Design of an Ergonomics-Based Auxiliary Chip Suction Device for Manual Drilling and Counterboring Operations

In the aviation manufacturing industry, high-reliability hole drilling and countersinking operations are crucial for ensuring aircraft structural quality and performance. However, during traditional manual hole drilling and countersinking processes, the real-time effectiveness of metal chip/dust removal directly impacts both product assembly quality and workers' health. Current operations employ one operator to perform drilling/countersinking tasks while requiring an additional worker to manually hold a dust collection pipe for real-time debris removal. This approach suffers from high labor costs, inconsistent debris collection efficiency due to coordination dependency between two operators, and poor ergonomic design. To address these issues, this study develops an auxiliary chip collection device for manual drilling/countersinking operations based on ergonomic principles and operational characteristics. Featuring a lightweight and ergonomically friendly structural design, the device enables single-operator real-time debris collection during drilling/countersinking processes. This innovation not only reduces production labor costs but also achieves significant improvements in product processing quality and production efficiency.