Structural Gap Filler Injection for Debris-Free One-Up Assembly
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Solution Overview
Problem
The aircraft manufacturing process is hindered by loose debris between components, requiring time-consuming disassembly and cleaning, which increases labor and reduces efficiency.
Innovation Solution
A method involving drilling an injection hole and encapsulating drilling debris with a structural gap filler, followed by drilling a hole through the filler to maintain clamp-up and reduce burr production, thereby eliminating the need for disassembly and cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If components are disassembled to remove drilling debris from gaps, then cleaning effectiveness is improved, but manufacturing time and labor increase
Solution Approach 1:
The gap filler material is applied to the gap between components before drilling operations begin. This preliminary application creates a barrier that prevents drilling debris from accumulating in the gap, eliminating the need for subsequent disassembly and cleaning operations while maintaining manufacturing precision
Solution Approach 2:
The invention converts the potentially harmful effect of drilling debris generation into a beneficial process by using the gap filler material to capture and contain the debris within the gap. The debris that would normally require cleaning is instead encapsulated by the curing filler, transforming a cleaning requirement into an automated containment solution
2Object-generated harmful factors
If components are disassembled to remove loose debris, then debris removal is improved, but labor and flow time increase
Solution Approach 1:
The gap filler is applied in advance before drilling operations, creating a protective barrier that prevents loose debris from generating in the first place. This preliminary protective measure eliminates the need for time-consuming disassembly and cleaning operations that would otherwise be required to remove harmful debris
Solution Approach 2:
The gap filler material performs the debris removal function automatically through its curing process. As the filler cures, it encapsulates any debris within the gap, performing the cleaning function self-service without requiring external intervention, disassembly, or additional labor
3Stability of the object's composition
If clamp-up is maintained during drilling operations, then assembly stability is improved, but burr production increases
Solution Approach 1:
The gap filler material serves as an intermediary substance between the components during drilling operations. It fills the gap that would otherwise allow burrs to form and accumulate, while still permitting clamp-up to be maintained for assembly stability. The filler material absorbs and contains burrs within the gap, preventing them from becoming loose harmful factors
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces manufacturing time and costs by encapsulating debris within the structural gap filler, maintaining clamp-up during processing, and minimizing burr production during subsequent drilling operations.
Implementation Method 1
Drilling debris generated between the first component and the second component during drilling of the injection hole are encapsulated by injecting a structural gap filler through the injection hole and between the first component and the second component
Implementation Method 2
Clamp-up of the first component and the second component is maintained between drilling the injection hole and drilling the hole
Data Source
AI summary
Methods and structural gap filler for one up assembly of structures. Drilling debris generated between the first component and the second component during drilling of an injection hole are encapsulated by injecting a structural gap filler through the injection hole and between the first component and the second component.