Flow drill screw installation method to reduce installation torque and permit installation into thick materials

A method of operating an automatic tool to install a flow drill screw (FDS) into a substrate, the method comprising:

• engaging the FDS with the automatic tool;
• operating the automatic tool at a first setting to drive the FDS into the substrate by causing flow of the substrate to permit the FDS to penetrate the substrate, the first setting being configured to rotate the FDS at a first rotational speed and to apply a first axial feed force on the FDS, the first setting being configured to cause flow of the substrate to permit the FDS to penetrate the substrate;
• detecting a predetermined first trigger condition, the predetermined first trigger condition including at least one of a depth gradient and a depth;
• detecting a predetermined second trigger condition using the one or more sensors, the predetermined second trigger condition detected in response to the predetermined first trigger condition being detected, the predetermined second trigger condition including at least one of a predetermined axial feed distance and a predetermined time delay;
• and
• switching the automatic tool from the first setting to a second setting in response to the predetermined second trigger condition being met, wherein the second setting is configured to rotate the FDS at a second rotational speed and to apply a second axial feed force to the FDS, wherein the second rotational speed is less than the first rotational speed and the second axial feed force is less than the first axial feed force
• wherein the one or more sensors send a signal to a controller, wherein the controller triggers the predetermined time delay in response to receiving the signal.