different thicknesses to be worked, the tuning assembly 300
allows the operator to adjust the expansion amount accordingly
without require multiple setups. Likewise, when manufacturing
tolerance would ordinarily require multiple setups, the tuning
assembly 300 has a tuning range that allows a single setup to
process workpieces with a wider range of tolerances than existing
devices.
[0098] IV. Sensors
[0099] The processing tool 100 can also include a number of sensors
or transducers to sense, measure or detect various operational
conditions or parameters.
[0100] For example, the processing tool 100 may include a number of
pressure sensors 420 coupled to sense pressure supplied to the
drive system hydraulic cylinder 120. Various types of pressures
sensors may be employed. For example, a pressure sensor or
transducer 420 is illustrated in FIG. 6. Multiple pressure sensors
420 may advantageously be positioned at or proximate the processing
tool 100, to avoid losses associated with the conduits, lines and
other structures between a hydraulic reservoir (not depicted) and
the cylinder 120. This may produce more accurate determination of
pressure, which may be particularly advantageous as explained in
detail herein with reference to various method of operation.
[0101] Also for example, the processing tool 100 may include a
number of position sensors coupled to sense a position of a
moveable element, for example a position of the piston 130. Various
types of position sensors may be employed. For example FIG. 7
illustrates a linear variable Linear Variable Differential
Transformer (LVDT) 440. The position sensor(s) 440 may
advantageously be positioned at a face of the piston 130 (FIG. 2),
for example between rearwardly facing face of the piston 130 and an
opposing wall of the cylinder 120 (FIG. 2). This may produce
accurate determinations of position, travel or stroke, which may be
particularly advantageous as explained in detail herein with
reference to various method of operation.
[0102] The process tool 100 may also include an indicator to alert
the operator that the actuator has reached the full forward
position for which it was calibrated. Such an indicator can be
located in the rear of the tool, for example, near the LVDT, and
may indicate when a drive member or actuator has reached a full
forward position,
[0103] As another example, the processing tool 100 may include a
number of actuation sensors (not shown) coupled to sense or detect
activation by an end user, for example a pull of trigger 112 or
other switch activation. Various types of activation sensors may be
employed, for example contact sensors. Accurate determinations of
actuation may be particularly advantageous as explained in detail
herein with reference to various method of operation.
[0104] As yet another example, the processing tool 100 may include
a number of accelerometers (not shown) to sense or detect
orientation and/or acceleration or movement of the processing tool.
Various types of accelerometers may be employed, for example 3-axis
accelerometers. Accurate determinations of orientation or movement
may be particularly advantageous as explained in detail herein with
reference to various method of operation.
[0105] Storage, analysis, and actions taken as a result of
information gathered from sensors associated with the processing
system are discussed in more detail in U.S. provisional patent
application Ser. No. 61/592,500, entitled "SMART
INSTALLATION/PROCESSING SYSTEMS, COMPONENTS, AND METHODS OF
OPERATING THE SAME," and U.S. non-provisional patent application
Ser. Nos. 13/750,604 and 13/750,607, the contents of each of which
are incorporated by reference herein in their entirety. For
example, the noted provisional application discusses that
information regarding performance of the process and/or materials
may be stored, for example a hole-by-hole or a
workpiece-by-workpiece basis, allowing validation of processing.
Information also allows dynamic operation of the processing tool.
Analysis of response relationships (e.g., pressure or force versus
position or distance) may provide insights into the process and
materials, and/or facilitate the real-time feedback including
control, alerts, ordering replacement for consumable components.
While the figures of the present disclosure illustrate a particular
expansion assembly, other structures may be employed in combination
with various aspects of the present disclosure. For example, the
structures described in U.S. Pat. No. 8,069,699, which is
incorporated herein by reference in its entirety.
[0106] Employing sensors allows more precise control over the
processing operations than conventional processing tools. Such, for
example, allows installation of expandable members to size.
Respective dimensional variation of the hole, mandrel, and
expandable member to be installed, as well as variation in the
material characteristics (e.g., yield strength) of the primary work
piece results in a tolerance stack up. That is, these individual
variances from nominal values accumulate for each installation. In
contrast to conventional processing tools, the processing systems
described herein allow installing expandable members to size,
(FORCEMATE TO SIZE.TM.).
[0107] Such may advantageously be measured proximate the piston
(e.g., at inlet valve to cylinder) via any variety of pressure
sensors or transducers. Alternatively, a force sensor may detect an
amount of force applied by the piston or some other drive element
(e.g., core element, segments of expansion assembly). The second
variable may, for example be a position of the piston at any given
time, or an amount or distance the piston has traveled.
Alternatively, the second variable may be a position of some other
drive element (e.g., core element, segments of expansion assembly).
Such may be measured via a variety of position sensors, for
instance a LVDT, or an encoder for instance an optical encoder or
magnetic encoder such as a Reed switch. Other variables may be
employed, for example temperature, strain, and/or stress.
[0108] V. General Observations
[0109] As noted above, the processing system of FIG. 1 may be used
to install expandable members. The term "expandable member" is used
herein interchangeably with "secondary workpiece", and is a broad
term which includes, but is not limited to, a bushing (including
flanged bushing, no flange bushing), washer, sleeve (including a
split sleeve), fitting, fastener, grommet, nut plate, conduit
connectors, structural expandable member (e.g., expandable members
that are incorporated into structural workpieces), and other
structures that are suitable for securing to or otherwise
physically coupling to a primary workpiece. In some embodiments,
the expandable member can be expanded from a first configuration
(pre-installed configuration) to a second configuration (installed
configuration). For example, the expandable member may be a bushing
having at least a portion that is radially expanded an amount
sufficient to form an interference fit with an interior surface of
a hole in a primary workpiece. The term expandable member refers to
a member in a pre-expanded state and a post-expanded state, unless
the context dictates otherwise.
[0110] In some embodiments, the expandable member is in a form of a
non-through hole expandable member. As used herein, the term
"non-through hole expandable member" is a broad term and includes,
but is not limited to, an expandable member which is sized and
dimensioned to fit within a non-through hole, such as a blind hole
or other hole that does not extend completely through a workpiece,
or otherwise has limited backside access.
[0111] Various types of expansion processes can be employed to
expand the expandable members. In a cold expansion process, for
example, the expandable member is radially expanded, without
appreciably raising the temperature of the expandable member, to
produce residual stresses in a workpiece and/or expandable member
to enhance fatigue performance. The residual stresses are
preferably compressive stresses that can minimize, limit, inhibit,
or substantially prevent initiation and/or crack propagation.
[0112] The various embodiments described above can be combined to
provide further embodiments. All patents and publications mentioned
herein are hereby incorporated by reference in their entireties.
Except as described herein, the embodiments, features, systems,
devices, materials, methods and techniques described herein may, in
some embodiments, be similar to any one or more of the embodiments,
features, systems, devices, materials, methods and techniques
described in U.S. Pat. Nos. 3,566,662; 3,892,121; 4,187,708;
4,423,619; 4,425,780; 4,471,643; 4,524,600; 4,557,033; 4,809,420;
4,885,829; 4,934,170; 5,083,363; 5,096,349; 5,405,228; 5,245,743;
5,103,548; 5,127,254; 5,305,627; 5,341,559; 5,380,111; 5,433,100;
8,069,699; and in U.S. patent application Ser. Nos. 09/603,857;
10/726,809; 10/619,226; 10/633,294, and 11/897,270, which are
incorporated herein by reference. In addition, the embodiments,
features, systems, devices, materials, methods and techniques
described herein may, in certain embodiments, be applied to or used
in connection with any one or more of the embodiments, features,
systems, devices, materials, methods and techniques disclosed in
the incorporated U.S. patents and patent applications.
[0113] The various primary and/or secondary workpieces and
consumable components disclosed herein may be formed through any
suitable means. For example, the workpieces can be formed through
injection molding, casting, rolling, forming, electrical discharge
machining, other machining, and other methods disclosed herein. The
various methods and techniques described above provide a number of
ways to carry out the various embodiments. Of course, it is to be
understood that not necessarily all objectives or advantages
described may be achieved in accordance with any particular
embodiment described herein. Thus, for example, those skilled in
the art will recognize that the methods may be performed in a
manner that achieves or optimizes one advantage or group of
advantages as taught herein without necessarily achieving other
objectives or advantages as may be taught or suggested herein.
[0114] Furthermore, the skilled artisan will recognize the
interchangeability of various features from different embodiments
disclosed herein. Similarly, the various features and acts
discussed above, as well as other known equivalents for each such
feature or act, can be mixed and matched by one of ordinary skill
in this art to perform methods in accordance with principles
described herein. Additionally, the methods which are described and
illustrated herein are not limited to the exact sequence of acts
described, nor are they necessarily limited to the practice of all
of the acts set forth. Other sequences of events or acts, or less
than all of the events, or simultaneous occurrence of the events,
may be utilized in practicing the embodiments of the invention.
[0115] Although the invention has been disclosed in the context of
certain embodiments and examples, it will be understood by those
skilled in the art that the invention extends beyond the
specifically disclosed embodiments to other alternative embodiments
and/or uses and obvious modifications and equivalents thereof.
Accordingly, it is not intended that the invention be limited,
except as by the appended claims.
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