Automated method and apparatus for driving fasteners into an electric fan assembly

A control system for controlling torque of a pneumatic driver in communication with a pressurized air source, the system comprising:

• a controller;
• a primary valve in communication with the air source to control an intake of air flow to the driver;
• a canister having a predetermined volume and connected to the primary valve;
• an adjustable air regulator connected to the canister;
• and
• a sensor connected to the pneumatic driver and in communication with the controller;
• wherein the sensor communicates with the controller to terminate the intake of air flow upon penetration of the fasteners into the fan shroud;
• and
• wherein the air regulator regulates a flow rate of air from the canister upon termination of intake air, thereby regulating torque generated by the pneumatic driver in relation to the regulation of the flow rate of air from the canister.

A control system for controlling torque of a pneumatic driver in communication with a pressurized air source, the system comprising:

• a controller;
• a canister having a predetermined volume in fluid communication with the pneumatic driver and in selective fluid communication with the air source;
• an adjustable air regulator connected to the canister;
• and
• a sensor connected to the pneumatic driver and in communication with the controller;
• wherein the sensor communicates with the controller to terminate the air flow from the air source to the cannister upon penetration of the fasteners into the fan shroud;
• and
• wherein the air regulator regulates a flow rate of air from the canister to the pneumatic driver upon termination of air flow to the cannister, thereby regulating torque generated by the pneumatic driver in relation to the regulation of the flow rate of air from the canister.

An apparatus for assembling a fan, comprising:

• a support structure having a moveable carriage disposed in a horizontal plane, the moveable carriage adapted to align and carry a first fan grill, a fan shroud, and a second fan grill of a fan assembly;
• a clamping structure moveably attached to the support structure in a direction transverse to the horizontal plane and having clamps adapted to clamp the fan assembly;
• a first plurality of automatic drivers attached to the clamping structure and moveable in a direction transverse to the horizontal plane;
• a second plurality of automatic drivers attached to the clamping structure and moveable in a direction transverse to the horizontal plane and generally opposite the movement direction of the first plurality of drivers;
• wherein the first set of automatic drivers drive a plurality of fasteners into the first fan grill while the second set of automatic drivers simultaneously drive a plurality of fasteners into the second fan grill.

An apparatus for assembling a fan comprising:

• a support structure having a moveable carriage disposed in a horizontal plane, the moveable carriage adapted to align and carry a first fan grill, a fan shroud, and a second fan grill of a fan assembly;
• a plurality of clamps moveably attached to the support structure in a direction transverse to the horizontal plane of the carriage and adapted to clamp the fan assembly;
• and
• at least one automatic driver moveably attached to the support structure in a first direction transverse to the horizontal plane of the carriage;
• and
• at least one automatic driver moveably attached to the support structure in a second direction transverse to the horizontal plane of the carriage;
• wherein the automatic drivers simultaneously drive a plurality of fasteners into the fan grills from the first and second directions.

A method of assembling a fan having a first fan grill, a shroud portion, and a second fan grill, the method comprising the steps of:

• placing the first fan grill, the shroud portion, and the second fan grill onto a moveable carriage disposed in a horizontal plane of an assembly apparatus;
• clamping the first fan grill and the second fan grill to the shroud portion in a direction transverse to the horizontal plane of the carriage;
• engaging the first fan grill with at least one automatic driver in a first direction transverse to the horizontal plane of the carriage;
• engaging the second fan grill with at least one automatic driver in a second direction transverse to the horizontal plane of the carriage;
• driving a plurality of fasteners with the automatic drivers into the fan grills from the first and second directions.

A method of controlling torque generated by a pneumatic driver in communication with a pressurized air source, the method comprising the steps of:

• pressurizing a canister having a predetermined volume in fluid communication with the pneumatic driver and in selective fluid communication with the air source;
• terminating the air flow from the air source to the cannister upon penetration of a fastener into a workpiece to a predetermined extent;
• and
• regulating a flow rate of air from the canister to the pneumatic driver upon termination of air flow to the cannister, thereby regulating torque generated by the pneumatic driver in relation to the regulation of the flow rate of air from the canister.