Rocket thrust structure assembly, and associated systems and methods
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.
1. A method of assembling an aerospace system, the method comprising:
positioning a plurality of optical targets on a body portion of the aerospace system;
directing a light beam from a measurement system toward each of the optical targets;
determining a position and orientation of the measurement system relative to the body portion in a reference coordinate system, wherein determining the position comprises determining a distance between the measurement system and each of the optical targets using the measurement system;
within the reference coordinate system, and using the measurement system, scanning and characterizing a plurality of first mounting faces on attachment features positioned on the body portion;
forming a digital representation of each of the first mounting faces within the reference coordinate system;
based on the digital representation of each of the first mounting faces, defining one or more shims, wherein when each shim is positioned on a corresponding first mounting face, the shim forms a corresponding new mounting face, wherein each of the new mounting faces are coplanar within the reference coordinate system;
positioning each shim on each corresponding first mounting face;
positioning a drill jig over a selected shim from the one or more shims, on the new mounting face, wherein the drill jig comprises a hole pattern;
adjusting the drill jig to position the hole pattern within the reference coordinate system, using the measurement system; and
making holes based on the hole pattern.
2. The method of claim 1 , wherein the drill jig comprises one or more attachment elements, and wherein positioning the drill jig comprises attaching the drill jig to the attachment feature on which the selected shim is positioned.
3. The method of claim 1 , wherein the drill jig comprises a plurality of movable plates, and wherein adjusting the drill jig comprises:
positioning one or more second optical targets in the hole pattern;
tracking, with the measurement system, a position of each of the one or more second optical targets within the reference coordinate system; and
moving one or more of the plurality of movable plates to align the hole pattern with a hole pattern position within the reference coordinate system.
4. The method of claim 1 , wherein the system comprises a thrust structure comprising a plurality of legs, and wherein the method further comprises:
attaching each leg to a first mounting face or a new mounting face.
5. The method of claim 1 , wherein positioning each shim on each corresponding first mounting face comprises attaching each shim to each corresponding first mounting face with adhesive or tape.
6. The method of claim 1 , wherein positioning the plurality of optical targets on the body portion comprises positioning the plurality of optical targets around a perimeter of the body portion.
7. A method of assembling an aerospace system, the method comprising:
positioning a constellation of targets on a body portion of the aerospace system; using a measurement system, determining a distance between the measurement system and each of the targets;
determining a position and orientation of the measurement system relative to the targets in a reference coordinate system;
within the reference coordinate system, using the measurement system, measuring two or more first mounting faces attached to the body portion;
forming a digital representation of each of the first mounting faces within the reference coordinate system;
based on the digital representation of each of the first mounting faces, defining one or more shims, wherein each shim is configured to be positioned on a corresponding first mounting face to form a second mounting face, wherein each second mounting face is coplanar with a first mounting face and/or another second mounting face within the reference coordinate system;
positioning each shim on each corresponding first mounting face; and
forming one or more mounting holes in each shim and each corresponding mounting face, based on a hole pattern within the reference coordinate system.
8. The method of claim 7 , wherein forming the mounting holes comprises positioning a drill jig on each shim, wherein the drill jig comprises the hole pattern, and wherein the method further comprises adjusting the drill jig to position the hole pattern within the reference coordinate system.
9. The method of claim 7 , wherein the system comprises a thrust structure comprising a plurality of legs, and wherein the method further comprises attaching each leg to a first mounting face or a second mounting face.
10. The method of claim 7 , wherein positioning each shim on each corresponding first mounting face comprises attaching each shim to each corresponding mounting face with adhesive or tape.
11. The method of claim 7 , wherein the first targets comprise optical targets, and wherein using the measurement system comprises emitting a light beam toward the optical targets.
12. A method of assembling a structure, the method comprising:
selecting a reference coordinate system;
within the reference coordinate system, and using a measurement system, scanning and characterizing an attachment feature positioned on a first structural element;
forming, in a computing system, a digital representation of the attachment feature within the reference coordinate system;
based on the digital representation of the attachment feature, defining a shim, wherein when the shim is positioned on the attachment feature, the shim forms a new mounting face that is positioned in a nominal location;
positioning the shim on the attachment feature;
positioning a drill jig over the shim and on the new mounting face, wherein the drill jig comprises a hole pattern;
adjusting the drill jig to position the hole pattern, using the measurement system; and making holes based on the hole pattern.
13. The method of claim 12 , further comprising attaching a second structural element to the first structural element via the attachment feature and the shim.
14. The method of claim 13 , wherein:
the structure is an aerospace structure;
the first structural element is one of (a) a head of a propellant tank or (b) a thrust structure configured to support a rocket engine; and
the second structural element is the other of (a) the head of a propellant tank or (b) the thrust structure.
15. The method of claim 13 , wherein attaching the second structural element to the first structural element comprises supporting the second structural element in a structure comprising one or more load measurement devices, wherein the method comprises using force-feedback to align the second structural element to the first structural element.
16. The method of claim 13 , wherein attaching the second structural element to the first structural element comprises using one or more metrology processes to align the second structural element to the first structural element.