Patent Description:
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.

For example, document <CIT>, in accordance with its abstract, states that a method involves routing/drilling/boring a calibrated hole in a panel. A fixing unit is provisionally connected to an interface for forming an assembly. The unit is inserted in the hole in alignment with an upper face of the panel, by a peripheral support of the interface. The unit is glued by injection of adhesive in a boring, by gluing inputs formed opposite to the interface and the fixing unit. The gluing process is controlled by detection of appearance of the adhesive by gluing outputs formed opposite to the interface and the unit. The interface is recovered. Document <CIT> also states an assembly of tooling modules for automatic installation of fixing units in a composite panel, and an automatic installation apparatus for fixing units.

Document <CIT>, in accordance with its abstract, states that a fastener automation system for assembly of fasteners to a substrate, includes a projection system for projecting an image on a substrate of a predetermined location of a correct fastener to be installed in the substrate and data relating to the correct fastener and the substrate, and a computer operably associated with the projection system storing data regarding the correct fastener and the predetermined location on the substrate where the correct fastener is to be installed. An automated method of installing a fastener in a substrate at a predetermined location includes using a projector system to identify a predetermined location for installation of a correct fastener to the substrate, collecting data regarding the correct fastener installation at the predetermined location and storing the data in a computer, and installing the correct fastener in the substrate at the predetermined location based upon the data.

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.

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 use in a composite panel fastener insert installation process. Such a system comprises an analysis device configured to determine a configuration or a size of the insert-receiving orifice defined by and extending through a major surface of a composite panel. A manipulation device is in communication with the analysis device and is configured to select and retrieve one of a plurality of fastener inserts engaged with an installation aide, in response to the configuration or the size of the insert-receiving orifice determined by the analysis device, and to insert the selected fastener insert into the insert-receiving orifice such that the installation aide engages the major surface of the composite panel. An adhesive dispenser device is configured to dispense an adhesive material through adhesive application orifices defined by the installation aide and the selected fastener insert, and into the insert-receiving orifice about selected fastener insert, such that the adhesive material interacts with the selected fastener insert and the composite panel defining the insert-receiving orifice so as to secure the selected fastener insert within the insert-receiving orifice, and an adhesive preparation device engaged with the adhesive dispenser device and configured to mix and actuate the adhesive material in an adhesive material kit, the adhesive dispenser device being configured to receive the adhesive material kit from the adhesive preparation device, to dispense the actuated adhesive material from the adhesive material kit, and the adhesive preparation device or the adhesive dispenser device being configured to limit dispensation of the actuated adhesive material from the adhesive material kit to within a predetermined working time.

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.

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. 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>, one aspect of the present disclosure provides an automated fastener insert installation system <NUM>, which may be particularly applicable to composite panels, such as, for example, a honeycomb-cored sheet. Such a system <NUM> may generally comprise a panel handling module or system <NUM>, an adhesive material preparation module or system <NUM>, a fastener insert assembly module or system <NUM>, and a fastener insert installation module or system <NUM>, configured to cooperate to automatically insert a fastener insert <NUM> (see, e.g., <FIG>) into a composite panel <NUM>.

The panel handling module or system <NUM> as shown, for example, in <FIG>, is configured to receive and secure the composite panel <NUM> with respect to an origin <NUM> of a first coordinate system <NUM>. The composite panel <NUM> is generally in the form of a sheet, and has opposed major surfaces 75A, 75B (see, e.g., <FIG>). In some instances, the fastener insert installation system <NUM> may be a downstream process receiving a previously-processed composite panel <NUM>. That is, in a previous upstream process, the composite panel <NUM> may be processed through a milling machine/device (not shown) configured to form at least one insert-receiving orifice <NUM> in the composite panel <NUM>, with the at least one orifice <NUM> extending through one of the major surfaces 75A, 75B of the composite panel <NUM>.

The panel handling module <NUM> includes opposing frame members <NUM>, <NUM>, wherein at least one of the frame members <NUM>, <NUM> is movable (i.e., pivotable) with respect to the other frame member. With the frame member(s) <NUM>, <NUM> moved to be in an open position with respect to each other, the panel handling module <NUM> is configured to receive the composite panel <NUM> therebetween. If necessary or desired, either or both frame members <NUM>, <NUM> may have adjustable supports <NUM> engaged therewith, wherein the supports <NUM> may be moved or rearranged, as necessary to assist in supporting composite panels having different configurations. The frame members <NUM>, <NUM> may then be moved to a closed position with respect to each other to thereby secure the composite panel <NUM> therebetween.

According to aspects of the disclosure, the composite panel <NUM> may be secured by the frame members <NUM>, <NUM>, and the adjustable supports <NUM>, if implemented, of the panel handling module <NUM>, such that one of the major surfaces 75A, 75B of the composite panel <NUM> is externally accessible. Moreover, the frame members <NUM>, <NUM>, and the adjustable supports <NUM>, if implemented, are configured and arranged such that the at least one insert-receiving orifice <NUM> defined by the composite panel <NUM> is externally accessible. In some instances, the composite panel <NUM> may be configured to receive fastener insert(s) <NUM> through both major surfaces 75A, 75B of the composite panel <NUM>. That is, both major surfaces 75A, 75B may define at least one insert-receiving orifice <NUM>. In such instances, the frame members <NUM>, <NUM> may be collectively mounted so as to be rotatable over at least <NUM> degrees, such that both major surfaces 75A, 75B of the composite panel <NUM> are externally accessible. In this manner, the frame members <NUM>, <NUM> may be configured to secure the composite panel <NUM> in one orientation such that one of the major surfaces 75A, 75B is externally accessible for installation of appropriate fastener inserts <NUM> therein, wherein the frame members <NUM>, <NUM> can then be collectively rotated <NUM> degrees such that the other of the major surfaces 75A, 75B is externally accessible such that appropriate fastener inserts <NUM> can then be installed therein.

In some aspects, a registration arrangement <NUM> may be operably engaged with one or both of the frame members <NUM>, <NUM>. In general, the registration arrangement <NUM> may be configured to interact with the composite panel <NUM> such that the composite panel <NUM> is registered with respect to the first coordinate system <NUM> upon being secured by the frame members <NUM>, <NUM> in the closed position. In one example, either or both of the frame members <NUM>, <NUM> may be configured such that, upon receipt of the composite panel <NUM> therebetween, the composite panel <NUM> interacts with an alignment provision (i.e., a mechanical guide) of the registration arrangement <NUM> configured to engage one or more features of the composite panel <NUM> upon insertion thereof, which thereby automatically aligns the composite panel <NUM> with the first coordinate system <NUM> with respect to the origin <NUM> thereof.

In other instances, the registration arrangement <NUM> may be configured to examine the composite panel <NUM> secured by the frame members <NUM>, <NUM>, and determine therefrom the relationship of the secured composite panel <NUM> to the first coordinate system <NUM>. For example, the registration arrangement <NUM> may comprise an image acquisition device (i.e., a digital camera) in communication with a computer device <NUM>. Images of the secured composite panel captured by the image acquisition device may be directed to the computer device <NUM>, and features of the composite panel determined by image analysis / machine vision processing. The origin <NUM> and the first coordinate system <NUM> may thus be registered with the analyzed image of the composite panel <NUM> to align the composite panel with the first coordinate system <NUM>.

Registration of the composite panel <NUM> with the first coordinate system <NUM> may be implemented by the fastener insert installation system <NUM> with regard to installing fastener inserts <NUM> in corresponding insert-receiving orifices <NUM> defined by the composite panel <NUM>. That is, the fastener insert installation system <NUM> may be configured to determine the locations of the insert-receiving orifices <NUM> in the composite panel <NUM>, according to the first coordinate system <NUM>, in order to implement an automated fastener insert installation process. As such, in some aspects, the composite panel <NUM> may have been previously processed upstream through a milling machine/device (not shown) to form the insert-receiving orifices <NUM> in either or both of the major surfaces 75A, 75B of the composite panel <NUM>. In forming the insert-receiving orifices <NUM>, the milling machine (i.e., a CNC-programmed milling machine) may implement machine code detailing the parameters associated with the orifices <NUM>. For instance, the machine code may include details related to the locations/coordinates of the orifices <NUM> in relation to a coordinate system (i.e., a "second coordinate system") associated with the composite panel <NUM>, 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 <NUM> 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 <NUM> subsequently received by the panel handling module <NUM> of the fastener insert installation system <NUM>. That is, in some aspects, the computer device <NUM> or the registration arrangement <NUM> associated therewith may be configured such that the first coordinate system <NUM> 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 <NUM> / 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 <NUM> to identify the insert-receiving orifices <NUM> and categorize the orifices <NUM> according to configuration, size, and coordinates (location) with respect to the composite panel <NUM> or the identified origin <NUM> associated therewith. On this basis, the computer device <NUM> may be configured to specify the fastener insert configuration (i.e., type) or size or other specification for installation in each orifice <NUM>, an efficient order of installation of the fastener inserts <NUM> across either or both major surfaces 75A, 75B of the composite panel <NUM>, and, if necessary, may move or adjust any of the supports <NUM> engaged with the frame member(s) <NUM>, <NUM> so as to assure external access to the orifices <NUM> for fastener insert installation.

In order to ascertain that the composite panel <NUM> received by the panel handling module <NUM> corresponds to the milling machine program code received by the computer device <NUM>, the panel handling module <NUM> may implement certain panel identification measures to minimize or eliminate the risk of an improper fastener insert installation process occurring with the composite panel <NUM>. For example, general identification of the composite panel <NUM>, and information associated with the configuration of each insert-receiving orifice <NUM> therein, the size of each insert-receiving orifice <NUM> therein, and/or the coordinates of each insert-receiving orifice <NUM> in the second coordinate system may be incorporated into a coded indicium (i.e., a bar code or other machine readable code) <NUM> associated with the composite panel <NUM>. In such instances, the computer device <NUM> or registration arrangement <NUM> may further include a code reader device <NUM> configured to read the coded indicium <NUM> associated with the particular composite panel <NUM> received and secured between the frame members <NUM>, <NUM> 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 <NUM> / registration arrangement <NUM> for association with the first coordinate system <NUM>. Implementation of the image acquisition device and/or the code reader device <NUM> may further allow a feedback loop or system to be implemented by the computer device <NUM> to ascertain, for example, that the same software revision and/or revision of the product specification for the particular composite panel <NUM> was / is being implemented by the upstream milling machine, as well as the fastener insert installation system <NUM>. The information processed in the feedback loop may thus facilitate and ensure, for instance, that the correct fastener insert <NUM> is being installed in the particular orifice <NUM>, that the correct size of the fastener insert <NUM> is being selected for the diameter of the orifice <NUM> or the depth of the composite panel <NUM>, or that any supports <NUM> associated with the frame member <NUM>, <NUM> are not impeding access to any of the orifices <NUM> receiving a fastener insert <NUM>.

The fastener insert assembly module or system <NUM> as shown, for example, in <FIG>, is configured to engage each of a plurality of fastener inserts <NUM> with an installation aide <NUM>. As shown in <FIG>, a fastener insert <NUM> for composite panels <NUM>, as disclosed herein, generally includes a body portion <NUM>, an engagement end <NUM> engaged with one end of the body portion <NUM>, and a retention end <NUM> engaged with the other end of the body portion <NUM>. <FIG> schematically illustrate two example fastener inserts <NUM>, wherein the fastener insert <NUM> illustrated in <FIG> has a "blind hole" configuration, and the fastener insert <NUM> illustrated in <FIG> has a "through hole" configuration. The engagement end <NUM> of the fastener insert <NUM> defines a plurality of adhesive application orifices <NUM> extending therethrough from an engagement surface <NUM> of the engagement end <NUM>, distal to the body portion <NUM>. When installed in the insert-receiving orifice <NUM> of the composite panel <NUM>, the fastener insert <NUM> is preferably disposed such that the engagement surface <NUM> is as close to flush with the one of the major surfaces 75A, 75B defining the orifice <NUM>, as possible (i.e., within a tolerance of about <NUM> inches). As such, it may be desirable to support the fastener insert <NUM> within the orifice <NUM> such that the engagement surface <NUM> is as close to flush as possible with the major surface of the composite panel <NUM>, while an adhesive material is directed through the adhesive application orifices <NUM> and into the insert-receiving orifice <NUM> about the body portion <NUM> of the fastener insert <NUM>, wherein the adhesive material, upon curing, interacts between the fastener insert <NUM> and the portion of the composite panel <NUM> defining the insert-receiving orifice <NUM> to retain and secure the fastener insert <NUM> therein. In order to support the fastener insert <NUM> in the desired position within the orifice <NUM>, an installation aide <NUM> (i.e., a temporary planar tab having a lateral dimension greater than the lateral dimension of the orifice <NUM>) may be affixed to the engagement surface <NUM> of the fastener insert <NUM>. As such, upon insertion of the fastener insert <NUM> in the orifice <NUM>, the installation aide <NUM> engages the major surface about the orifice <NUM> and supports the engagement surface <NUM> close to flush with the major surface, while the adhesive material is directed through the adhesive application orifices <NUM> and about the fastener insert <NUM> within the orifice <NUM>.

Since the fastener insert <NUM> must be assembled with the installation aide <NUM> prior to the fastener insert installation process, a further aspect of the present disclosure provides a fastener insert assembly module or system <NUM> which may initially be configured to sort the fastener inserts <NUM> 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 <NUM> may include three separate hoppers <NUM>, <NUM>, <NUM> for receiving three different configurations or sizes of fasteners inserts <NUM>. In one instance, one hopper <NUM> may receive a first configuration/size of a through hole insert, a second hopper <NUM> may receive a second configuration/size of a through hole insert, and a third hopper <NUM> may receive a first configuration/size of a blind-hole insert. An alignment provision may be associated with each hopper <NUM>, <NUM>, <NUM> such that respective fastener inserts <NUM> fed therethrough are aligned with respect to each other (i.e., such that the longitudinal axes of the fastener inserts <NUM> are parallel to each other).

A fastener insert manipulation device <NUM> (i.e., a robotic arm) as shown, for example, in <FIG>, is configured to select from among the sorted and aligned fastener inserts <NUM>, and to manipulate the selected fastener insert <NUM> so as to engage the engagement surface <NUM> of the fastener insert <NUM> with an engagement surface <NUM> of an installation aide <NUM>. The installation aides <NUM> may be affixed (i.e., by a temporary adhesive) to an elongate sheet material <NUM> in a serial manner, wherein the sheet material <NUM> can then be wrapped about a roll. The rolled sheet material <NUM> may be fed to an interaction location so that the installation aides <NUM> engaged therewith are sequentially presented such that the engagement surface <NUM> thereof is exposed for interaction with one of the fastener inserts <NUM>. The engagement surface <NUM> may have an adhesive material (i.e., a temporary adhesive) engaged therewith. Since each fastener insert <NUM> defines a plurality of adhesive application orifices <NUM> spaced apart about the engagement surface <NUM>, and since each installation aide <NUM> defines a plurality of adhesive application orifices <NUM> spaced apart about an engagement surface <NUM> thereof, the fastener insert manipulation device <NUM> may also be configured to align the adhesive application orifices <NUM> of each fastener insert <NUM> with corresponding adhesive application orifices <NUM> of the installation aide <NUM>.

Such alignment of the adhesive application orifices <NUM>, <NUM> may be accomplished, for example, by a machine vision / feedback system (not shown) in communication with the fastener insert manipulation device <NUM>. The machine vision / feedback system may be configured to guide the fastener insert manipulation device <NUM> to orient the fastener insert <NUM> selected thereby, until the adhesive application orifices <NUM> thereof correspond and align with the adhesive application orifices <NUM> of the installation aide <NUM> at the interaction location. Once the adhesive application orifices <NUM>, <NUM> of the fastener insert <NUM> and the installation aide <NUM> are aligned, the fastener insert manipulation device <NUM> causes the engagement between the engagement surfaces <NUM>, <NUM>. The fastener insert manipulation device <NUM> then moves the fastener insert <NUM>, now engaged with the installation aide <NUM>, away from the interaction location such that the installation aide <NUM> is removed from adherence to the sheet material. The fastener insert manipulation device <NUM> 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 <NUM> and the installation aide <NUM> that could cause misalignment between the adhesive application orifices <NUM>, <NUM>. In some instances, a fastener insert supply device <NUM> may be configured to receive the fastener inserts <NUM>, each engaged with respective installation aides <NUM>, from the fastener insert manipulation device <NUM>, with the fasteners inserts <NUM> oriented in the insertion orientation relative to the installation aide <NUM> and sorted according to the configuration or the size thereof. For example, the fastener insert supply device <NUM> may comprise a series of conveyors <NUM>, <NUM>, <NUM> 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 <NUM> in the composite panel <NUM>, and wherein the opportunities for misalignment of the fastener insert / installation aide assemblies between each other, as well as misalignment between the fastener insert <NUM> and the installation aide <NUM>, are limited or minimized.

As previously disclosed, typical fastener inserts <NUM> of the types herein may often be installed in the composite panel <NUM> 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 <NUM> 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 <NUM> as shown, for example, in <FIG>, may thus be configured to receive one or more adhesive material kits <NUM>, for example, of the type shown in <FIG>, and to mix and actuate the adhesive material therein. As illustrated, each adhesive material kit <NUM> may comprise a tubular body <NUM> having the two components of the adhesive material therein separated by a membrane (not shown). A plunger/mixer <NUM> extends longitudinally outward from the tubular body <NUM>. In order to actuate the adhesive material, the plunger/mixer <NUM> is urged longitudinally with respect to the tubular body <NUM> so as to rupture the membrane and introduce the two parts of the potting compound to each other within the tubular body <NUM>. The plunger/mixer <NUM> 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 <NUM> from the tubular body <NUM>, following the actuation of the adhesive material therein, leaves a dispensation opening (not shown) in the tubular body <NUM> through which actuated adhesive material is dispensed.

The adhesive material preparation module <NUM> may be configured to include a supply device <NUM> for receiving un-actuated adhesive material kits <NUM> in a suitable arrangement for providing a continuous supply for use in the fastener insert installation process, with each kit <NUM> being in a suitable orientation for selection by a manipulation device <NUM> (i.e., a robotic arm) controlled by a controller device (i.e., the computer device <NUM> or other appropriate computer device). Upon selection of a kit <NUM> from the supply device <NUM>, the kit is moved to a mixing device <NUM>, wherein the kit <NUM> is then processed to actuate the adhesive material therein. The kit <NUM> having the actuated adhesive material is then delivered to the fastener insert installation module <NUM> for use in the fastener insert installation process. In this regard, as previously disclosed, the actuated adhesive material in a kit <NUM> may have an effective application lifetime on the order of about <NUM> or <NUM> minutes. As such, the actual working time in which a kit <NUM> may be used to dispense the actuated adhesive material may be on the order of about <NUM> or <NUM> 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 <NUM> may thus also be configured to prepare a subsequent adhesive material kit <NUM> 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 <NUM>.

Due to the sensitive timing requirements involved with the use of the adhesive material kits <NUM>, the adhesive material preparation module <NUM> may also be configured to monitor the operational time for each kit <NUM>. In this regard, the adhesive material preparation module <NUM> may also be in communication with the controller device for control and/or monitoring thereof. In regard to the timing of the kits <NUM>, a time stamp may be associated with a kit <NUM> upon actuation of the adhesive material within the kit <NUM> at the mixing device <NUM>, for example, by scanning a coded indicium (i.e., a bar code) associated with the kit <NUM> 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 <NUM>. Upon expiration of the working time, the kit <NUM> is recalled by the controller, recovered and discarded, and replaced with a subsequent kit <NUM> having actuated adhesive material therein and subject to the same time stamp limitations as the previous kit <NUM>.

It may be possible that the dispensation of the actuated adhesive material from a kit <NUM> causes the actuated adhesive material in that kit <NUM> to be exhausted prior to the expiration of the working time. As such, in some instances, each kit <NUM> 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 <NUM>. 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 <NUM> to determine usage of the actuated adhesive material in a kit <NUM> in comparison to the working time limit. In any event, the adhesive material preparation module <NUM> is configured to minimize process down time upon the expiration of a current kit <NUM> by way of the controller determining that expiration of the current kit <NUM> and directing the adhesive material preparation module <NUM> (i.e., the manipulation device <NUM> and the mixing device <NUM>) to prepare a subsequent kit <NUM> for deployment at an appropriate time after the expired kit <NUM> is recovered and discarded.

The fastener insert installation module or device <NUM> as shown, for example, in <FIG>, may be engaged with or disposed in proximity to the panel handling module <NUM>, and may include an analysis device <NUM> configured to determine a configuration or a size of the insert-receiving orifice <NUM> defined by and extending through a major surface of the composite panel <NUM> received and secured by the panel handling module <NUM>. A manipulation device <NUM> is in communication with the analysis device <NUM> and is configured to select and retrieve one of the plurality of fastener inserts <NUM> engaged with the installation aide <NUM>, in response to the configuration or the size of the insert-receiving orifice <NUM> determined by the analysis device <NUM>. The manipulation device <NUM> is also configured to deliver the selected fastener insert <NUM> to a fastener installation / adhesive dispenser device <NUM> configured to insert the selected fastener insert <NUM> into the insert-receiving orifice <NUM> such that the installation aide <NUM> engages the major surface 75A, 75B of the composite panel <NUM>. The fastener installation / adhesive dispenser device <NUM> is further configured to dispense the actuated adhesive material from the adhesive material kit <NUM> and through the adhesive application orifices <NUM>, <NUM> defined by the installation aide <NUM> and the selected fastener insert <NUM>, and into the insert-receiving orifice <NUM> about selected fastener insert <NUM>, such that the actuated adhesive material interacts with the selected fastener insert <NUM> and the composite panel <NUM> defining the insert-receiving orifice <NUM> so as to secure the selected fastener insert <NUM> within the insert-receiving orifice <NUM> upon curing of the actuated adhesive material. The manipulation device <NUM> may also be configured to retrieve an adhesive material kit <NUM> from the adhesive material preparation module <NUM>, deliver the kit <NUM> to the fastener installation / adhesive dispenser device <NUM>, and recover the kit <NUM> from the fastener installation / adhesive dispenser device <NUM> and discard the kit <NUM> upon expiration thereof.

Initially, the analysis device <NUM> is configured to inspect the composite panel <NUM> secured by the panel handling module <NUM> to determine or confirm whether the insert-receiving orifice <NUM> defined by the composite panel <NUM> 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 <NUM>) of the insert-receiving orifice <NUM>. In making such determinations or confirmations, the analysis device <NUM> may implement, for example, machine vision, laser measurements, or the like. In some instances, the analysis device <NUM> may be in communication with the computer device <NUM>. In such instances, the configuration, size, and/or coordinates (location) of the insert-receiving orifice(s) <NUM> defined by and extending through a major surface of the composite panel <NUM> received and secured by the panel handling module <NUM>, 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 <NUM> 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 <NUM> have been determined or confirmed by the analysis device <NUM>, the manipulation device <NUM> is directed to retrieve one of the fastener inserts <NUM> of the appropriate configuration and size (and having the installation aide <NUM> engaged therewith) from one of the series of conveyors <NUM>, <NUM>, <NUM> (staging area) of the fastener insert supply device <NUM> of the fastener insert assembly module <NUM>, and to deliver the selected fastener insert <NUM> in an appropriate orientation to the fastener installation / adhesive dispenser device <NUM> for installation in the composite panel <NUM>. The installation aide <NUM> engaged with the selected fastener insert <NUM> may include an adhesive material (i.e., a temporary adhesive) on the engagement surface <NUM> thereof engaging engagement surface <NUM> of the fastener insert <NUM>. The fastener installation / adhesive dispenser device 975is further configured to insert the selected fastener insert <NUM> into the insert-receiving orifice <NUM>, for instance, such that the fastener insert <NUM> is centered within the orifice <NUM>. Upon insertion of the fastener insert <NUM> into the orifice <NUM>, the portion of the engagement surface <NUM> exceeding the lateral dimension of the engagement end <NUM> of the fastener insert <NUM> engages and adheres, via the adhesive material, to the major surface 75A, 75B of the composite panel <NUM> defining the insert-receiving orifice <NUM>. In this manner, the installation aide <NUM> secures the fastener insert <NUM> in a desired position within the orifice <NUM>, and supports the engagement surface <NUM> of the fastener insert <NUM> substantially flush with the major surface 75A, 75B or the composite panel <NUM>.

The manipulation device <NUM> may also be configured to retrieve an adhesive material kit <NUM> containing the actuated adhesive material (i.e., potting compound) from the adhesive material preparation module <NUM>, and to deliver the kit <NUM> to the fastener installation / adhesive dispenser device <NUM>. The fastener installation / adhesive dispenser device <NUM> is further configured to align the dispensation opening of the tubular body <NUM> of the kit <NUM> with each adhesive application orifice <NUM>, <NUM> extending through the installation aide <NUM> and the engagement end <NUM> of the fastener insert <NUM>, in turn. For each adhesive application orifice <NUM>, <NUM>, the actuated adhesive material is dispensed from the kit <NUM> by the fastener installation / adhesive dispenser device <NUM> by reducing the volume of the tubular body <NUM> of the adhesive material kit <NUM>. For example, the tubular body <NUM> may include a movable end plate (not shown) engaged therewith opposite to the dispensation opening, wherein the fastener installation / adhesive dispenser device <NUM> may be configured to move the end plate toward the dispensation opening along the tubular body <NUM> in order to reduce the volume within the tubular body <NUM> and dispense the actuated adhesive material through the dispensation opening. The dispensed actuated adhesive material enters the insert-receiving orifice <NUM> about the body portion <NUM> of the fastener insert <NUM> and is sufficiently viscous so as to flow to fill the space between the fastener insert <NUM> and the portion of the composite panel <NUM> defining the orifice <NUM> (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 <NUM>, <NUM>, at which time the fastener installation / adhesive dispenser device <NUM> ceases dispensing the actuated adhesive material from the kit <NUM>. In some instances, the appropriate excess amount realized through the adhesive application orifice <NUM>, <NUM> before ceasing the dispensation of the actuated adhesive material may be determined, for example, by the analysis device <NUM> using machine vision. For example, it may be specified that a sufficient amount of the actuated adhesive material has been dispensed into the orifice <NUM> about the fastener insert <NUM> when an adhesive overflow of about <NUM> inches long is detected and determined by the analysis device <NUM>.

Due to the viscous nature of the actuated adhesive material, the dispensation opening of the adhesive material kit <NUM> may remain in contact with the dispensed actuated adhesive material when the fastener installation / adhesive dispenser device <NUM> is directed to cease dispensation. In some instance, the fastener installation / adhesive dispensation device <NUM> 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 <NUM>, in order, for example, to retract excess actuated adhesive material from the dispensation opening back into the tubular body <NUM> of the adhesive material kit <NUM>. That is, for instance, the fastener installation / adhesive dispenser device <NUM>, upon being directed to cease dispensation of the actuated adhesive material from the kit <NUM>, may retract the end plate of the kit <NUM> away from the dispensation opening by a predetermined amount so as to expand the effective volume of the tubular body <NUM> 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 <NUM> moving the dispensation opening of the kit <NUM> away from the adhesive application orifice <NUM>, <NUM> concurrently with the application of the negative pressure of the kit <NUM>. Some results of this procedure may be, for instance, a cleaner dispensation opening of the kit <NUM> for subsequent dispensing of the actuated adhesive material therefrom and/or preventing contamination of the composite panel <NUM> from excess adhesive material.

Claim 1:
An automated fastener insert installation system (<NUM>) for use in a composite panel fastener insert installation process, comprising:
an analysis device (<NUM>) configured to determine a configuration or a size of the insert-receiving orifice (<NUM>) defined by and extending through a major surface of a composite panel (<NUM>);
a manipulation device (<NUM>, <NUM>, <NUM>) in communication with the analysis device (<NUM>) and configured to select and retrieve one of a plurality of fastener inserts (<NUM>) engaged with an installation aide (<NUM>), in response to the configuration or the size of the insert-receiving orifice (<NUM>) determined by the analysis device (<NUM>), and to insert the selected fastener insert (<NUM>) into the insert-receiving orifice (<NUM>) such that the installation aide (<NUM>) engages the major surface of the composite panel (<NUM>); and
an adhesive dispenser device (<NUM>) configured to dispense an adhesive material through adhesive application orifices (<NUM>, <NUM>) defined by the installation aide (<NUM>) and the selected fastener insert (<NUM>), and into the insert-receiving orifice (<NUM>) about selected fastener insert (<NUM>), such that the adhesive material interacts with the selected fastener insert (<NUM>) and the composite panel (<NUM>) defining the insert-receiving orifice (<NUM>) so as to secure the selected fastener insert (<NUM>) within the insert-receiving orifice (<NUM>), and
an adhesive preparation device engaged with the adhesive dispenser device (<NUM>) and configured to mix and actuate the adhesive material in an adhesive material kit (<NUM>),
the adhesive dispenser device (<NUM>) being configured to receive the adhesive material kit (<NUM>) from the adhesive preparation device, to dispense the actuated adhesive material from the adhesive material kit (<NUM>), and
the adhesive preparation device or the adhesive dispenser device being configured to limit dispensation of the actuated adhesive material from the adhesive material kit (<NUM>) to within a predetermined working time.