Integral clamping-and-bucking apparatus for utilizing a constant force and installing rivet fasteners in a sheet metal joint

Abstract

One advantageous embodiment of the present invention is an integral clamping-and-bucking apparatus ( 12 ) for a system ( 10 ), which is utilized for applying rivet fasteners ( 56 ) to two or more panels ( 14 a , 14 b ) and forming a joint ( 24 ) therebetween. The integral clamping-and-bucking apparatus ( 16 ) includes a clamping foot ( 46 ) for clamping the panels ( 14 a , 14 b ) in a predetermined configuration and for drilling a hole ( 54 ) in the panels ( 14 a , 14 b ) the panels ( 14 a , 14 b ) at the joint ( 24 ). Also, the integral clamping-and-bucking apparatus ( 12 ) further includes a bucking bar ( 48 ) for bucking a rivet tail ( 62 ) that extends from the hole ( 54 ). The clamping foot ( 46 ) and the bucking bar ( 48 ) are coupled to and actuated by a controller ( 32 ). This controller ( 32 ) actuates the bucking bar ( 48 ) and the clamping foot ( 46 ) for transferring power between the clamping foot ( 32 ) and the bucking bar ( 48 ) while maintaining a substantially constant total force applied to the panels ( 14 a , 14 b ).

1 . An integral clamping-and-bucking apparatus for a system that is utilized for applying rivet fasteners to at least two components and forming a joint between those components, comprising: 
 a clamping foot for applying a clamping force to the components and securing the components in a predetermined configuration for drilling a hole in the components at the joint;    a bucking bar for applying a bucking force to a rivet disposed within said hole so as to couple the components at the joint; and    a controller coupled to said clamping foot for actuating said clamping foot to apply said clamping force to the components, said controller also coupled to said bucking bar for actuating said bucking bar to apply said bucking force to said rivet and said components;    wherein a sum of said clamping force and said bucking force comprise a total force;    wherein said controller regulates said clamping force and said bucking force and maintains a substantially constant total force applied to the components.    
   
   
       2 . The integral clamping-and-bucking apparatus as recited in  claim 1  further comprising: 
 a motor coupled between said controller and said clamping foot for actuating said clamping foot to apply said clamping force to the components.    
   
   
       3 . The integral clamping-and-bucking apparatus as recited in  claim 2  wherein said motor is selected from the group consisting of a pneumatically-driven mechanism, an electrically-driven servo mechanism, a screw mechanism, and a pulley mechanism.  
   
   
       4 . The integral clamping-and-bucking apparatus as recited in  claim 1  further comprising: 
 a motor coupled between said controller and said clamping foot for actuating said clamping foot to apply said clamping force to the components.    
   
   
       5 . The integral clamping-and-bucking apparatus as recited in  claim 4  wherein said motor is selected from the group consisting of a pneumatically-driven mechanism, an electrically-driven servo mechanism, a screw mechanism, and a pulley mechanism.  
   
   
       6 . An integral clamping-and-bucking apparatus for a system that is utilized for applying rivet fasteners to at least two panels and forming a joint between those panels, comprising: 
 a base member that is movable substantially along the panels;    a clamping foot coupled to said base member, said clamping foot having a substantially concentric construction for applying a clamping force to the panels and securing the panels in a predetermined configuration for drilling a hole in the panels at the joint and riveting the panels at the joint;    a bucking bar slidably disposed within said base member for applying a bucking force to a rivet disposed within said hole so as to couple the panels at the joint; and    a controller coupled to said clamping foot and said bucking bar for actuating said clamping foot to apply said clamping force to the panels and said bucking bar to apply said bucking force to said rivet;    wherein said controller applies a substantially constant total force to the panels, said substantially constant total force being comprised of said clamping force and said bucking force that is applied to the panels via said rivet.    
   
   
       7 . The integral clamping-and-bucking apparatus as recited in  claim 6  wherein said base member has an end portion with a channel formed therethrough, said channel for passing said bucking bar therethrough and installing said rivet in the panels within said hole.  
   
   
       8 . The integral clamping-and-bucking apparatus as recited in  claim 7  wherein said clamping foot substantially surrounds said channel for applying substantially evenly distributed force to the panels adjacent to said hole.  
   
   
       9 . The integral clamping-and-bucking apparatus as recited in  claim 8  wherein said clamping foot has a ring construction.  
   
   
       10 . The integral clamping-and-bucking apparatus as recited in  claim 6  wherein said clamping foot is comprised of an elastic material.  
   
   
       11 . The integral clamping-and-bucking apparatus as recited in  claim 6  wherein said clamping foot is comprised of a polyurethane material.  
   
   
       12 . The integral clamping-and-bucking apparatus as recited in  claim 6  further comprising: 
 a carrier member having said base member mounted thereon for moving said base member along at least one axis;    wherein said carrier member is located in a fixed position when said controller decreases said clamping force and increases said bucking force.    
   
   
       13 . A system for applying rivet fasteners to at least two panels for forming a joint between those panels, comprising: 
 an integral clamping-and-bucking apparatus disposed on a first side of the joint and comprising a clamping foot and a bucking bar, said clamping foot for applying a clamping force to the panels and securing the panels in a predetermined configuration for drilling a hole in the panels at the joint and riveting the panels at the joint, said bucking bar for applying a bucking force to a rivet disposed within said hole so as to couple the panels at the joint;    an integral drilling-and-riveting apparatus disposed on a second side of the joint and comprising a drilling device and a riveting device, said drilling device for drilling said hole in the panels, said riveting device for applying an impulse force to said rivet; and    a controller coupled to said clamping foot for actuating said clamping foot to apply said clamping force to the panels, said controller also coupled to said bucking bar for actuating said bucking bar to apply said bucking force to said rivet;    wherein said controller applies a substantially constant total force to the panels, said substantially constant total force being comprised of said clamping force and said bucking force.    
   
   
       14 . The system as recited in  claim 13  wherein said integral drilling-and-riveting apparatus further includes an indexing foot for positioning the panels in said predetermined configuration.  
   
   
       15 . The system as recited in  claim 16  wherein said indexing foot and said clamping foot sandwich the panels therebetween in said predetermined configuration.  
   
   
       16 . The system as recited in  claim 16  wherein said indexing foot is coupled to and actuated by said controller.  
   
   
       17 . The system in  claim 13  wherein said indexing foot has a ring construction for substantially surrounding said hole for applying a substantially evenly distributed force to the panels adjacent to said hole.  
   
   
       18 . The system in  claim 13  wherein said clamping foot has a ring construction.  
   
   
       19 . The system in  claim 13  wherein said clamping foot is comprised of an elastic material for deforming against the panels and normalizing the panels against said indexing foot for positioning the panels in said predetermined position.  
   
   
       20 . The system in  claim 19  wherein said clamping foot is comprised of a polyurethane material.  
   
   
       21 . The system in  claim 13  further comprising: 
 a motor coupled between said controller and said clamping foot for actuating said clamping foot to apply said clamping force to the panels.    
   
   
       22 . The system in  claim 21  wherein said motor is selected from the group consisting of a pneumatically-driven mechanism, an electrically-driven servo mechanism, a screw mechanism, and a pulley mechanism.  
   
   
       23 . The system in  claim 13  further comprising: 
 a motor coupled between said controller and said clamping foot for actuating said clamping foot to apply said clamping force to the panels.    
   
   
       24 . The system in  claim 23  wherein said motor is selected from the group consisting of a pneumatically-driven mechanism, an electrically-driven servo mechanism, a screw mechanism, and a pulley mechanism.  
   
   
       25 . A system for applying rivet fasteners to at least two panels and forming a joint between those panels, comprising: 
 an integral clamping-and-bucking apparatus disposed on a first side of the joint of an airframe, said integral clamping bucking apparatus comprising a base member, a clamping foot coupled to said base member, and a bucking bar slidably coupled to said base member, said clamping foot having a substantially concentric construction for applying a clamping force to the panels and securing the panels in a predetermined configuration for drilling a hole in the panels at the joint and riveting the panels at the joint, said bucking bar for applying a bucking force to a rivet disposed within said hole so as to couple the panels at the joint;    an integral drilling-and-riveting apparatus disposed on a second side of the joint and comprising a drilling device and a riveting device, said drilling device for drilling said hole in the panels, said riveting device for applying an impulse force to said rivet; and    a controller coupled to said clamping foot for actuating said clamping foot to apply said clamping force to the panels, said controller also coupled to said bucking bar for actuating said bucking bar to apply said bucking force to said rivet;    wherein said controller applies a substantially constant total force to the panels, said substantially constant total force being comprised of said clamping force and said bucking force.    
   
   
       26 . The system in  claim 25  wherein said base member has an end portion with a channel formed therethrough, said channel for passing said bucking bar therethrough.  
   
   
       27 . The system in  claim 26  wherein said clamping foot substantially surrounds said channel for applying substantially evenly distributed force to the panels adjacent to said hole.  
   
   
       28 . The system in  claim 25  wherein said clamping foot has a ring construction.  
   
   
       29 . The system in  claim 25  wherein said clamping foot is comprised of an elastic material for deforming against the panels and normalizing the panels against said indexing foot for positioning the panels in said predetermined configuration.  
   
   
       30 . The system in  claim 29  wherein said clamping foot is comprised of a polyurethane material.  
   
   
       31 . The system in  claim 25  further comprising: 
 an airframe structure for mounting the panels thereon.    
   
   
       32 . The system in  claim 25  further comprising: 
 at least one rail coupled to the panels for mounting said integral drilling-and-riveting apparatus thereon.    
   
   
       33 . The system in  claim 25  wherein said integral clamping-and-bucking apparatus further comprises: 
 a carrier member having said base member mounted thereon for moving said base member along at least one axis on said first side of the joint;    wherein said carrier member is located in a fixed position when said controller decreases said clamping force and increases said bucking force.    
   
   
       34 . The system in  claim 25  wherein said integral drilling-and-riveting apparatus further comprises: 
 a guide member having said drilling device and said riveting device mounted thereon for moving said drilling device and said riveting device along at least one axis on said second side of the joint.    
   
   
       35 . A method for applying rivet fasteners to at least two panels and forming a joint between those panels, comprising: 
 positioning an integral clamping-and-bucking apparatus in a first predetermined position on a first side of the panels, said integral clamping-and-bucking apparatus including a clamping foot and a bucking bar that is slidably coupled to said clamping foot;    actuating said clamping foot for applying a clamping force to the panels and securing the panels in a predetermined configuration for drilling a hole in the panels at the joint and riveting the panels at the joint;    decreasing said clamping force by a predetermined amount;    increasing said bucking force by about said predetermined amount;    applying a substantially constant total force that is applied to the panels, said substantially constant total force being comprised of said clamping force and said bucking force.    
   
   
       36 . The system as recited in  claim 35  further comprising: 
 mounting the panels to a frame in said predetermined configuration;    positioning an integral drilling-and-riveting apparatus in said first predetermined position on a second side of the panels;    actuating said integral drilling-and-riveting apparatus to drill said hole in the panels;    inserting a blank rivet in said hole;    actuating said integral drilling-and-riveting apparatus and said integral clamping-and-bucking apparatus to install said rivet in the panels within said hole;    unclamping the panels;    positioning said integral clamping-and-bucking apparatus in a second predetermined position on a first side of the joint between the panels;    positioning an integral drilling-and-riveting apparatus in said second predetermined position on a second side of the joint between the panels.    
   
   
       37 . The method as recited in  claim 36  further comprising: 
 positioning an indexing foot of said integral drilling-and-riveting apparatus in said first predetermined position on said second side of the panels; and    actuating a clamping foot of said integral clamping-and-bucking apparatus to force the panels against said indexing foot.    
   
   
       38 . The method as recited in  claim 37  wherein actuating said clamping foot comprises: 
 deforming said clamping foot against the panels and normalizing the panels on said indexing foot for positioning the panels in said predetermined configuration.    
   
   
       39 . A method for manufacturing an airframe, comprising: 
 mounting at least two airframe components on a frame in a predetermined configuration;    positioning an integral clamping-and-bucking apparatus in a first predetermined position on a first side of the panels, said integral clamping-and-bucking apparatus including a clamping foot and a bucking bar that is slidably coupled to said clamping foot;    positioning an integral drilling-and-riveting apparatus in said first predetermined position on a second side of the panels; said integral drilling-and-riveting apparatus including a guide that is movable along said second side of the panels, an indexing foot coupled to said guide, a drilling device slidably coupled to said guide, a riveting device slidably coupled to said guide;    applying said clamping force for sandwiching the panels in said predetermined configuration between said indexing foot and said clamping foot;    drilling a hole in the panels;    inserting a blank rivet in said hole;    decreasing said clamping force by a predetermined amount;    increasing said bucking force by about said predetermined amount;    applying a substantially constant total force that is applied to the panels, said substantially constant total force being comprised of said clamping force and said bucking force.    
   
   
       40 . actuating said riveting device for installing a rivet in the panels within said hole; 
 unclamping the panels;    positioning said integral clamping-and-bucking apparatus in a second predetermined position on a first side of the joint between the panels;    positioning an integral drilling-and-riveting apparatus in said second predetermined position on a second side of the joint between the panels.