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

Patent metadata

Field	Value
Publication number	US-11753183-B2
Application number	US-202117321058-A
Country	US
Kind code	B2
Filing date	May 14, 2021
Priority date	May 14, 2021
Publication date	Sep 12, 2023
Grant date	Sep 12, 2023

Abstract

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.

First claim

I claim:

1. An aerospace system comprising an alignment tool configured to align a first fastener hole in a first launch vehicle portion with a second fastener hole in a second launch vehicle portion, wherein the alignment tool comprises:
(a) a receiver assembly comprising a first locking mechanism and a first peg, the first locking mechanism and the first peg configured to connect the receiver assembly to the first launch vehicle portion, wherein the first peg is positionable in the first fastener hole and the first locking mechanism comprises a first movable shoe positionable to press against the first launch vehicle portion; and
(b) an actuation assembly comprising a second locking mechanism and a second peg, the second locking mechanism and the second peg configured to connect the actuation assembly to the second launch vehicle portion, wherein the second peg is positionable in the second fastener hole and the second locking mechanism comprises a second movable shoe positionable to press against the second launch vehicle portion;
wherein:
the actuation assembly is separate from, and connectable to, the receiver assembly at a force interface between the actuation assembly and the receiver assembly; and
when the receiver assembly is connected to the first launch vehicle portion, when the actuation assembly is connected to the second launch vehicle portion, and when the actuation assembly is engaged with the receiver assembly at the force interface, the actuation assembly is operable to apply opposing forces to the receiver assembly and the second launch vehicle portion.

2. The aerospace system of claim 1 , wherein the force interface comprises a first connecting element carried by the receiver assembly and a second connecting element carried by the actuation assembly, wherein the first and second connecting elements are positionable to engage each other to transfer force between the receiver assembly and the actuation assembly.

3. The aerospace system of claim 2 , wherein the first connecting element comprises one of a nub or a socket, and wherein the second connecting element comprises the other of a nub or a socket, and wherein the force interface comprises the actuation nub in engagement with the socket.

4. The aerospace system of claim 3 , wherein the socket is formed as an opening between two shear pins.

5. The aerospace system of claim 2 , wherein the actuation assembly comprises a chassis and the first connecting element is movable relative to the chassis via a mechanism carried by the chassis.

6. The aerospace system of claim 5 , wherein the mechanism comprises a threaded shaft that is rotatable relative to the chassis and an actuation block positioned to move along the threaded shaft when the threaded shaft is rotated, wherein the actuation block carries the second connecting element, and wherein when the actuation block moves along the threaded shaft, the second connecting element applies force to the first connecting element.

7. The aerospace system of claim 6 , further comprising an input shaft connected to the threaded shaft to provide torque to the threaded shaft, wherein the input shaft is configured to engage a hand tool for a user to apply torque to the threaded shaft.

8. The aerospace system of claim 7 , wherein the input shaft is connected to the threaded shaft via a torque limiting coupler.

9. The aerospace system of claim 1 , wherein the first locking mechanism comprises a pushing rod connected to the first movable shoe, and wherein the first locking mechanism further comprises a pushing device positioned to move the pushing rod.

10. The aerospace system of claim 9 , wherein the pushing device comprises a lever.

11. The aerospace system of claim 10 , further comprising a bushing positionable within one of the fastener holes and configured to receive one of the pegs.

12. The aerospace system of claim 1 , further comprising the first launch vehicle portion and the second launch vehicle portion.

13. The aerospace system of claim 12 , wherein the first launch vehicle portion or the second launch vehicle portion comprises a radially-inward depression forming an open space for receiving the first movable shoe or the second movable shoe, and wherein the corresponding first fastener hole or second fastener hole is positioned in a flange extending radially outwardly from the depression.

14. The aerospace system of claim 1 , wherein the alignment tool is a first alignment tool, the system further comprising a second alignment tool configured to align a third fastener hole in the first launch vehicle portion with a fourth fastener hole in the second launch vehicle portion.

15. The aerospace system of claim 14 , further comprising a bracing beam for connecting the first alignment tool to the second alignment tool.

16. The aerospace system of claim 15 , wherein the bracing beam is a first bracing beam, the system further comprising a second bracing beam, wherein the first bracing beam is configured to connect the actuation assembly of the first alignment tool to an actuation assembly of the second alignment tool, and wherein the second bracing beam is configured to connect the receiver assembly of the first alignment tool to a receiver assembly of the second alignment tool.

17. The aerospace system of claim 1 , wherein the force interface comprises a first connecting element carried by the receiver assembly and a second connecting element carried by the actuation assembly, wherein the first connecting element is positionable in the second connecting element or the second connecting element is positionable in the first connecting element.

18. A system for aligning first fastener holes in a first tubular structure with second fastener holes in a second tubular structure, the system comprising an alignment tool, the alignment tool comprising:
a receiver assembly comprising a first chassis, a first peg attached to the first chassis and configured to be positioned in one of the first fastener holes, and a first connecting element attached to the first chassis; and
an actuation assembly comprising a second chassis, a second peg attached to the second chassis and configured to be positioned in one of the second fastener holes, and a second connecting element movably attached to the second chassis;
wherein:
(a) the first connecting element and the second connecting element are positioned and configured to engage one another, wherein the first connecting element is positionable in the second connecting element, or the second connecting element is positionable in the first connecting element; and
(b) when the first connecting element is engaged with the second connecting element and the second connecting element is moved relative to the second chassis, the actuation assembly applies force to the receiver assembly.

19. The system of claim 18 , wherein one of the first connecting element or the second connecting element comprises a nub, and wherein the other of the first connecting element or the second connecting element comprises a socket configured to receive the nub.

20. The system of claim 18 , wherein:
the actuation assembly comprises a threaded shaft rotatably attached to the second chassis;
the second connecting element is movably attached to the second chassis via the threaded shaft; and
wherein rotation of the threaded shaft causes the second connecting element to move along the threaded shaft.

21. The system of claim 18 , wherein the receiver assembly comprises a first locking mechani

Assignees

• Blue Origin Llc

Inventors

• Johnson Derek

Classifications

• B64G1/002

  Launch systems · CPC title

• B64F5/10 Primary

  Manufacturing or assembling aircraft, e.g. jigs therefor · CPC title

• B23Q3/186

  Aligning devices · CPC title

• B23P19/10

  Aligning parts to be fitted together · CPC title