Launch Vehicle Alignment Tooling for Horizontal Section Assembly
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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, leading to misalignment of fastening features during assembly.
Innovation Solution
The use of alignment tools comprising a receiver assembly and an actuation assembly that apply oppositely-directed forces to tubular structures to align fastener holes, including the use of pegs and connecting elements to reshape and align the sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If component sections are assembled horizontally at ground level, then the need for tall assembly buildings is reduced, but the component sections sag and deflect out of their intended shapes due to gravity
Solution Approach 1:
The alignment tools are installed on the component sections before final assembly to prevent sag and deflection from occurring during the assembly process. By establishing alignment features in advance, the tools enable horizontal assembly without requiring tall buildings while maintaining the intended cross-sectional shape.
Solution Approach 2:
Alignment tools serve as intermediary devices between the component sections and the assembly process. These tools include rigid structures with alignment features that interface with fastening features on the component sections, transferring and maintaining proper alignment while compensating for gravitational effects.
2Ease of manufacture
If component sections are assembled horizontally, then ground-level assembly is achieved, but misalignment of fastening features occurs due to sag and deflection
Solution Approach 1:
The alignment tools replace complex mechanical alignment systems with simpler alignment features built into the tool structure. The rigid alignment tools incorporate alignment features that directly interface with fastening features, eliminating the need for complex mechanical adjustment systems and ensuring precise alignment at ground level.
3Shape
If alignment tools apply forces to reshape tubular structures, then cross-sectional shape is restored, but additional equipment and complexity are introduced
Solution Approach 1:
The alignment tools are divided into multiple independent alignment tool assemblies, each responsible for a specific location or function. This segmentation allows each assembly to be relatively simple in structure while the collection of assemblies collectively restores and maintains the cross-sectional shape of the entire tubular structure.
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.