Horizontal Launch Vehicle Alignment Tooling for Sagged Sections

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Solution Overview

Problem

The challenge of horizontal integration in launch vehicles is the tendency for component sections to sag and deflect out of their intended shapes due to gravity, causing misalignment of fastening features during assembly.

Innovation Solution

The use of alignment tools with receiver and actuation assemblies that apply opposing forces to align fastener holes in launch vehicle portions, including a locking mechanism to secure the assemblies in place, and optionally using bracing beams to maintain alignment during integration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If component sections are assembled horizontally at ground level, then assembly building height requirements are reduced, but gravity causes sag and deflection of component sections

Engineering Contradiction:

Improveassembly building height requirementVSAvoidcomponent section shape

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The alignment tool applies forces to component sections before final assembly to pre-correct for gravitational sag and deflection. By performing this shaping action in advance during the alignment process, the tool ensures that components maintain their intended geometry throughout assembly without requiring tall assembly buildings.

Inventive Principle:

Principle #10Preliminary action

2Device complexity

If component sections are assembled horizontally, then assembly complexity is reduced, but misalignment of fastening features occurs due to sag and deflection

Engineering Contradiction:

Improveassembly complexityVSAvoidfastening feature alignment

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The alignment tool dynamically adjusts applied forces based on measured misalignment conditions. By changing force parameters in response to observed sag and deflection, the tool achieves precise alignment of fastening features while maintaining the simplicity of horizontal assembly procedures.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system uses measured alignment conditions as feedback to adjust the application of force during the alignment process. This closed-loop approach ensures that fastening features are precisely aligned despite gravitational effects, while keeping the overall assembly process simple and horizontal.

Inventive Principle:

Principle #23Feedback

3Manufacturing precision

If alignment tools apply force to reshape component sections, then fastening feature alignment is achieved, but additional assembly steps are required

Engineering Contradiction:

Improvefastening feature alignmentVSAvoidassembly process steps

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The alignment tool combines the alignment function and the shaping function into a single integrated operation. By merging these functions, the tool achieves precise fastening feature alignment without requiring separate shaping and alignment steps, thereby reducing overall assembly complexity while maintaining high precision.

Inventive Principle:

Principle #5Merging (Combining)

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

The solution effectively aligns fastener holes and maintains the cross-sectional shape of launch vehicle portions, facilitating secure connection without the need for tall assembly buildings and reducing assembly time and complexity.

Implementation Method 1

the actuation assembly applies a force to the receiver assembly to align fastener holes in the launch vehicle portions

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 2

including a locking mechanism to secure the assemblies in place

Methodology Applied

Scientific EffectMechanical Constraint: Mechanical Force

Implementation Method 3

optionally using bracing beams to maintain alignment during integration

Methodology Applied

Scientific EffectStructural Support: Mechanical Force

Data Source

PatentUS12486048B2Horizontal integration tooling for launch vehicles, and associated systems and methods

Publication Date: 2025.12.02 BLUE ORIGIN MANUFACTURING LLC

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.