Apparatus and methods for pushing out and drilling an aerial flare

An apparatus configured for pushing out and drilling a flare grain in an aerial flare, the apparatus comprising:

• a base;
• a first stand mounted to the base and including a first electric linear actuator with a throw rod positioned to interface with a first end of an aerial flare and exert a force on a first end of a flare grain within the aerial flare to cause the flare grain to move relative to a case of the aerial flare;
• a second stand mounted to the base and configured to receive and fixedly hold the aerial flare;
• a third stand mounted to the base and movable relative to at least the second stand, the third stand further including a drilling device attached to a top portion thereof;
• a second electric linear actuator coupled to the third stand and configured to move the third stand and the attached drilling device relative to a second end of the flare grain to engage the drilling device with the second end of the flare grain for drilling a hole in at least one portion of the flare grain;
• and
• a processor communicatively coupled to the first and second electric linear actuators and configured to control the first and second electric linear actuators according to a pre-programmed sequence of operation.

A method for pushing out and drilling of a flare pyrotechnic substance of an aerial flare comprising:

• mounting an aerial decoy flare to a unit under test (UUT) stand;
• initiating a push out sequence wherein a first electric linear actuator is operated to cause a push rod of the first electric linear actuator to exert a pushing force on a first end of the flare to push out an end cap of flare, as well as push at least a portion of the flare pyrotechnic substance of a casing of the flare;
• initiating a drilling sequence wherein a drilling device is started and a second linear electric actuator is operated to move a movable stand holding the drilling device to engage with a second end of the flare and the flare pyrotechnic substance to drill a hole in the flare pyrotechnic substance of a predetermined depth and diameter;
• and
• ceasing powering of all electrical devices including the first and second electric linear actuators and the drilling device to allow retrieval of the drilled flare pyrotechnic substance.