Portable Fastener Installation Device

ABSTRACT:To address the Air Force need for an integrated drilling, sealing, and fastener installation solution that does not require stack-up disassembly in sheet metal aircraft, Physical Optics Corporation (POC) has developed the Portable Fastener Installation Device (PFID), which provides adequate clamping force between sheet metal layers to prevent interlaminate burrs, drills holes to the specified tolerance without de-stacking, applies sealant to the hole, and inserts either a standard or interference-fit fastener. As a result, this device offers the ability to combine multiple processes into a single setup, greatly improving manufacturing process time, eliminating the current need for disassembly and deburring processes, reducing operator error, and increasing safety, which directly addresses the Air Forces current quality and labor concerns for C-130 aircraft production and repair. In Phase I, POC demonstrated the feasibility of the PFID by building a completely functional prototype tool capable of demonstrating complete functionality. In Phase II, POC will continue development of the PFID to improve tool precision, durability, safety, and cost-effective manufacturability, as well as begin tailoring the tool to immediate customer needs, culminating in a final prototype, capable of reliably installing fasteners in a production-representative environment, with a clear, detailed path toward transition to production.BENEFIT:The proposed PFID system will meet the needs of the Air Force by greatly reducing both the labor required to install fasteners, as well as ensuring quality and consistency while reducing production costs of the C-130. PFID will also prove valuable while performing repairs and maintenance on legacy C-130J aircraft. It will ensure that the Air Forces aircraft fleet will be produced efficiently, spend as much time as possible in service, and have reduced maintenance time and costs. Furthermore, PFID can be adapted to reduce costs and improve quality for other manufacturers in both the commercial and defense aircraft markets, as well as be adapted to markets with similar manufacturing methodologies, such as those in the automotive and ship building industries.