Rivetless fastener and installation tool

Abstract

A fastener for retaining a bolt in a hole in a structure, comprising a bushing integrally formed with and extending from the bottom surface of a retainer, the bushing being dimensioned for insertion into the hole in the structure and having a wall thickness ranging from about 0.005 inches to about 0.030 inches, wherein the bushing is configured to be expanded within the hole, thereby securely coupling the expanded bushing within the hole of the structure and anchoring the retainer to the surface of the structure surrounding the hole. A tool for installing a fastener, comprising a tapered mandrel configured for insertion within a fastener situated within a hole of the structure, a drive mechanism configured to retract the mandrel through the fastener and thereby expand the fastener, and a force sensor configured for measuring a force applied by the drive mechanism to retract the mandrel through the fastener.

What is claimed is: 
     
         1 - 10 . (canceled) 
     
     
         11 . A tool for installing a fastener to a structure, the tool comprising:
 a mandrel having a tapered shape, the mandrel configured for insertion within a fastener situated within a hole of the structure;   a drive mechanism configured to retract the mandrel through the fastener and thereby expand the fastener within the hole of the structure; and   a force sensor configured for measuring a force applied by the drive mechanism to retract the mandrel through the fastener.   
     
     
         12 . The tool of  claim 11 ,
 wherein the drive mechanism includes a lead screw coupled with a threaded sleeve, and   wherein rotating the lead screw causes the threaded sleeve to move axially to retract and extend the mandrel.   
     
     
         13 . The tool of  claim 12 , wherein a head of the lead screw is configured to couple with at least one of an electric drill and an impact driver. 
     
     
         14 . The tool of  claim 11 , further comprising an integrated drive device for driving the drive mechanism. 
     
     
         15 . The tool of  claim 11 ,
 further comprising a free-floating component situated adjacent to the force sensor and partially extending from a distal end of a housing of the tool, and   wherein the free-floating component is configured to transmit, to the force sensor, a pressure generated between the free-floating component and the structure when the mandrel is retracted to expand the fastener.   
     
     
         16 . The tool of  claim 15 , further comprising a first pressure plate and a second pressure plate situated on opposing sides of the force sensor, the first pressure plate and the second pressure plate acting to evenly distribute and direct forces applied by the free-floating component to act perpendicular to the force sensor. 
     
     
         17 . The tool of  claim 11 , further comprising a processor configured to determine at least one of a maximum force measured by the force sensor during installation of the fastener and a total force measured by the force sensor throughout the installation of the fastener. 
     
     
         18 . The tool of  claim 17 , wherein the processor is configured to store, or transmit for remote storage, at least one of the measured maximum force and the measured total force. 
     
     
         19 . The tool of  claim 17 , wherein the processor is further configured to:
 compare at least one of the measured maximum force and the measured total force to a predetermined range of corresponding forces, the predetermined range defining a range of corresponding forces indicative of a successful installation, and   automatically provide a notification to a user of the tool indicating whether the measured maximum force and/or the measured total force is within the predetermined range.   
     
     
         20 . The tool of  claim 17 ,
 further comprising a radio frequency identification (RFID) reader positioned near a distal end of the tool,   wherein the RFID reader is configured to automatically scan an RFID tag located on or in the fastener, and   wherein the processor is configured to associate at least one of the measured maximum force and the measured total force with an identification of the RFID tag.   
     
     
         21 . A tool for measuring a force associated with installation of a fastener in a structure, the tool comprising:
 a housing adapter shaped and dimensioned for coupling to a nosepiece of a mandrel pulling tool;   a mandrel having a tapered shape, the mandrel having a proximal end configured for coupling to the mandrel pulling tool and a distal portion configured for insertion within a fastener situated within a hole of the structure; and   a force sensor configured for automatically measuring a force applied by the drive mechanism to retract the mandrel through the fastener during installation.   
     
     
         22 . The tool of  claim 21 ,
 further comprising a free-floating component situated adjacent to the force sensor and partially extending from a distal end of the housing adapter, and   wherein the free-floating component is configured to transmit, to the force sensor, a pressure generated between the free-floating component and the structure when the mandrel is retracted to expand the fastener.   
     
     
         23 . The tool of  claim 22 , further comprising a first pressure plate and a second pressure plate situated on opposing sides of the force sensor, the first pressure plate and second pressure plate acting to evenly distribute and direct forces applied by the free-floating component to act perpendicular to the force sensor. 
     
     
         24 . The tool of  claim 21 , further comprising a processor configured to determine at least one of a maximum force measured by the force sensor during installation of the fastener and a total force measured by the force sensor throughout the installation of the fastener. 
     
     
         25 . The tool of  claim 24 , wherein the processor is configured to store, or transmit for remote storage, at least one of the measured maximum force and the measured total force. 
     
     
         26 . The tool of  claim 24 , wherein the processor is further configured to:
 compare at least one of the measured maximum force and the measured total force to a predetermined range of corresponding forces, the predetermined range defining a range of corresponding forces indicative of a successful installation, and   automatically provide a notification to a user of the tool indicating whether the measured maximum force and/or the measured total force is within the corresponding predetermined range.   
     
     
         27 . The tool of  claim 24 ,
 further comprising a radio frequency identification (RFID) reader positioned near a distal end of the tool,   wherein the RFID reader is configured to automatically scan an RFID tag located on or in the fastener, and   wherein the processor is configured to associate at least one of the measured maximum force and the measured total force with an identification of the RFID tag.   
     
     
         28 . A tool for measuring a force associated with installation of a fastener in a structure, the tool comprising:
 a housing;   a force sensor situated within the housing; and   a free-floating component situated adjacent to the force sensor and partially extending from a distal end of the housing, the free-floating component being configured to transmit, to the force sensor, a pressure generated between the free-floating component and the structure during installation of the fastener.   
     
     
         29 . The tool of  claim 28 ,
 further comprising a mandrel configured for insertion within the fastener situated within a hole of the structure, and   wherein installation of the fastener comprises retracting the mandrel through the fastener and thereby expand the fastener within the hole of the structure.   
     
     
         30 . The tool of  claim 29 , further comprising a drive mechanism configured to retract the mandrel through the fastener and thereby expand the fastener within the hole of the structure. 
     
     
         31 . The tool of  claim 28 , wherein the tool is configured to be coupled to the nosepiece of a mandrel pulling tool. 
     
     
         32 . The tool of  claim 28 , further comprising a first pressure plate and a second pressure plate situated on opposing sides of the force sensor, the first pressure plate and second pressure plate acting to evenly distribute and direct forces applied by the free-floating component to act perpendicular to the force sensor. 
     
     
         33 . The tool of  claim 28 , further comprising a processor configured to determine at least one of a maximum force measured by the force sensor during installation of the fastener and a total force measured by the force sensor throughout the installation of the fastener. 
     
     
         34 . The tool of  claim 33 , wherein the processor is configured to store, or transmit for remote storage, at least one of the measured maximum force and the measured total force. 
     
     
         35 . The tool of  claim 33 , wherein the processor is further configured to:
 compare at least one of the measured maximum force and the measured total force to a predetermined range of corresponding forces, the predetermined range defining a range of corresponding forces indicative of a successful installation, and   automatically provide a notification to a user of the tool indicating whether the measured maximum force and/or the measured total force is within the corresponding predetermined range.   
     
     
         36 . The tool of  claim 28 ,
 further comprising a radio frequency identification (RFID) reader positioned near a distal end of the tool,   wherein the RFID reader is configured to automatically scan an RFID tag located on or in the fastener, and   wherein the processor is configured to associate at least one of the measured maximum force and the measured total force with an identification of the RFID tag.