Helicopter cabin door debugging and mounting method

Abstract

The invention belongs to a helicopter assembly technology, and particularly relates to a helicopter cabin door debugging and mounting method. A cabin door simulation tool of an existing installation process method is poor in positioning precision, and a cabin door simulation tool clamping plate is difficult to be 100% relative to a machine body due to machine body manufacturing errors. According to the helicopter cabin door debugging and installing method, a cabin door simulation tool and a plurality of shape follow-up cushion blocks need to be prefabricated, the cabin door simulation tool is provided with a lock bracket drilling jig and a hinge support drilling jig, and the shape and the size of the shape follow-up cushion blocks are matched with the space between a helicopter body in the area where the shape follow-up cushion blocks are located and the cabin door when no sealing rubber strip is installed. The positioning precision of the cabin door simulation tool is improved, the cabin door simulation tool adjusting time is shortened, the cabin door hinge adjusting time is shortened, the cabin door installation efficiency is improved by 50%, the key problems in the traditional cabin door installation process can be effectively solved, and an efficient, accurate and reliable novel installation method can be provided for the aeronautical manufacturing field.

Description

Technical Field

[0001] This invention pertains to helicopter assembly technology, specifically relating to a method for debugging and installing helicopter cabin doors. Background Technology

[0002] The helicopter door system is a crucial component of a helicopter, and its structural design and installation process directly impact the aircraft's safety, sealing performance, and user comfort. A typical door consists of key components such as the door body, hinges, locking mechanism, pneumatic struts, and sealing strips, each playing a vital role. The door body, as the primary load-bearing structure, needs sufficient strength and rigidity to withstand various loads generated during flight. Simultaneously, the door body design must consider aerodynamic characteristics, ensuring both good aerodynamic performance and convenient access for passengers. Hinges are essential components connecting the door body to the fuselage; their design must balance flexibility and reliability, ensuring smooth door opening and closing while possessing sufficient strength to withstand various external forces. During actual installation, precise adjustment of the step and clearance between the door and the fuselage is necessary. This step directly affects the door's performance and sealing effect: inconsistent step height can lead to obstructed door opening or poor sealing; excessive clearance affects airtightness and watertightness, while insufficient clearance can cause the door to jam.

[0003] Existing installation methods typically achieve precise positioning by fabricating specialized hatch simulation fixtures. These fixtures generally consist of multiple sets of shaped clamps, which, after being fixed on the machine, are used to determine the positions of key interfaces such as hinge supports, lock holes, and struts. Precise control of these fixtures effectively avoids errors that may arise from traditional manual measurements, ensuring that all connections meet design requirements. The main disadvantages are as follows: 1. The positioning accuracy of the hatch simulation tooling is poor. Due to the manufacturing error of the aircraft, it is difficult for the hatch simulation tooling plate to be 100% aligned with the aircraft body, and manual judgment and selection are required.

[0004] 2. The installation and adjustment efficiency of the hatch simulation tooling on the machine is low. The hoisting tooling, installation plate and rough adjustment tooling need to use a series of adjustment shims to repeatedly adjust the thickness of the shims and adjust the position of the hatch simulation tooling on the machine body.

[0005] 3. The installation and adjustment process on the hatch door machine is inefficient. The installation on the hatch door machine requires adjustment of the door frame hinges. It is necessary to repeatedly disassemble and reassemble the hatch to adjust the thickness of the adjustment shims on the door frame hinges and check the step gap until it meets the design conditions.

[0006] The aforementioned problems arise from the complexity of disassembly during installation and subsequent maintenance, increasing costs and time. Therefore, a new installation method is urgently needed to improve installation quality, stability, and maintainability. Summary of the Invention

[0007] The purpose of this invention is to provide a method for debugging and installing helicopter doors, which solves the shortcomings of traditional installation processes such as poor positioning accuracy and low efficiency in tooling and door installation.

[0008] This invention proposes a method for debugging and installing a helicopter cabin door. The method requires prefabricating a cabin door simulation fixture and several conformal pads. The cabin door simulation fixture includes a lock seat drill and a hinge support drill. The shape and size of the conformal pads match the space between the fuselage and the cabin door when no sealing strip is installed. The debugging and installation includes the following steps: S1. Fix the conformal pad to the designed position on the machine body; S2. Position the hatch simulation tooling according to the guidance of the conformal pad block; S3. Tighten the clamps to secure the hatch simulation fixture to the fuselage; S4. Drill the mounting holes for the lock seat and hinge support using the lock seat drilling mold and hinge support drilling mold. S5. Disassemble the hatch simulation tooling and install blind hole nuts in the mounting holes of the hinge support and lock seat; S6. Initially install the lock seat and hinge support by combining the peelable washer and the toothed washer; S7. Position the hatch according to the guidance of the conformal pad; S8. Use toothed shims to adjust and fix the installation positions of the hinge support and lock seat, requiring an assembly step difference of ±2mm and a gap of ±2mm. S9. Remove the conformal pad and install sealing strips and gas spring struts on the fuselage and hatch. S10, Delivery after inspection.

[0009] Advantageously, the conformal pad is prefabricated according to the functional requirements of the hatch, its positional relationship with the fuselage, and the requirements for step and clearance.

[0010] Advantageously, the conformal pad is used to ensure the frontal and circumferential clearances between the hatch and the fuselage.

[0011] Advantageously, the conformal pad is positioned in the corner transition area or deformation area of ​​the adhesive strip.

[0012] Advantageously, the number of the conformal pads is at least four.

[0013] Advantageously, the outer surface of the conformal pad is consistent with the inner surface of the hatch at the location, the inner surface is consistent with the outer surface of the aircraft at the location, and the conformal pad installed on the aircraft can represent the thickness of the rubber strip at the location after compression when the door is closed.

[0014] Advantageously, the conformal pad has a small gap reserved in the R-angle avoidance area.

[0015] Advantageously, the lifting rings on the hatch simulation tool can be lifted using a crane or spring balancer and then approached to the aircraft body.

[0016] Advantageously, in S3, the fit between each conformal pad and the hatch simulation tooling is checked by local pressing. If there is a gap, the clamping device needs to be adjusted and conformal pads of other thicknesses need to be replaced.

[0017] Advantageously, the thickness of the toothed gasket is ≥1mm, and the thickness of the peelable gasket is ≤3mm.

[0018] The advantages are: This invention simplifies the tooling structure, improves the positioning accuracy of the simulated door tooling, reduces the adjustment time of the simulated door tooling, reduces the adjustment time of the door hinges, and increases door installation efficiency by 50%. It not only effectively solves key problems in the traditional door installation process but also provides a new, efficient, precise, and reliable installation method for the aerospace manufacturing industry. Furthermore, this invention pays special attention to the versatility and applicability of the tooling. By optimizing the design parameters and installation process of the conformal pad, it is suitable for the installation requirements of different aircraft door models. In practical applications, this solution can significantly improve installation efficiency and reduce production costs. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the hatch structure; Figure 2 This is an example of the installation of the conformal pad and the simulated door fixture 5; Figure 3 This is a schematic diagram of the cross-section of the conformal pad.

[0020] 1-Fuselage, 2-Door, 3-Hinge Support, 4-Lock Seat, 5-Door Simulation Fixture, 6-Conformal Pad, 7-Lock Seat Drill Jig, 8-Hinge Support Drill Jig, 9-Lifting Ring, 11-Door Inner Surface, 12-Fuselage Door Frame Outer Surface, 13-R-Angle Clearance Area Detailed Implementation See Figure 1-3 The present invention utilizes a conformal pad 6 to position the hatch simulation tool 5 to make the intersection of the hinge support 3, lock seat 4 mounting holes, etc., and uses the conformal pad 6 to position the hatch 2 to adjust the toothed pads and peelable pads of the upper and lower hinge supports, thereby completing the installation of the hatch.

[0021] The present invention comprises three aspects: the design of conformal pads, the preparation of installation intersections, and the adjustment method for hatch installation.

[0022] I. Design of Conformal Pads The conformal pad 6 is designed according to the functional requirements of the hatch 2 and its positional relationship, step difference and clearance requirements with the fuselage 1. It can accurately match the installation reference of the hatch 2 with the fuselage 1, thereby realizing the high-precision manufacturing of the hinge support 3 and lock seat 4 mounting holes.

[0023] The conformal pad 6 is used to ensure the frontal and circumferential clearances between the hatch 2 and the fuselage 1, thereby ensuring that the forward and circumferential rubber strips have appropriate compression. It is positioned in characteristic areas such as the transition area or deformation area of ​​the rubber strip corner, thus providing a self-positioning function during installation with the fuselage. At least four conformal pads 6 are used. Their outer surface matches the inner surface 11 of the hatch at their location, and their inner surface matches the outer surface 12 of the fuselage at their location. A small gap should be reserved at the R-corner avoidance area 13. The conformal pad 6, when installed on the fuselage 1, represents the thickness of the rubber strip at its location after compression when the door is closed, thereby limiting the installation position of the hatch 2.

[0024] For each position, the conformal pad 6 is prepared with multiple thicknesses. Three thicknesses are recommended: theoretical thickness, theoretical thickness +1mm, and theoretical thickness -1mm. Non-metallic materials such as nylon are selected to prevent scratching the product and to provide a certain degree of hardness so that it does not deform under compression.

[0025] The hatch simulation fixture 5 is consistent with the theoretical internal shape of the hatch 2 in the area of ​​the conformal pad 6.

[0026] II. Determination of Installation Intersections The present invention uses a conformal pad 6 to precisely position the hatch simulation fixture 5. The hatch simulation fixture 5 also has a lock seat drill 7 and a hinge support drill 8. When the hatch simulation fixture 5 is placed against the conformal pad 6, the intersection of the hinge support 3 and the lock seat 4 mounting holes on the fuselage is made by using the drill holes.

[0027] III. Adjustment Method for Hatch Door Installation In actual installation, this invention uses conformal pads 6 to precisely position the hatch 2, and adjusts the toothed pads and peelable pads to complete the installation of the hinge support 3 and lock seat 4. This adjustment method can effectively eliminate errors caused by manual operation in traditional installation methods, ensuring the consistency of the hatch 2's position during installation.

[0028] Specifically, taking the debugging and installation method of a certain type of helicopter cabin door as an example, it mainly includes: Step 1: Use adhesive tape to install the conformal pad 6 onto the machine body 1. It does not need to be firmly glued, just make sure that the conformal pad does not fall off.

[0029] Step 2: Use a crane or spring balancer to lift the lifting ring 9 of the hatch simulation tool 5. When it approaches the body 1, guide the hatch simulation tool 5 to the correct installation position using the conformal pad 6.

[0030] Step 3: Tighten the clamp to fix the hatch simulation fixture 5 onto the body 1. Check the fit between each conformal pad 6 and the hatch simulation fixture 5 by pressing locally. If there is a gap, the clamp needs to be adjusted and the conformal pad 6 of other thicknesses needs to be replaced.

[0031] Step 4: Drill the mounting holes for hinge support 3 and lock seat 4 according to the holes of lock seat drill 7 and hinge support drill 8 of hatch simulation tooling 5.

[0032] Note: Both of the above-mentioned hole-making areas are closed areas. The length of the cutting tool must be controlled to avoid damaging other parts on the opposite side.

[0033] Step 5: Disassemble the hatch simulation tool 5 and install blind hole nuts at the mounting holes of hinge support 3 and lock seat 4 as required.

[0034] Step 6: Initially install the lock seat 4, hinge support 3, peelable washer, and toothed washer. Do not tighten the mounting screws of the lock seat 4 and hinge support 3 too much, in case of subsequent adjustment.

[0035] Step 7: Position the hatch 2 onto the fuselage 1 using the conformal pad 6.

[0036] Step 8: With the hatch 2 positioned, use toothed shims (minimum = 1mm) and peelable shims (minimum = 0mm; maximum = 3mm) to adjust and fix the installation positions of the hinge support 3 and lock seat 4. The adjustment goal is to achieve the following assembly requirements: step difference = ±2mm; clearance = ±2mm.

[0037] Step 9: Remove all conformal pads 6 and install sealing strips, gas spring struts and other accessories on the fuselage 1 and hatch 2.

[0038] Step 10: Inspect the hatch installation according to the technical conditions for hatch installation and acceptance.

[0039] The following are specific embodiments of the invention described above. The description of each specific embodiment should include: structure and effect, and multiple embodiments may be listed.

[0040] Example 1 Step 1: Use adhesive tape to install several conformal pads 6 on the characteristic positions of the machine body 1. No need to firmly adhere them, just make sure the conformal pads do not fall off.

[0041] Step 2: Use a crane or spring balancer to lift the hatch simulation fixture 5. When it approaches the fuselage, guide the hatch simulation fixture 5 to the correct installation position using the conformal pad 6.

[0042] Step 3: Tighten the clamp to fix the hatch simulation fixture 5 onto the body 1. Check the fit between each conformal pad 6 and the hatch simulation fixture 5 by pressing locally. If there is a gap, the clamp needs to be adjusted and the conformal pad 6 of other thicknesses needs to be replaced.

[0043] Step 4: Drill the mounting holes for the hinge support and lock seat according to the holes of the lock seat drill 7 and hinge support drill 8 of the hatch simulation tooling 5.

[0044] Note: Both of the above-mentioned hole-making areas are closed areas. The length of the cutting tool must be controlled to avoid damaging other parts on the opposite side.

[0045] Step 5: Disassemble the hatch simulation tool 5 and install blind hole nuts at the mounting holes of hinge support 3 and lock seat 4 as required.

[0046] Step 6: Perform preliminary installation of the lock seat, hinge support, peelable washer, and toothed washer. Install the toothed washer and peelable washer according to their theoretical thickness. Do not overtighten the mounting screws of the lock seat and hinge support to allow for later adjustments.

[0047] Step 7: Position the hatch 2 onto the fuselage 1 using the conformal pad 6.

[0048] Note: The fixing components on the hatch frame and the main sealing strip of the hatch will not be installed at this time.

[0049] Step 8: With the hatch 2 positioned, adjust the door frame hinge and door frame hinge slotted hole using the following parameters: hinge toothed pad minimum = 1mm, peelable pad minimum = 0mm; maximum = 3mm, and washer minimum = 0mm; maximum = 8mm. The adjustment aims to achieve the following assembly requirements: the hinge toothed pad and peelable pad are general structural components, not shown in the figure; step difference = ±2mm; clearance = ±2mm. To meet the above criteria, readjustment may be necessary in other areas.

[0050] Step 9: Adjust the lock seat 4 by installing four shims with a thickness of 0.5mm. Adjust the shims under the lock seat 4 so that the minimum thickness is 0mm and the maximum thickness is 1.5mm, so that the overlap h between the latch of the door 2 and the lock seat is ≥8mm after the door is closed.

[0051] Step 10: Remove all conformal pads 6 and install sealing strips, gas spring struts and other accessories on the fuselage 1 and the hatch 2.

[0052] Step 11: Perform multiple opening and closing tests on hatch 2 to check its smoothness and sealing performance. If any problems are found, adjust or repair them in a timely manner.

[0053] Step 12: A comprehensive inspection by professionals ensures all components are securely installed, functioning properly, and comply with aviation safety standards. Alternatively, the door installation may be inspected according to the technical requirements for door installation acceptance.

[0054] Example 2 Step 1: Use adhesive tape to install several conformal pads 6 on the characteristic positions of the machine body 1. No need to firmly adhere them, just make sure the conformal pads do not fall off.

[0055] Step 2: Position the hatch 2 onto the fuselage 1 using the conformal pad 6.

[0056] Step 3: Prepare mounting holes for hinge support 3 and lock seat 4 according to the hatch 2.

[0057] Note: Both of the above-mentioned hole-making areas are closed areas. The length of the cutting tool must be controlled to avoid damaging other parts on the opposite side.

[0058] Step 4: Disassemble hatch 2 and install blind hole nuts at the mounting holes of hinge support 3 and lock seat 4 as required. Blind hole nuts are general structural components and are not shown in the figure.

[0059] Step 5: Position the hatch 2 onto the fuselage 1 again using the conformal pad 6, and install the hinge support 3, lock seat 4, and peelable pad under the toothed pad according to the theoretical thickness.

[0060] Note: The fixing components on the hatch frame and the main sealing strip of the hatch will not be installed at this time.

[0061] Step 6: With the hatch 2 positioned, use the hinge toothed pad (minimum = 1mm), the peelable pad (minimum = 0mm; maximum = 3mm), and the washer (minimum = 0mm; maximum = 8mm) to adjust the door frame hinge and the door frame hinge waist hole. The adjustment goal is to achieve the following assembly requirements: the hinge toothed pad and peelable pad are general structural parts, not shown in the figure.

[0062] Step difference = ±2mm; Gap = ±2mm; To meet the above criteria, it may be necessary to readjust in other areas.

[0063] Step 7: Adjust the lock seat 4. Use four shims with a thickness of 0.5mm to install the lock seat. Adjust the shims under the lock seat 4 so that the minimum thickness is 0mm and the maximum thickness is 1.5mm, so that the overlap h between the latch of the door 2 and the lock seat is ≥8mm after the door is closed.

[0064] Step 8: Remove all conformal pads 6 and install sealing strips, gas spring struts and other accessories on the fuselage 1 and hatch 2.

[0065] Step 9 involves performing multiple opening and closing tests on hatch 2 to check its smoothness and sealing performance. If any problems are found, adjustments or repairs should be made promptly.

[0066] Step 10 involves a comprehensive inspection by professionals to ensure all components are securely installed, functioning properly, and comply with aviation safety standards. Alternatively, the door installation may be inspected according to the technical requirements for door installation acceptance.

Claims

1. A method for debugging and installing a helicopter cabin door, characterized in that: This method requires the prefabrication of a hatch simulation fixture (5) and several conformal pads (6). The hatch simulation fixture (5) has a lock seat drill (7) and a hinge support drill (8). The shape and size of the conformal pads (6) match the space between the fuselage (1) and the hatch (2) in the area where no sealing strip is installed. The debugging and installation include the following steps: S1. Fix the conformal pad (6) at the designed position on the body (1); S2. Position the hatch simulation tooling (5) according to the guidance of the conformal pad (6); S3. Tighten the clamp to fix the hatch simulation fixture (5) onto the body (1); S4. The mounting holes of the lock seat (4) and hinge support (3) are made by using the lock seat drilling jig (7) and hinge support drilling jig (8); S5. Disassemble the hatch simulation tool (5) and install blind hole nuts in the mounting holes of the hinge support (3) and lock seat (4); S6. Initially install the lock seat (4) and hinge support (3) by combining the peelable washer and the toothed washer. S7. Position the hatch (2) according to the guidance of the conformal pad (6); S8. Use toothed shims to adjust and fix the installation positions of the hinge support (3) and lock seat (4), requiring the assembly step difference = ±2mm and the gap = ±2mm; S9. Remove the conformal pad (6) and install sealing strips and gas spring struts on the fuselage (1) and hatch (2); S10, Delivery after inspection.

2. The helicopter door debugging and installation method according to claim 1, characterized in that: The conformal pad (6) is prefabricated according to the functional requirements of the hatch (2), its positional relationship with the fuselage (1), the step difference and the clearance requirements.

3. The helicopter door debugging and installation method according to claim 2, characterized in that: The conformal pad (6) is used to ensure the frontal and circumferential clearances between the hatch (2) and the fuselage (1).

4. The helicopter door debugging and installation method according to claim 3, characterized in that: The conformal pad (6) is positioned in the corner transition area or deformation area of ​​the adhesive strip.

5. The helicopter door debugging and installation method according to claim 4, characterized in that: The number of the conformal pads (6) is at least 4.

6. The helicopter door debugging and installation method according to claim 5, characterized in that: The outer surface of the conformal pad (6) is consistent with the inner surface (11) of the hatch at the location, and the inner surface is consistent with the outer surface (12) of the fuselage at the location. The conformal pad (6) installed on the fuselage (1) can represent the thickness of the rubber strip at the location after compression when the door is closed.

7. The helicopter door debugging and installation method according to claim 6, characterized in that: The conformal pad (6) has a small gap reserved in the R-angle avoidance area (13).

8. The helicopter door debugging and installation method according to claim 1, characterized in that: After using a crane or spring balancer to lift the lifting ring (9) on the hatch simulation tool (5), it approaches the fuselage (1).

9. The helicopter door debugging and installation method according to claim 1, characterized in that: In S3, the fit between each conformal pad (6) and the hatch simulation tool (5) is checked by local pressing. If there is a gap, the clamping device needs to be adjusted and conformal pads (6) of other thicknesses need to be replaced.

10. The helicopter door debugging and installation method according to claim 1, characterized in that: The thickness of the toothed gasket is ≥1mm, and the thickness of the peelable gasket is ≤3mm.

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