Launch Vehicle Alignment Tooling for Horizontal Section Deflection
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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 for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If horizontal integration is used to avoid tall assembly buildings, then assembly building height requirement is reduced, but component sections sag and deflect out of shape due to gravity
Solution Approach 1:
The alignment tool is installed on the component sections before final assembly to prevent sagging and deflection from occurring. By applying corrective forces in advance through the actuation assembly, the tool maintains the intended circular shape of horizontal sections during the assembly process, eliminating the need for tall assembly buildings while preventing gravitational deformation.
Solution Approach 2:
The alignment tool acts as an intermediary device between the horizontal component sections and the assembly process. It includes a receiver assembly that attaches to fastener holes and an actuation assembly that applies opposing forces to counteract gravitational sagging, thereby maintaining the circular shape without requiring vertical support structures.
2Device complexity
If horizontal integration is used to simplify assembly, then assembly complexity is reduced, but misalignment of fastening features occurs due to deflection
Solution Approach 1:
The alignment tool incorporates alignment features that detect and correct misalignment of fastener holes caused by gravitational deflection. The tool provides real-time feedback on the position of fastening features and applies corrective forces through the actuation assembly to restore proper alignment, ensuring precise connection of horizontal component sections.
Solution Approach 2:
The alignment tool serves as an intermediary mechanism that mediates between the deflected component sections and the fastening process. It includes alignment features that engage with fastener holes and apply corrective forces to realign them, thereby maintaining manufacturing precision while enabling simplified horizontal assembly.
3Ease of operation
If component sections are oriented horizontally for ground-level assembly, then assembly accessibility is improved, but gravitational deflection increases
Solution Approach 1:
The actuation assembly of the alignment tool applies opposing forces to counteract the gravitational force causing sagging. By installing the tool on horizontal component sections and actuating it to apply upward forces, the system neutralizes the effect of gravity on the component sections, maintaining their intended shape and alignment while preserving the benefits of horizontal orientation.
Solution Approach 2:
The alignment tool is designed to be dynamically adjustable during the assembly process. The actuation assembly can apply varying forces to counteract gravitational deflection in real-time, allowing the tool to adapt to different component section weights and orientations while maintaining assembly accessibility at ground level.
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 alignment tool system effectively addresses the sagging issue by aligning fastener holes, allowing for accurate integration of launch vehicle sections without the need for tall assembly structures, enhancing the efficiency of horizontal integration processes.
Implementation Method 1
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
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.