Patent Publication Number: US-9844929-B2

Title: Automated fastener insert installation system for composite panels

Description:
BACKGROUND 
     Field of the Disclosure 
     The present disclosure is directed to an automated fastener insert installation system for composite panels. 
     Description of Related Art 
     Composite panels, such as honeycomb-cored sheets, often cannot have mechanical fasteners directly affixed thereto. In some instances wherein such a composite panel may require a mechanical fastener to be affixed thereto, a fastener-receiving insert may first be installed in and secured to the composite panel, and the mechanical fastener is then engaged with the insert. In this manner, the mechanical fastener can be used with the installed insert to secure the composite panel to other composite panels or structures. 
     However, such inserts often require a high degree of precision and conformance to tolerances when installed in the composite panel in order to provide an effective anchor for the mechanical fastener. For example, there may be several configurations or sizes of inserts, and each insert requires that the insertion orifice in the composite panel be correspondingly configured or sized. It is not desirable to install an insert configured for a through-hole orifice in a blind-hole-configured orifice, and vice versa. Moreover, insert-receiving-orifice defined by the composite panel must have an appropriate diameter and/or length/depth corresponding to the diameter and/or length of the insert received thereby. Further, the inserts may have to be installed so as to be as close to flush or coplanar with the outer surface of the composite panel as possible, in order to provide optimal interaction with the mechanical fastener and structural integrity of the assembled end product. In addition, such an insert may often be installed in the composite panel using an adhesive material (i.e., a special purpose two-part potting compound). However, such a special purpose potting compound typically requires careful handling, but also has a limited time in which it can be applied once mixed or actuated. Also, such a potting compound cures and hardens, once applied, which may limit re-work opportunities in the event of an imprecise insert installation procedure. In some instances, one imprecise insert installation in a composite panel will, at a minimum, require labor intensive rework, and may cause that composite panel to be designated as scrap. 
     As such, there exists a need for a system and method for installing fastener inserts in composite panels that addresses issues in a conventional process. 
     SUMMARY OF THE DISCLOSURE 
     The above and other needs are met by aspects of the present disclosure which, in one aspect, provides an automated fastener insert installation system for composite panels. Such a system may comprise a panel handling module configured to receive and secure a composite panel with respect to an origin of a first coordinate system, wherein the composite panel has opposed major surfaces and defines an insert-receiving orifice extending through one of the major surfaces, and wherein the composite panel is secured by the panel handling module such that one of the major surfaces of the composite panel is externally accessible. A fastener insert assembly module is configured to engage each of a plurality of fastener inserts with an installation aide. A fastener insert installation module is configured to determine a configuration or size of the insert-receiving orifice defined by the composite panel received by the handling module, to select a corresponding one of the fastener inserts engaged with the installation aide from the fastener insert assembly module in response to the determined configuration or size of the insert-receiving orifice, to insert the selected fastener insert into the insert-receiving orifice, and to dispense an adhesive material through the installation aide and into the insert-receiving orifice about selected fastener insert such that the adhesive material secures the selected fastener insert within the insert-receiving orifice. 
     Another aspect of the present disclosure provides an automated fastener insert installation system for use in a composite panel fastener insert installation process. Such a system comprises a panel handling system for handling a composite panel. The panel handling system may include opposing frame members, wherein at least one of the frame members is pivotable about one end thereof with respect to the other frame member. The at least one of the frame members is pivotable to an open position with respect to the other frame member, to receive the composite panel therebetween, and to a closed position with respect to the other frame member to secure the composite panel therebetween. A registration arrangement is operably engaged with one of the frame members, wherein the registration arrangement is configured to interact with the composite panel such that the composite panel is registered with respect to a first coordinate system upon being secured by the frame members in the closed position. 
     A further aspect of the present disclosure provides an automated fastener insert installation system for use in a composite panel fastener insert installation process. Such a system comprises a fastener insert assembly system, which includes a fastener insert manipulation device configured to engage an engagement surface of each of a plurality of fastener inserts with an engagement surface of an installation aide, wherein each fastener insert defines a plurality of adhesive application orifices spaced apart about the engagement surface, and each installation aide defines a plurality of adhesive application orifices spaced apart about an engagement surface thereof, such that the adhesive application orifices of each fastener insert are aligned with corresponding adhesive application orifices of the installation aide upon engagement between the engagement surfaces thereof. 
     The aspects, functions and advantages discussed herein may be achieved independently in various example implementations/aspects or may be combined in yet other example implementations/aspects, further details of which may be seen with reference to the following description and drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Having thus described the disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein: 
         FIG. 1  schematically illustrates a fastener insert installation system, according to one aspect of the present disclosure; 
         FIG. 2  schematically illustrates a panel handling system and a fastener insert installation system, according to one aspect of the present disclosure; 
         FIG. 3  schematically illustrates a fastener insert assembly system, according to one aspect of the present disclosure; 
         FIG. 4  schematically illustrates an adhesive material preparation system, according to one aspect of the present disclosure; 
         FIG. 5A  schematically illustrates an example configuration of a blind hole fastener insert, according to one aspect of the present disclosure; 
         FIG. 5B  schematically illustrates an example configuration of a through-hole fastener insert, according to one aspect of the present disclosure; and 
         FIG. 6  schematically illustrates an adhesive material kit, according to one aspect of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     The present disclosure now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all aspects of the disclosure are shown. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the aspects set forth herein; rather, these aspects are provided so that this disclosure will be thorough and complete, will fully convey the scope of the disclosure to those skilled in the art, and will satisfy applicable legal requirements. Like numbers refer to like elements throughout. As used in this specification and the claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. 
     As schematically illustrated in  FIG. 1 , one aspect of the present disclosure provides an automated fastener insert installation system  100 , which may be particularly applicable to composite panels, such as, for example, a honeycomb-cored sheet. Such a system  100  may generally comprise a panel handling module or system  300 , an adhesive material preparation module or system  500 , a fastener insert assembly module or system  700 , and a fastener insert installation module or system  900 , configured to cooperate to automatically insert a fastener insert  50  (see, e.g.,  FIGS. 5A and 5B ) into a composite panel  75 . 
     The panel handling module or system  300  as shown, for example, in  FIG. 2 , is configured to receive and secure the composite panel  75  with respect to an origin  1100  of a first coordinate system  1200 . The composite panel  75  is generally in the form of a sheet, and has opposed major surfaces  75 A,  75 B (see, e.g.,  FIGS. 5A and 5B ). In some instances, the fastener insert installation system  100  may be a downstream process receiving a previously-processed composite panel  75 . That is, in a previous upstream process, the composite panel  75  may be processed through a milling machine/device (not shown) configured to form at least one insert-receiving orifice  25  in the composite panel  75 , with the at least one orifice  25  extending through one of the major surfaces  75 A,  75 B of the composite panel  75 . 
     The panel handling module  300  includes opposing frame members  320 ,  340 , wherein at least one of the frame members  320 ,  340  is movable (i.e., pivotable) with respect to the other frame member. With the frame member(s)  320 ,  340  moved to be in an open position with respect to each other, the panel handling module  300  is configured to receive the composite panel  75  therebetween. If necessary or desired, either or both frame members  320 ,  340  may have adjustable supports  360  engaged therewith, wherein the supports  360  may be moved or re-arranged, as necessary to assist in supporting composite panels having different configurations. The frame members  320 ,  340  may then be moved to a closed position with respect to each other to thereby secure the composite panel  75  therebetween. 
     According to aspects of the disclosure, the composite panel  75  may be secured by the frame members  320 ,  340 , and the adjustable supports  360 , if implemented, of the panel handling module  300 , such that one of the major surfaces  75 A,  75 B of the composite panel  75  is externally accessible. Moreover, the frame members  320 ,  340 , and the adjustable supports  360 , if implemented, are configured and arranged such that the at least one insert-receiving orifice  25  defined by the composite panel  75  is externally accessible. In some instances, the composite panel  75  may be configured to receive fastener insert(s)  50  through both major surfaces  75 A,  75 B of the composite panel  75 . That is, both major surfaces  75 A,  75 B may define at least one insert-receiving orifice  25 . In such instances, the frame members  320 ,  340  may be collectively mounted so as to be rotatable over at least 180 degrees, such that both major surfaces  75 A,  75 B of the composite panel  75  are externally accessible. In this manner, the frame members  320 ,  340  may be configured to secure the composite panel  75  in one orientation such that one of the major surfaces  75 A,  75 B is externally accessible for installation of appropriate fastener inserts  50  therein, wherein the frame members  320 ,  340  can then be collectively rotated 180 degrees such that the other of the major surfaces  75 A,  75 B is externally accessible such that appropriate fastener inserts  50  can then be installed therein. 
     In some aspects, a registration arrangement  1300  may be operably engaged with one or both of the frame members  320 ,  340 . In general, the registration arrangement  1300  may be configured to interact with the composite panel  75  such that the composite panel  75  is registered with respect to the first coordinate system  1200  upon being secured by the frame members  320 ,  340  in the closed position. In one example, either or both of the frame members  320 ,  340  may be configured such that, upon receipt of the composite panel  75  therebetween, the composite panel  75  interacts with an alignment provision (i.e., a mechanical guide) of the registration arrangement  1300  configured to engage one or more features of the composite panel  75  upon insertion thereof, which thereby automatically aligns the composite panel  75  with the first coordinate system  1200  with respect to the origin  1100  thereof. 
     In other instances, the registration arrangement  1300  may be configured to examine the composite panel  75  secured by the frame members  320 ,  340 , and determine therefrom the relationship of the secured composite panel  75  to the first coordinate system  1200 . For example, the registration arrangement  1300  may comprise an image acquisition device (i.e., a digital camera) in communication with a computer device  1500 . Images of the secured composite panel captured by the image acquisition device may be directed to the computer device  1500 , and features of the composite panel determined by image analysis/machine vision processing. The origin  1100  and the first coordinate system  1200  may thus be registered with the analyzed image of the composite panel  75  to align the composite panel with the first coordinate system  1200 . 
     Registration of the composite panel  75  with the first coordinate system  1200  may be implemented by the fastener insert installation system  100  with regard to installing fastener inserts  50  in corresponding insert-receiving orifices  25  defined by the composite panel  75 . That is, the fastener insert installation system  100  may be configured to determine the locations of the insert-receiving orifices  25  in the composite panel  75 , according to the first coordinate system  1200 , in order to implement an automated fastener insert installation process. As such, in some aspects, the composite panel  75  may have been previously processed upstream through a milling machine/device (not shown) to form the insert-receiving orifices  25  in either or both of the major surfaces  75 A,  75 B of the composite panel  75 . In forming the insert-receiving orifices  25 , the milling machine (i.e., a CNC-programmed milling machine) may implement machine code detailing the parameters associated with the orifices  25 . For instance, the machine code may include details related to the locations/coordinates of the orifices  25  in relation to a coordinate system (i.e., a “second coordinate system”) associated with the composite panel  75 , as well as, for example, the configuration of each orifice (i.e., whether a through-hole configuration or a blind hole configuration) and the size (i.e., lateral size or longitudinal size) of each orifice. 
     Since at least some of this same information included in the machine code is required by the automated fastener insert installation process, aspects of the present disclosure provide that the computer device  1500  is configured to receive or read the machine code implemented by the previous upstream milling machine (i.e., the CNC milling program) for the composite panel  75  subsequently received by the panel handling module  300  of the fastener insert installation system  100 . That is, in some aspects, the computer device  1500  or the registration arrangement  1300  associated therewith may be configured such that the first coordinate system  1200  corresponds with the second coordinate system used by the upstream milling machine. As such, upon the first and second coordinate systems being associated by the computer device  1500 /registration arrangement, a programming output from the milling machine program code may be used to create fastener insertion data for driving the fastener insert installation process, for example, by allowing the computer device  1500  to identify the insert-receiving orifices  25  and categorize the orifices  25  according to configuration, size, and coordinates (location) with respect to the composite panel  75  or the identified origin  1100  associated therewith. On this basis, the computer device  1500  may be configured to specify the fastener insert configuration (i.e., type) or size or other specification for installation in each orifice  25 , an efficient order of installation of the fastener inserts  50  across either or both major surfaces  75 A,  75 B of the composite panel  75 , and, if necessary, may move or adjust any of the supports  360  engaged with the frame member(s)  320 ,  340  so as to assure external access to the orifices  25  for fastener insert installation. 
     In order to ascertain that the composite panel  75  received by the panel handling module  300  corresponds to the milling machine program code received by the computer device  1500 , the panel handling module  300  may implement certain panel identification measures to minimize or eliminate the risk of an improper fastener insert installation process occurring with the composite panel  75 . For example, general identification of the composite panel  75 , and information associated with the configuration of each insert-receiving orifice  25  therein, the size of each insert-receiving orifice  25  therein, and/or the coordinates of each insert-receiving orifice  25  in the second coordinate system may be incorporated into a coded indicium (i.e., a bar code or other machine readable code)  1550  associated with the composite panel  75 . In such instances, the computer device  1500  or registration arrangement  1300  may further include a code reader device  1600  configured to read the coded indicium  1550  associated with the particular composite panel  75  received and secured between the frame members  320 ,  340  and to communicate the general identification information and at least information associated with the coordinates of the insert-receiving orifice in the second coordinate system to the computer device  1500 /registration arrangement  1300  for association with the first coordinate system  1200 . Implementation of the image acquisition device and/or the code reader device  1600  may further allow a feedback loop or system to be implemented by the computer device  1500  to ascertain, for example, that the same software revision and/or revision of the product specification for the particular composite panel  75  was/is being implemented by the upstream milling machine, as well as the fastener insert installation system  100 . The information processed in the feedback loop may thus facilitate and ensure, for instance, that the correct fastener insert  50  is being installed in the particular orifice  25 , that the correct size of the fastener insert  50  is being selected for the diameter of the orifice  25  or the depth of the composite panel  75 , or that any supports  360  associated with the frame member  320 ,  340  are not impeding access to any of the orifices  25  receiving a fastener insert  50 . 
     The fastener insert assembly module or system  700  as shown, for example, in  FIG. 3 , is configured to engage each of a plurality of fastener inserts  50  with an installation aide  45 . As shown in  FIGS. 5A and 5B , a fastener insert  50  for composite panels  75 , as disclosed herein, generally includes a body portion  62 , an engagement end  64  engaged with one end of the body portion  62 , and a retention end  66  engaged with the other end of the body portion  62 .  FIGS. 5A and 5B  schematically illustrate two example fastener inserts  50 , wherein the fastener insert  50  illustrated in  FIG. 5A  has a “blind hole” configuration, and the fastener insert  50  illustrated in  FIG. 5B  has a “through hole” configuration. The engagement end  64  of the fastener insert  50  defines a plurality of adhesive application orifices  65  extending therethrough from an engagement surface  68  of the engagement end  64 , distal to the body portion  62 . When installed in the insert-receiving orifice  25  of the composite panel  75 , the fastener insert  50  is preferably disposed such that the engagement surface  68  is as close to flush with the one of the major surfaces  75 A,  75 B defining the orifice  50 , as possible (i.e., within a tolerance of about 0.005 inches). As such, it may be desirable to support the fastener insert  50  within the orifice  25  such that the engagement surface  68  is as close to flush as possible with the major surface of the composite panel  75 , while an adhesive material is directed through the adhesive application orifices  65  and into the insert-receiving orifice  25  about the body portion  62  of the fastener insert  50 , wherein the adhesive material, upon curing, interacts between the fastener insert  50  and the portion of the composite panel  75  defining the insert-receiving orifice  25  to retain and secure the fastener insert  50  therein. In order to support the fastener insert  50  in the desired position within the orifice  25 , an installation aide  45  (i.e., a temporary planar tab having a lateral dimension greater than the lateral dimension of the orifice  25 ) may be affixed to the engagement surface  68  of the fastener insert  50 . As such, upon insertion of the fastener insert  50  in the orifice  25 , the installation aide  45  engages the major surface about the orifice  25  and supports the engagement surface  68  close to flush with the major surface, while the adhesive material is directed through the adhesive application orifices  65  and about the fastener insert  50  within the orifice  25 . 
     Since the fastener insert  50  must be assembled with the installation aide  45  prior to the fastener insert installation process, a further aspect of the present disclosure provides a fastener insert assembly module or system  700  which may initially be configured to sort the fastener inserts  50  by configuration (i.e., according to a through-hole insert configuration or a blind-hole insert configuration) or size (i.e., according to a lateral size or a longitudinal size) thereof. For example, the fastener assembly module  700  may include three separate hoppers  710 ,  720 ,  730  for receiving three different configurations or sizes of fasteners inserts  50 . In one instance, one hopper  710  may receive a first configuration/size of a through hole insert, a second hopper  720  may receive a second configuration/size of a through hole insert, and a third hopper  730  may receive a first configuration/size of a blind-hole insert. An alignment provision may be associated with each hopper  710 ,  720 ,  730  such that respective fastener inserts  50  fed therethrough are aligned with respect to each other (i.e., such that the longitudinal axes of the fastener inserts  50  are parallel to each other). 
     A fastener insert manipulation device  750  (i.e., a robotic arm) as shown, for example, in  FIG. 3 , is configured to select from among the sorted and aligned fastener inserts  50 , and to manipulate the selected fastener insert  50  so as to engage the engagement surface  68  of the fastener insert  50  with an engagement surface  47  of an installation aide  45 . The installation aides  45  may be affixed (i.e., by a temporary adhesive) to an elongate sheet material  760  in a serial manner, wherein the sheet material  760  can then be wrapped about a roll. The rolled sheet material  760  may be fed to an interaction location so that the installation aides  45  engaged therewith are sequentially presented such that the engagement surface  47  thereof is exposed for interaction with one of the fastener inserts  50 . The engagement surface  47  may have an adhesive material (i.e., a temporary adhesive) engaged therewith. Since each fastener insert  50  defines a plurality of adhesive application orifices  65  spaced apart about the engagement surface  68 , and since each installation aide  45  defines a plurality of adhesive application orifices  40  spaced apart about an engagement surface  47  thereof, the fastener insert manipulation device  750  may also be configured to align the adhesive application orifices  65  of each fastener insert  50  with corresponding adhesive application orifices  40  of the installation aide  45 . 
     Such alignment of the adhesive application orifices  65 ,  40  may be accomplished, for example, by a machine vision/feedback system (not shown) in communication with the fastener insert manipulation device  750 . The machine vision/feedback system may be configured to guide the fastener insert manipulation device  750  to orient the fastener insert  50  selected thereby, until the adhesive application orifices  65  thereof correspond and align with the adhesive application orifices  40  of the installation aide  45  at the interaction location. Once the adhesive application orifices  65 ,  40  of the fastener insert  50  and the installation aide  45  are aligned, the fastener insert manipulation device  750  causes the engagement between the engagement surfaces  68 ,  47 . The fastener insert manipulation device  750  then moves the fastener insert  50 , now engaged with the installation aide  45 , away from the interaction location such that the installation aide  45  is removed from adherence to the sheet material. The fastener insert manipulation device  750  is subsequently configured to orient each fastener insert engaged with one of the installation aides into an insertion orientation relative to the installation aide, and to store the fastener insert such that no external forces are exerted on the interface between the fastener insert  50  and the installation aide  45  that could cause misalignment between the adhesive application orifices  65 ,  40 . In some instances, a fastener insert supply device  800  may be configured to receive the fastener inserts  50 , each engaged with respective installation aides  45 , from the fastener insert manipulation device  750 , with the fasteners inserts  50  oriented in the insertion orientation relative to the installation aide  45  and sorted according to the configuration or the size thereof. For example, the fastener insert supply device  800  may comprise a series of conveyors  820 ,  840 ,  860  each configured to store and serve as a staging area for the different fastener insert/installation aide configurations or sizes, wherein a selected one of the fastener insert/installation aide assembly is already oriented for insertion into the insert receiving orifice  25  in the composite panel  75 , and wherein the opportunities for misalignment of the fastener insert/installation aide assemblies between each other, as well as misalignment between the fastener insert  50  and the installation aide  45 , are limited or minimized. 
     As previously disclosed, typical fastener inserts  50  of the types herein may often be installed in the composite panel  75  using a special purpose two-part potting compound as an adhesive material. However, such a special purpose potting compound may include, for example, weight-reducing glass microspheres, which typically require careful handling to avoid damage to the microspheres. As such, bulk mixing and dispensing provisions may not necessarily be desirable or appropriate for such types of adhesive materials. In addition, once actuated by mixing the two parts of the potting compound, the actuated adhesive material has a limited time in which it can be applied (i.e., on the order of 12 minutes maximum application life), and thus the amount of the actuated adhesive material that can be dispensed in connection with the fastener insert installation process is likewise limited. In such instances, one practical solution may be mixing and dispensing small batches of the potting compound, and timing the mixing of a series of small batches to optimize the dispensation of the actuated adhesive material during the fastener insert installation process. 
     The adhesive material preparation module or system  500  as shown, for example, in  FIG. 4 , may thus be configured to receive one or more adhesive material kits  550 , for example, of the type shown in  FIG. 6 , and to mix and actuate the adhesive material therein. As illustrated, each adhesive material kit  550  may comprise a tubular body  560  having the two components of the adhesive material therein separated by a membrane (not shown). A plunger/mixer  570  extends longitudinally outward from the tubular body  560 . In order to actuate the adhesive material, the plunger/mixer  570  is urged longitudinally with respect to the tubular body  560  so as to rupture the membrane and introduce the two parts of the potting compound to each other within the tubular body  560 . The plunger/mixer  570  may be subsequently rotated about the longitudinal axis and simultaneously translated along the longitudinal axis such that the two parts of the potting compound are thoroughly mixed and the adhesive material actuated (which starts the timing of the application life of the actuated adhesive material). Removal of the plunger/mixer  570  from the tubular body  560 , following the actuation of the adhesive material therein, leaves a dispensation opening (not shown) in the tubular body  560  through which actuated adhesive material is dispensed. 
     The adhesive material preparation module  500  may be configured to include a supply device  600  for receiving un-actuated adhesive material kits  550  in a suitable arrangement for providing a continuous supply for use in the fastener insert installation process, with each kit  550  being in a suitable orientation for selection by a manipulation device  625  (i.e., a robotic arm) controlled by a controller device (i.e., the computer device  1500  or other appropriate computer device). Upon selection of a kit  550  from the supply device  600 , the kit is moved to a mixing device  650 , wherein the kit  550  is then processed to actuate the adhesive material therein. The kit  550  having the actuated adhesive material is then delivered to the fastener insert installation module  900  for use in the fastener insert installation process. In this regard, as previously disclosed, the actuated adhesive material in a kit  550  may have an effective application lifetime on the order of about 11 or 12 minutes. As such, the actual working time in which a kit  550  may be used to dispense the actuated adhesive material may be on the order of about 7 or 8 minutes in order, for instance, to produce a suitable margin of effectiveness before the actuated adhesive material proceeds to cure. The adhesive material preparation module  500  may thus also be configured to prepare a subsequent adhesive material kit  550  for mixing and actuation of the adhesive material therein prior to expiration of the working time of the actuated adhesive material in a previous adhesive material kit  550 . 
     Due to the sensitive timing requirements involved with the use of the adhesive material kits  550 , the adhesive material preparation module  500  may also be configured to monitor the operational time for each kit  550 . In this regard, the adhesive material preparation module  500  may also be in communication with the controller device for control and/or monitoring thereof. In regard to the timing of the kits  550 , a time stamp may be associated with a kit  550  upon actuation of the adhesive material within the kit  550  at the mixing device  650 , for example, by scanning a coded indicium (i.e., a bar code) associated with the kit  550  and initiating a timer limited to a predetermined working time, which may be, but is not necessarily, less than the effective application lifetime of the actuated adhesive material in the kit  550 . Upon expiration of the working time, the kit  550  is recalled by the controller, recovered and discarded, and replaced with a subsequent kit  550  having actuated adhesive material therein and subject to the same time stamp limitations as the previous kit  550 . 
     It may be possible that the dispensation of the actuated adhesive material from a kit  550  causes the actuated adhesive material in that kit  550  to be exhausted prior to the expiration of the working time. As such, in some instances, each kit  550  may be monitored by the controller device, either directly or indirectly, to determine the amount of the actuated adhesive material dispensed or the amount of the actuated adhesive material remaining. Direct monitoring may be accomplished, for example, with an appropriate sensor in communication with the computer device  1500 . Indirect monitoring may be accomplished, for example, through analysis of the order and the configurations of the fastener inserts and the installation rate of the fastener insert installation process for a particular composite panel  75  to determine usage of the actuated adhesive material in a kit  550  in comparison to the working time limit. In any event, the adhesive material preparation module  500  is configured to minimize process down time upon the expiration of a current kit  550  by way of the controller determining that expiration of the current kit  550  and directing the adhesive material preparation module  500  (i.e., the manipulation device  625  and the mixing device  650 ) to prepare a subsequent kit  550  for deployment at an appropriate time after the expired kit  550  is recovered and discarded. 
     The fastener insert installation module or device  900  as shown, for example, in  FIG. 2 , may be engaged with or disposed in proximity to the panel handling module  300 , and may include an analysis device  925  configured to determine a configuration or a size of the insert-receiving orifice  25  defined by and extending through a major surface of the composite panel  75  received and secured by the panel handling module  300 . A manipulation device  950  is in communication with the analysis device  925  and is configured to select and retrieve one of the plurality of fastener inserts  50  engaged with the installation aide  45 , in response to the configuration or the size of the insert-receiving orifice  25  determined by the analysis device  925 . The manipulation device  950  is also configured to deliver the selected fastener insert  50  to a fastener installation/adhesive dispenser device  975  configured to insert the selected fastener insert  50  into the insert-receiving orifice  25  such that the installation aide  45  engages the major surface  75 A,  75 B of the composite panel  75 . The fastener installation/adhesive dispenser device  975  is further configured to dispense the actuated adhesive material from the adhesive material kit  550  and through the adhesive application orifices  65 ,  40  defined by the installation aide  45  and the selected fastener insert  50 , and into the insert-receiving orifice  25  about selected fastener insert  50 , such that the actuated adhesive material interacts with the selected fastener insert  50  and the composite panel  75  defining the insert-receiving orifice  25  so as to secure the selected fastener insert  50  within the insert-receiving orifice  25  upon curing of the actuated adhesive material. The manipulation device  950  may also be configured to retrieve an adhesive material kit  550  from the adhesive material preparation module  500 , deliver the kit  550  to the fastener installation/adhesive dispenser device  975 , and recover the kit  550  from the fastener installation/adhesive dispenser device  975  and discard the kit  550  upon expiration thereof. 
     Initially, the analysis device  925  is configured to inspect the composite panel  75  secured by the panel handling module  300  to determine or confirm whether the insert-receiving orifice  25  defined by the composite panel  75  was formed in a through-hole configuration or a blind-hole configuration, and/or determine or confirm a location, a lateral size (i.e., diameter) or a longitudinal size (i.e., the thickness of the composite panel  75 ) of the insert-receiving orifice  25 . In making such determinations or confirmations, the analysis device  925  may implement, for example, machine vision, laser measurements, or the like. In some instances, the analysis device  925  may be in communication with the computer device  1500 . In such instances, the configuration, size, and/or coordinates (location) of the insert-receiving orifice(s)  25  defined by and extending through a major surface of the composite panel  75  received and secured by the panel handling module  300 , may already be known by way of the machine code received from the prior upstream milling process. Accordingly, the information gathered by the analysis device  925  may serve to verify or confirm the information included in the machine code from the upstream milling process. 
     Once the parameters of the insert-receiving orifice  25  have been determined or confirmed by the analysis device  925 , the manipulation device  950  is directed to retrieve one of the fastener inserts  50  of the appropriate configuration and size (and having the installation aide  45  engaged therewith) from one of the series of conveyors  820 ,  840 ,  860  (staging area) of the fastener insert supply device  800  of the fastener insert assembly module  700 , and to deliver the selected fastener insert  50  in an appropriate orientation to the fastener installation/adhesive dispenser device  975  for installation in the composite panel  75 . The installation aide  45  engaged with the selected fastener insert  50  may include an adhesive material (i.e., a temporary adhesive) on the engagement surface  47  thereof engaging engagement surface  68  of the fastener insert  50 . The fastener installation/adhesive dispenser device  975  is further configured to insert the selected fastener insert  50  into the insert-receiving orifice  25 , for instance, such that the fastener insert  50  is centered within the orifice  25 . Upon insertion of the fastener insert  50  into the orifice  25 , the portion of the engagement surface  47  exceeding the lateral dimension of the engagement end  64  of the fastener insert  50  engages and adheres, via the adhesive material, to the major surface  75 A,  75 B of the composite panel  75  defining the insert-receiving orifice  25 . In this manner, the installation aide  45  secures the fastener insert  50  in a desired position within the orifice  25 , and supports the engagement surface  68  of the fastener insert  50  substantially flush with the major surface  75 A,  75 B or the composite panel  75 . 
     The manipulation device  950  may also be configured to retrieve an adhesive material kit  550  containing the actuated adhesive material (i.e., potting compound) from the adhesive material preparation module  700 , and to deliver the kit  550  to the fastener installation/adhesive dispenser device  975 . The fastener installation/adhesive dispenser device  975  is further configured to align the dispensation opening of the tubular body  560  of the kit  550  with each adhesive application orifice  40 ,  65  extending through the installation aide  45  and the engagement end  64  of the fastener insert  50 , in turn. For each adhesive application orifice  40 ,  65 , the actuated adhesive material is dispensed from the kit  550  by the fastener installation/adhesive dispenser device  975  by reducing the volume of the tubular body  560  of the adhesive material kit  550 . For example, the tubular body  560  may include a movable end plate (not shown) engaged therewith opposite to the dispensation opening, wherein the fastener installation/adhesive dispenser device  975  may be configured to move the end plate toward the dispensation opening along the tubular body  560  in order to reduce the volume within the tubular body  560  and dispense the actuated adhesive material through the dispensation opening. The dispensed actuated adhesive material enters the insert-receiving orifice  25  about the body portion  62  of the fastener insert  50  and is sufficiently viscous so as to flow to fill the space between the fastener insert  50  and the portion of the composite panel  75  defining the orifice  25  (i.e., the honeycomb material structure). In some instances, the actuated adhesive material is dispensed until a certain excess amount or overfill flows back outwardly of the particular adhesive application orifice  40 ,  65 , at which time the fastener installation/adhesive dispenser device  975  ceases dispensing the actuated adhesive material from the kit  550 . In some instances, the appropriate excess amount realized through the adhesive application orifice  40 ,  65  before ceasing the dispensation of the actuated adhesive material may be determined, for example, by the analysis device  925  using machine vision. For example, it may be specified that a sufficient amount of the actuated adhesive material has been dispensed into the orifice  25  about the fastener insert  50  when an adhesive overflow of about  0 . 25  inches long is detected and determined by the analysis device  925 . 
     Due to the viscous nature of the actuated adhesive material, the dispensation opening of the adhesive material kit  550  may remain in contact with the dispensed actuated adhesive material when the fastener installation/adhesive dispenser device  975  is directed to cease dispensation. In some instance, the fastener installation/adhesive dispensation device  975  may be further configured to exert a negative pressure on the actuated adhesive material, upon dispensation of a selected amount of the actuated adhesive material from the adhesive material kit  550 , in order, for example, to retract excess actuated adhesive material from the dispensation opening back into the tubular body  560  of the adhesive material kit  550 . That is, for instance, the fastener installation/adhesive dispenser device  975 , upon being directed to cease dispensation of the actuated adhesive material from the kit  550 , may retract the end plate of the kit  550  away from the dispensation opening by a predetermined amount so as to expand the effective volume of the tubular body  560  and exert a negative pressure on the actuated adhesive material about the dispensation opening. In such instances, the application of the negative pressure may break the flow of the actuated adhesive material from the dispensation opening and provide a cleaner tail end of the dispensed actuated adhesive material and/or the excess amount/overflow associated therewith. The break of the actuated adhesive material may be further facilitated, in some instances, by the fastener installation/adhesive dispenser device  975  moving the dispensation opening of the kit  550  away from the adhesive application orifice  40 ,  65  concurrently with the application of the negative pressure of the kit  550 . Some results of this procedure may be, for instance, a cleaner dispensation opening of the kit  550  for subsequent dispensing of the actuated adhesive material therefrom and/or preventing contamination of the composite panel  75  from excess adhesive material. 
     Once the dispensation process for one of the adhesive application orifices  40 ,  65  is completed, the fastener installation/adhesive dispenser device  975  is configured to move the dispensation opening of the kit  550  to each of the adhesive application orifices  40 ,  65 , in turn, until all such adhesive application orifices  40 ,  65  are determined to demonstrate the specified overflow amount of the actuated adhesive material. As previously disclosed, in some instances, the fastener insert installation module  900  or a component thereof may be configured to limit dispensation of the actuated adhesive material from the adhesive material kit  550  to within a predetermined working time, or to otherwise monitor the dispensation of the actuated adhesive material from a kit, and to direct the current kit  550  to be replaced with a subsequent kit  550  upon expiration of the current kit  550 . Once the fastener insert installation process is completed and the adhesive material is cured, the installation aides  45  can be removed from the composite panel  75  by dissolving or otherwise negating the adhesive material securing the installation aide  45  to the major surface  75 A,  75 B, along with removing any excess/overflow amounts of the cured adhesive material extending outwardly of the adhesive application orifices  40 ,  65 . 
     Many modifications and other aspects of the disclosures set forth herein will come to mind to one skilled in the art to which these disclosures pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the disclosures are not to be limited to the specific aspects disclosed and that equivalents, modifications, and other aspects are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.