Horizontal Launch Vehicle Tooling for Deflection-Corrected Section Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Horizontal integration of launch vehicle sections is hindered by sagging and deflection due to gravity, causing misalignment of fastening features, which complicates the connection of cylindrical sections.
Innovation Solution
An alignment tool system comprising a receiver assembly and an actuation assembly that apply opposing forces to reshape and align fastener holes, using pegs and connecting elements to correct deflection and ensure proper alignment of bolt holes, facilitated by a movable platform providing multiple degrees of freedom.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If component sections are assembled horizontally at ground level, then the need for tall assembly buildings is eliminated, but sag and deflection due to gravity cause misalignment of fastening features
Solution Approach 1:
The alignment tool applies preliminary action by de-ovalizing the cylindrical sections before fastening occurs. The tool engages with the outer surface of the sections and applies radial forces to counteract gravity-induced sag and deflection, restoring the sections to their intended circular shape and aligning fastening features prior to connection
Solution Approach 2:
The alignment tool serves as an intermediary between the gravitational force causing sag and the fastening process requiring precision. By positioning the tool between these two factors, it actively compensates for gravitational deformation through mechanical adjustment, enabling accurate alignment without requiring vertical assembly
2Manufacturing precision
If component sections are assembled vertically, then alignment of fastening features is easier, but tall assembly buildings and equipment are required
Solution Approach 1:
The invention inverts the traditional vertical assembly approach by performing horizontal assembly at ground level. Instead of relying on gravity to maintain alignment during vertical stacking, the system uses the alignment tool to actively counteract gravity's detrimental effects on horizontal sections, achieving precision without height
Solution Approach 2:
The alignment tool enables parameter changes by adjusting the radial position and shape of the cylindrical sections during assembly. The tool's adjustable mechanism allows real-time modification of section geometry to compensate for gravitational deformation, maintaining optimal alignment parameters throughout the horizontal assembly process
Data Source
AI summary
A representative system includes an alignment tool for aligning attachment interfaces of horizontally-oriented launch vehicle portions. The tool can include a receiver assembly for connecting to a first launch vehicle portion and an actuation assembly for connecting to a second launch vehicle portion. When a first connecting element of the receiver assembly is engaged with a second connecting element of the actuation assembly, the second connecting element can apply force to the receiver assembly, and the actuator assembly applies an opposite force to the second launch vehicle portion, to align fastening features in the launch vehicle portions and/or to reshape the launch vehicle portions. A representative method includes connecting the alignment tool to the launch vehicle portions and operating the tool to apply oppositely-directed forces to align the launch vehicle portions for installing fasteners to connect the launch vehicle portions. One or more bracing beams can connect two tools together.