Special tool for removing excess adhesive from leak holes in aircraft air intakes

Abstract

This invention belongs to the technical field of excess adhesive removal after gluing on aircraft air intake stacks, and relates to a special tool for removing excess adhesive from aircraft air intake drainage holes. Analysis of existing excess adhesive removal methods and tools reveals several problems, including high workload, low efficiency, potential scratches on drainage hole edges during removal, incomplete removal, excessive removal volume, significant susceptibility to subjective judgment and operator skill, and inconvenience and difficulty in removing excess adhesive from complex airframe structures or semi-enclosed areas. These disadvantages directly affect the standard of excess adhesive removal, increase labor costs, and extend product delivery cycles.

Description

Technical Field

[0001] This invention belongs to the technical field of removing excess adhesive after applying adhesive to the assembly of aircraft air intake stacks, and relates to a special tool for removing excess adhesive from the water leakage holes of aircraft air intakes. Background Technology

[0002] Aircraft skin and other aerodynamic shape areas are usually designed with drainage holes to allow the aircraft to drain water in rainy or snowy weather to ensure flight safety. After the sealant is applied, the excess sealant can flow into the drainage holes, causing the holes to shrink or even become blocked. This increases the risk of accidents during flight, affecting product quality and flight safety. Therefore, the control and inspection of excess adhesive during aircraft manufacturing and inspection are key concerns, and removing excess adhesive from drainage holes has become a top priority with strict standards.

[0003] Currently, the main method for removing excess adhesive from leaks in aviation products is scraping. This involves using a slanted scraper. After the excess adhesive has dried and covered the leak, the obtuse angle of the scraper is used to scrape away the excess adhesive layer by layer until the leak is exposed. Then, the center of the leak is manually predicted based on the exposed portion of the hole, and the sharp tip of the scraper is inserted at a certain angle into the excess adhesive. The scraper is then manually rotated along the blade direction, removing the excess adhesive layer by layer until the leak is completely exposed. The advantage of this method is that it thoroughly removes excess adhesive, requires only a slanted scraper, and is relatively simple and convenient. The disadvantages are that it is slow, has high labor costs, and because it is manual, rotating the scraper just before exposing the leak can easily scratch the edges of the leak. Furthermore, the scraper needs to be at a certain angle during operation, and the long blade can easily result in excessive removal, failing to meet process standards. The blade is also quite sharp, posing a safety hazard to the operator. Therefore, a specialized tool for removing excess adhesive is needed. Summary of the Invention

[0004] To address the aforementioned problems, this invention explores a simple method with advantages such as low labor intensity, high efficiency in removing excess adhesive, independence from operator skill level, adaptability to various complex machine environments, particularly in semi-enclosed areas with poor openness or complex structures, high precision in rotation angle control, and minimal risk of scratching the edges of leak holes. This invention aims to provide on-site operators with a method for removing excess adhesive from leak holes. A dedicated electronic removal tool is designed specifically for this purpose. Its adjustable shape, simple operation, and ease of use minimize operator skill requirements. The removal head can be flexibly selected based on the applicable scenario. Furthermore, to reduce operating costs, the head can be 3D printed, making it suitable for various confined and complex areas. This invention is also rechargeable, eliminating the need for an external power source, thus reducing operator labor intensity and improving excess adhesive removal efficiency.

[0005] The technical problem solved by this invention is achieved by the following technical solution:

[0006] Specialized tool for removing excess adhesive from leaking holes in aircraft air intakes, as included. Figure 1 and attached Figure 2 As shown, it includes a transmission operation section, a control system section, and a machine body structure section;

[0007] The transmission mechanism is the main working part of this invention, used to remove excess adhesive. It includes a guide rod, a cutter head, a caliper, a working end drive shaft, a retaining ring, a handle, a universal drive shaft, a bushing, an external hexagonal screwdriver head, a power end drive shaft, a stepper motor, and bearings. The guide rod features a small-angle taper transition to guide the tool, ensuring a straight-line forward movement and preventing damage to other parts. The cutter head is the direct working part of the tool and can be customized in various specifications. Different types are selected based on the degree of blockage in the drain hole. For minor blockages, a countersunk drill type cutter head (as shown in Appendix 3) can be used; for complete blockages, a drill type cutter head (as shown in Appendix 4) can be used. It is mainly used to remove excess adhesive from the drain hole. To prevent scratching the drain hole, a material with a lower hardness than the drain hole is used. This invention uses polyphenylene sulfide (PPS), which has advantages such as high temperature resistance, chemical resistance, high ignition point, and good thermal stability. The caliper is the clamping device of this invention, using a miniature three-jaw chuck to hold the cutter head. The working end drive shaft uses an internal drive shaft design, which converts the rotation of the universal drive shaft to the caliper, thereby driving the rotation of the cutter head to remove excess adhesive. The retaining ring is the handle's supporting mechanism, used to connect the working end drive shaft and the universal drive shaft, and to receive the universal drive shaft's motion transmission. The handle is the tool's handheld structure, mainly used for removing excess adhesive from narrow, unopen areas. The universal drive shaft allows for bending and rotation transmission, and is covered with black rubber. Inside is a flexible stainless steel shaft with an external hexagonal head. The shaft is replaceable, facilitating maintenance after wear, and allows for bending and rotation transmission. The bushing is a hollow design, as shown in the attached image. Figure 2 As shown, the tool features bearings with internal hexagonal holes on both the left and right sides. The internal hexagonal shaft, which enables the universal drive shaft and the external hexagonal screwdriver head, is inserted into the bearings within the hexagonal holes of the bushing, achieving a reliable transmission connection. The power-end drive shaft transmits the torque from the stepper motor to the external hexagonal screwdriver head, enabling torque output. The stepper motor is the power structure of this tool; a 12V high-torque reduction stepper motor is used, generating high-precision angular torque for accurate rotational positioning. Its low speed and high torque ensure a smooth, burr-free cutting process for excess adhesive.

[0008] The control system section is the control function implementation part of this invention, used to realize the power supply and action control of the system. It includes control buttons, switches, a charging module, a power module, a microcontroller, and a controller. The control buttons control the forward and reverse rotation of the tool. The rotation direction of the stepper motor varies depending on the position and angle, and this is selected via the control buttons. The switch is the tool's start / stop device; pressing it starts the tool, and the degree of pressing controls the rotation speed. More pressing results in greater torque and thus a higher rotation speed. The charging module and power module are the tool's energy storage and power supply components. One end of the charging module is connected to the power module, and the other end is connected to the charging port. The power module stores energy through the charging port. The power module is a 3.7V lithium battery, which is boosted to 12V by a boost module to power the control buttons, microcontroller, controller, and stepper motors to complete the control actions. The microcontroller is the tool's information processing component, receiving signals from the control buttons and switches, processing them, and then transmitting the information. The controller is the component that issues action commands to this tool. It controls the operation by receiving information processed by the microcontroller and completes the cleaning of excess adhesive.

[0009] The aforementioned body structure is the main load-bearing structure of this tool, used to support and fix various components. It includes the main housing, charging port, back cover, and screws. The housing is the primary load-bearing component, and spaces are reserved inside as needed for the power module, charging module, microcontroller, controller, and stepper motor. The charging port uses a mainstream Type-C interface, allowing charging of the power module using a mobile phone charging cable. The back cover and screws are used to seal the cavity structure; after the internal components of the housing are installed, the back cover is sealed using screws.

[0010] The beneficial effects of this invention are:

[0011] This invention analyzes existing methods and tools for removing excess adhesive, revealing several drawbacks: high workload, low efficiency, potential scratches on the edges of drainage holes, incomplete removal, excessive removal volume, susceptibility to subjective judgment and operator skill, and inconvenience and difficulty in removing adhesive from complex machine structures or semi-enclosed areas. These disadvantages directly affect the standards for removing excess adhesive, increase labor costs, and extend product delivery cycles.

[0012] During the product manufacturing process, by implementing the above-mentioned methods for removing excess adhesive and using the aforementioned specialized electronic tools, the efficiency of excess adhesive removal is effectively improved, and the operator's working time is significantly reduced. This plays a positive role in controlling the amount of excess adhesive applied to water leakage holes in aerospace products and improving the surface quality of parts. At the same time, the specialized tools are easy to carry and have a high degree of effectiveness and obvious advantages in troubleshooting water leakage holes in complex areas after the product has been formed in the field. This saves troubleshooting time and leaves valuable time for the next process, thus playing a positive role in reducing labor costs, reducing time waste, optimizing production rhythm, and planning the layout of the production line. Attached Figure Description

[0013] Figure 1 This is an isometric view of a tool for removing excess adhesive from leaking holes;

[0014] Figure 2 This is a front sectional view of a tool for removing excess adhesive from leaking holes;

[0015] Figure 3 It is a countersunk drill bit;

[0016] Figure 4 It is a drill bit type cutter head.

[0017] Among them, 1-guide rod, 2-cutting head, 3-caliper, 4-working end drive shaft, 5-fixed ring, 6-handle, 7-universal drive shaft, 8-bushing, 9-external hexagonal screwdriver head, 10-power end drive shaft, 11-main housing, 12-control button, 13-switch, 14-charging port, 15-rear cover, 16-screw, 17-charging module, 18-power module, 19-microcontroller, 20-controller, 21-stepper motor, 22-bearing. Detailed Implementation

[0018] The embodiments of the present invention will be described in detail below with reference to the accompanying drawings. This embodiment is based on the technical solution of the invention and provides detailed implementation methods and specific implementation processes. However, the scope of protection of the present invention is not limited to the following implementation examples.

[0019] Example 1:

[0020] Specialized tool for removing excess adhesive from leaking holes in aircraft air intakes, as included. Figure 1 and attached Figure 2 As shown, it includes a transmission operation section, a control system section, and a machine body structure section;

[0021] The transmission mechanism is the main working part of this invention, used to remove excess adhesive. It includes a guide rod 1, a cutter head 2, a caliper 3, a working end drive shaft 4, a retaining ring 5, a handle 6, a universal drive shaft 7, a bushing 8, an external hexagonal screwdriver head 9, a power end drive shaft 10, a stepper motor 21, and a bearing 22. The guide rod 1 uses a small-angle conical transition to guide the tool, ensuring it moves in a straight line and preventing damage to other parts. The cutter head 2 is the direct working part of this tool and can be customized in various specifications. Different types are selected based on the degree of blockage of the drain hole. For slight blockage, a countersunk drill type cutter head 2 (as shown in Appendix 3) can be used; for complete blockage, a drill type cutter head 2 (as shown in Appendix 4) can be used. It is mainly used to remove excess adhesive from the drain hole. To prevent scratching the drain hole, a material with a lower hardness than the drain hole is used. This invention uses polyphenylene sulfide (PPS) material, which has advantages such as high temperature resistance, chemical resistance, high ignition point, and good thermal stability. The caliper 3 is the clamping device of this invention, employing a miniature three-jaw chuck to clamp the cutter head 2. The working end drive shaft 4 is an internal drive shaft that can transfer the rotation of the universal drive shaft 7 to the caliper 3, thereby driving the rotation of the cutter head 2 to complete the removal of excess adhesive. The retaining ring 5 is the bearing mechanism of the handle 6, used to connect the working end drive shaft 4 and the universal drive shaft 7, and to receive the motion transmission of the universal drive shaft 7. The handle 6 is the handheld structure of this tool, mainly used to remove excess adhesive in narrow, closed areas. The universal drive shaft 7 enables the bending and rotation transmission of this tool. It is covered with black rubber and contains a bendable stainless steel shaft. The shaft head has an external hexagonal structure, and the shaft core is replaceable, facilitating maintenance after wear. The bushing 8 is a hollow design, as shown in the attached... Figure 2 As shown, the bearings 22 with internal hexagonal holes on both the left and right sides of the bushing 8 allow the universal drive shaft 7 and the external hexagonal screwdriver head 9 to be inserted into the hexagonal holes of the bearings 22, achieving a transmission connection with high reliability. The power-end drive shaft 10 transmits the torque of the stepper motor 21 to the external hexagonal screwdriver head 9, realizing the torque output function. The stepper motor 21 is the power structure of this tool. It adopts a 12V high-torque reduction stepper motor, which can generate high-precision angular torque, achieve precise positioning of rotation, and has low speed and high torque, which can ensure a smooth and burr-free cutting process for excess glue.

[0022] The control system section is the control function implementation part of this invention, used to realize the power supply and action control of the system. It includes control button 12, switch 13, charging module 17, power module 18, microcontroller 19, and controller 20. Control button 12 controls the forward and reverse rotation adjustment of the tool. Since the rotation direction of the stepper motor 21 varies depending on the position and angle, the control button 12 is used to select the direction. Switch 13 is the start / stop device of the tool; pressing it starts the tool. The degree of pressing controls the speed; the more it is pressed, the greater the torque, and thus the greater the speed. Charging module 17 and power module 18 are the power storage and power supply components of the tool. One end of charging module 17 is connected to power module 18, and the other end is connected to charging port 14. Power module 18, a 3.7V lithium battery, is charged through charging port 14 and charged via charging module 17 to store power. Power module 18 is a 3.7V lithium battery, boosted to 12V by a boost module to power control button 12, microcontroller 19, controller 20, and stepper motor 21 to complete the control actions. The microcontroller 19 is the information processing element of this tool. It receives signals from the control button 12 and the switch 13, processes them, and then transmits the information. The controller 20 is the action command issuing element of this tool. It receives the information processed by the microcontroller 19 to control the operation and complete the cleaning of excess glue.

[0023] The main structural component is the primary load-bearing structure of this tool, used to support and secure the various components. It includes the main housing 11, charging port 14, back cover 15, and screws 16. The housing 11 is the main load-bearing component, and spaces are reserved inside as needed for the power module 18, charging module 17, microcontroller 19, controller 20, and stepper motor 21. The charging port 14 uses a mainstream Type-C interface, allowing charging of the power module 18 using a mobile phone charging cable. The back cover 15 and screws 16 are used to seal the cavity structure; after the internal components of the housing 11 are installed, the back cover 15 is sealed using the screws 16.

[0024] Example 2:

[0025] Taking a minor blockage of the φ5 drainage hole in the open area of ​​a product's skin as an example, the method for removing excess adhesive is as follows:

[0026] Step 1: Tool Assembly. Select a φ5 countersink drill bit 2 according to the operational requirements, install it on the caliper 3, and ensure that the installation is secure and coaxial;

[0027] Step 2: Insert the external hex screwdriver bit 9 into the bushing 8. You will hear a "click" sound, which indicates that the safety ball has popped up and is fully inserted.

[0028] Step 3: Operate control button 12 to select whether the stepper motor 21 rotates forward or backward. Press switch 13 to check that the tool is rotating properly, has sufficient power, and is fully charged.

[0029] Step 4: Hold the main housing 11 with one hand and the handle 6 with the other hand. Align the guide rod 1 with the φ5 drain hole and ensure that the axis of the countersink drill bit 2 is perpendicular to the drain hole.

[0030] Step 5: Slowly apply pressure to the handle 6 towards the drain hole, and at the same time slowly squeeze the switch 13. The countersink drill bit 2 will start to rotate and work.

[0031] Step Six: Since the hardness of the cutter head 2 is lower than that of the part material, when there is no stroke when pressure is applied, it indicates that the excess adhesive has been removed. At this time, continue to keep switch 13 closed and slowly retract the cutter head 2 while it is rotating. The operation is now complete.

[0032] Example 3:

[0033] Taking the example of a completely blocked φ6 water leakage hole at the joint of a semi-enclosed area of ​​a certain product as an example, the method for removing excess adhesive is as follows:

[0034] Step 1: Tool Assembly. Select a φ6 drill bit 2 according to the operational requirements, install it on the caliper 3, and ensure that the installation is secure and coaxial.

[0035] Step 2: Insert the external hex screwdriver bit 9 into the bushing 8. You will hear a "click" sound, which indicates that the safety ball has popped up and is fully inserted.

[0036] Step 3: Manually bend the universal drive shaft 7 into a 'Z' shape to ensure that the drill bit 2 can work at the φ6 water leakage hole position in the semi-enclosed area;

[0037] Step 4: Operate control button 12 to select whether the stepper motor 21 rotates forward or backward. Press switch 13 to check that the tool is rotating properly, has sufficient power, and is fully charged.

[0038] Step 5: Hold the main housing 11 with one hand and the handle 6 with the other hand. Align the drill bit 2 with the φ6 drain hole and ensure that the axis of the drill bit 2 is perpendicular to the drain hole.

[0039] Step 6: Slowly apply pressure to the handle 6 towards the drain hole, while simultaneously slowly pressing down the switch 13. The drill bit 2 will then begin to rotate.

[0040] Step 7: As the drill bit 2 rotates and cuts away excess adhesive, it will gradually become coaxial with the drain hole. Since the material of the drill bit 2 is less hard than that of the part, it will not scratch the part. When the drill bit 2 passes through the drain hole, it indicates that the excess adhesive has been removed. At this point, keep switch 13 closed and slowly withdraw the drill bit 2 while it is rotating. The operation is now complete.

Claims

1. A special tool for removing excess adhesive from leaking holes in aircraft air intakes, characterized in that: It includes the transmission and operation parts, the control system parts, and the body structure parts; The transmission operation part includes a guide rod (1), a cutter head (2), a caliper (3), a working end drive shaft (4), a retaining ring (5), a handle (6), a universal drive shaft (7), a bushing (8), an external hexagonal screwdriver head (9), a power end drive shaft (10), a stepper motor (21), and a bearing (22); the guide rod (1) adopts a small-angle conical transition, and the cutter head (2) is selected according to the state of the drain hole being blocked; The caliper (3) uses a miniature three-jaw chuck to clamp the cutter head (2); the working end drive shaft (4) is an internal drive shaft that can transfer the rotation of the universal drive shaft (7) to the caliper (3), thereby driving the rotation of the cutter head (2); the retaining ring (5) is the bearing mechanism of the handle (6), used to connect the working end drive shaft (4) and the universal drive shaft (7), and to receive the motion transmission of the universal drive shaft (7); the handle (6) is the handheld structure of this tool; the universal drive shaft (7) The exterior is covered with black rubber, and the interior contains a flexible stainless steel shaft. The shaft head has an external hexagonal structure and the shaft core is replaceable. The bushing (8) is hollow, and bearings (22) with internal hexagonal holes are set on the left and right sides of the bushing. The internal hexagonal shafts that enable universal drive shaft (7) and external hexagonal screwdriver head (9) are respectively inserted into the bearings (22) with internal hexagonal holes in the bushing (8). The power end drive shaft (10) is used to transmit the torque of the stepper motor (21) to the external hexagonal screwdriver head (9) to realize the torque output function. The control system includes a control button (12), a switch (13), a charging module (17), a power module (18), a microcontroller (19), and a controller (20). The control button (12) controls the forward and reverse rotation of the tool. The rotation direction of the stepper motor (21) is inconsistent for different positions and angles, and the control button (12) is used to select the direction. The switch (13) is the start and stop device of the tool. Pressing it will start the tool. The charging module (17) and the power module (18) are the power storage and power supply components of the tool. One end of the charging module (17) is connected to the power module (18), and the other end is connected to the charging port (14). The power module (18) is charged through the charging port (14) and the charging module (17) to store power. The power module (18) is a 3.7V lithium battery, which is boosted to 12V by the boost module to supply power to the control button (12), the microcontroller (19), the controller (20), and the stepper motor (21) to complete the control action. The main body structure includes a main housing (11), a charging port (14), a back cover (15), and screws (16). The main housing (11) is the main load-bearing component of this tool. As needed, the main housing (11) has reserved positions for a power module (18), a charging module (17), a microcontroller (19), a controller (20), and a stepper motor (21). The charging port (14) adopts the mainstream Type-C interface and uses a mobile phone charging cable to charge the power module (18). The back cover (15) and screws (16) are used to seal the cavity structure. After the internal components of the main housing (11) are installed, the screws (16) are used to seal the back cover (15).

2. The special tool for removing excess adhesive from leaking holes in aircraft air intakes as described in claim 1, characterized in that, The cutter head (2) is of the countersink drill type (2) when it is slightly blocked, and of the drill type (2) when it is completely blocked.

3. The special tool for removing excess adhesive from leaking holes in aircraft air intakes as described in claim 1 or 2, characterized in that, The blade (2) is made of polyphenylene sulfide.

4. The special tool for removing excess adhesive from leaking holes in aircraft air intakes as described in claim 1 or 2, characterized in that, The stepper motor (21) is the power structure of this tool, and it adopts a 12V high torque reduction stepper motor.

5. The special tool for removing excess adhesive from leaking holes in aircraft air intakes as described in claim 3, characterized in that, The stepper motor (21) is the power structure of this tool, and it adopts a 12V high torque reduction stepper motor.

6. The special tool for removing excess adhesive from leaking holes in aircraft air intakes as described in claim 1, 2, or 5, characterized in that, The microcontroller (19) is the information processing element of this tool. It receives signals from the control button (12) and the switch (13), processes them, and then transmits the information. The controller (20) is the action command issuing element of this tool. It receives the information processed by the microcontroller (19) to control the operation and complete the cleaning of excess glue.

7. The special tool for removing excess adhesive from leaking holes in aircraft air intakes as described in claim 3, characterized in that, The microcontroller (19) is the information processing element of this tool. It receives signals from the control button (12) and the switch (13), processes them, and then transmits the information. The controller (20) is the action command issuing element of this tool. It receives the information processed by the microcontroller (19) to control the operation and complete the cleaning of excess glue.

8. The special tool for removing excess adhesive from leaking holes in aircraft air intakes as described in claim 4, characterized in that, The microcontroller (19) is the information processing element of this tool. It receives signals from the control button (12) and the switch (13), processes them, and then transmits the information. The controller (20) is the action command issuing element of this tool. It receives the information processed by the microcontroller (19) to control the operation and complete the cleaning of excess glue.

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