Rocket Thrust Structure Assembly With Metrology-Based Shim Alignment
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Solution Overview
Problem
Aerospace systems, such as rocket systems, face challenges in precisely connecting large components like rocket engines to the rest of the assembly due to manufacturing tolerances, which can lead to misalignment and require cumbersome assembly fixtures, especially when access for drilling is limited.
Innovation Solution
Utilizing metrology systems to characterize real-world interfaces, create shims to align mounting faces, and employ drill jigs to accurately position holes, allowing for precise attachment without match drilling, thereby reducing manufacturing tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If match drilling is used to achieve high precision alignment, then manufacturing precision is improved, but device complexity and difficulty of operation increase due to requiring monumental assembly fixtures and limited tool access
Solution Approach 1:
The patent applies preliminary action by pre-characterizing the real-world interfaces of large components using metrology systems before assembly. This creates a digital representation of actual geometric deviations, allowing the alignment system to be programmed in advance with correction data. The alignment features are prepared beforehand with measured deviation data, enabling subsequent automated alignment without requiring complex manual match-drilling fixtures during the actual assembly operation.
Solution Approach 2:
The patent replaces the traditional mechanical match-drilling system with an automated alignment system that uses metrology-based measurement and computer-controlled positioning. Instead of relying on mechanical fixtures and manual match-drilling operations, the system uses measured geometric data to programmatically align components. This substitution eliminates the need for monumental assembly fixtures and complex mechanical alignment tools, reducing device complexity while maintaining or improving alignment precision.
2Manufacturing precision
If traditional assembly methods with large fixtures are used, then alignment precision is maintained, but productivity decreases due to cumbersome assembly processes and extended assembly time
Solution Approach 1:
The patent applies self-service by enabling the alignment system to automatically determine and correct its own positioning errors. The system measures the actual positions of alignment features on both components, calculates the deviation from ideal alignment, and programmatically adjusts its positioning accordingly. This automated self-correction eliminates the need for operators to manually operate complex fixtures or perform time-consuming alignment procedures, significantly improving assembly throughput while maintaining precision.
Solution Approach 2:
The patent implements feedback by using metrology systems to continuously measure the actual geometric positions of components during assembly. This measured data is fed back to the control system, which then adjusts the positioning of components or alignment tools in real-time to compensate for manufacturing tolerances and geometric deviations. This closed-loop feedback mechanism ensures high alignment precision without requiring slow, iterative manual adjustment processes, thereby improving productivity.
3Manufacturing precision
If Class 1 tolerances are enforced through pre-drilling, then manufacturing precision is improved, but loss of time increases due to the need for extreme control and meticulous hole pattern drilling
Solution Approach 1:
The patent replaces time-consuming mechanical pre-drilling operations with an automated alignment and drilling system. The system uses metrology-measured data to programmatically position drilling tools with high precision, eliminating the need for meticulous manual pre-drilling and fit-checking operations. This automation maintains Class 1 tolerance levels while dramatically reducing the time required for hole pattern creation and component assembly.
Data Source
AI summary
Aerospace systems, and systems and methods for assembling an aerospace system or another system or structure, are disclosed. A representative system can include a propellant tank with a dome-shaped head; attachment features on the dome-shaped head; and a thrust structure with legs attached to the attachment features. A representative method can include forming shims to be positioned between the legs and the attachment features. The shims can be formed based on digital characterizations of mounting faces on the attachment features within a reference coordinate system. The method can include positioning a drill jig within the reference coordinate system and using the drill jig to make holes in the shims and/or the attachment features for fastening the legs to the attachment features. A drill jig can include plates that are movable relative to each other. At least one of the plates can include a mounting hole pattern.