US-20260125163-A1 - Methods and Devices for Alignment and Joining Large Components

Abstract

Methods, apparatus, and devices for fixturing and alignment of parts and panels for assembly into aerospace components, are provided. These methods and devices are designed for joining together several large part segments into a larger complete component.

Inventors

• Jared Rogers
• Samuel BUTLER
• Elizabeth Barranco
• Adam Bermudez
• John Cummings
• Collin Cain

Assignees

• Relativity Space, Inc.

Dates

Publication Date

20260507

Application Date

20251014

Claims (20)

1. 1 .- 5 . (canceled)
2. 6 . A system for joining panels, the system comprising: a friction stir welder configured to friction stir weld together a first panel and a second panel within a joining area; a first hanging element configured to hang the first panel so that the first panel is substantially straightened under its own weight; a second hanging element configured to hang the second panel so that the second panel is substantially straightened under its own weight; and an alignment system configured to align two adjacent edges of the first panel and the second panel within the joining area, the alignment system comprising a plurality of alignment towers and a constraint system, the alignment system configured to constrain at least one of the first panel and the second panel in an orientation relative to the other panel.
3. 7 . The system of claim 6 , wherein each hanging element comprises a bracket configured to couple the respective panel to an overhead support structure disposed on a plurality of support towers.
4. 8 . The system of claim 6 , further comprising a circular rail and at least two carts configured to translate respective hanging elements and panels into the joining area.
5. 9 . The system of claim 6 , wherein each hanging element is configured to translate at least one of the panels radially relative to an axis.
6. 10 . The system of claim 6 , wherein the constraint system comprises at least one clamp configured to secure the adjacent edges of the first panel and the second panel against an alignment mechanism during friction stir welding.
7. 11 . The system of claim 6 , further comprising a circular rail, wherein the first hanging element is configured to translate along the circular rail.
8. 12 . The system of claim 6 , further comprising a circular rail, wherein the first hanging element is configured to translate radially with respect to the circular rail.
9. 13 . The system of claim 6 , further comprising a circular rail comprising a plurality of rail segments that circumscribe the joining area.
10. 14 . The system of claim 6 , wherein each one of the plurality of alignment towers further comprises: at least one upper roller proximal to a first end of the alignment tower; and at least one lower roller proximal to a second end of the alignment tower; wherein the first end of the alignment tower comprises at least one first alignment bolt; wherein the second end of the alignment tower comprises at least one second alignment bolt; wherein the alignment system is configured to align the at least one upper roller with the at least one first alignment bolt; and wherein the alignment system is configured to align the at least one lower roller with the at least one second alignment bolt.
11. 15 . A system for joining panels, the system comprising: a welder configured to weld together a first panel and a second panel within a joining area; a first hanging element configured to hang the first panel so that the first panel is substantially straightened under its own weight; a second hanging element configured to hang the second panel so that the second panel is substantially straightened under its own weight; and an alignment system configured to align two adjacent edges of the first panel and the second panel within the joining area.
12. 16 . The system of claim 15 , wherein each hanging element comprises a bracket configured to couple the respective panel to a support structure disposed on a plurality of support towers.
13. 17 . The system of claim 15 , further comprising a rail and at least one cart configured to translate at least one of the panels into the joining area.
14. 18 . The system of claim 15 , wherein the alignment system is further configured to translate at least one of the panels radially.
15. 19 . The system of claim 15 , further comprising at least one clamp configured to secure the two adjacent edges of the first panel and the second panel.
16. 20 . The system of claim 15 , further comprising a circular rail, wherein the first hanging element is configured to translate along the circular rail.
17. 21 . The system of claim 15 , further comprising a circular rail, wherein the first hanging element is configured to translate radially with respect to the circular rail.
18. 22 . The system of claim 15 , further comprising a circular rail comprising a plurality of rail segments that circumscribe the joining area.
19. 23 . The system of claim 15 , wherein the alignment system further comprises at least one alignment tower configured to constrain at least one of the panels in an orientation relative to the other panel.
20. 24 . The system of claim 23 , wherein the alignment tower further comprises a lower clamp assembly configured to translate up and down a linear rail.

Description

CROSS REFERENCE TO RELATED APPLICATIONS The current application is a divisional of U.S. patent application Ser. No. 19/195,599, entitled “Methods and Devices for Alignment and Joining Large Components”, filed Apr. 30, 2025, which claims the benefit of U.S. Provisional Patent Application No. 63/717,726 entitled “Methods and Devices for Alignment and Joining Large Components” filed Nov. 7, 2024, the disclosures of which are incorporated herein by reference in their entireties for all purposes. FIELD OF THE INVENTION This invention is generally related to methods and devices for fixturing and alignment of parts and panels for assembly into aerospace components, machined parts and devices, and methods thereof. BACKGROUND Friction Stir Welding (FSW) is a joining process that uses a rotating tool to fuse two adjacent workpieces. The process generates heat through friction between the tool and the materials, softening the areas close to the tool. As the tool moves along the joint line, it welds the pieces together, creating a weld with high strength, which makes FSW ideal for applications that require robust structural components, such as aerospace applications. FSW does not require filler materials, which can result in lighter structures, which is an important consideration for aerospace applications, where weight reduction is a critical design factor. Additionally, FSW can produce welds with superior strength and consistency compared to alternative joining methods. However, FSW also poses several challenges, particularly when used for large aerospace components. One major challenge is fixturing and aligning large panels. Ensuring that these panels are correctly positioned and securely held during the welding process can be complex and labor-intensive. Even minor misalignments can lead to significant issues. In large structures, even slight deviations in alignment can combine to produce considerable errors, and the cumulative effect of the small misalignments across multiple panels can create significant deviations from design specifications. SUMMARY OF THE INVENTION Aspects of the disclosure are directed to methods and devices for friction stir welding and part fixturing. Additional embodiments and features are in part set forth in the description that follows, and in part will become apparent to those skilled in the art upon examination of the specification or may be learned by the practice of the disclosure. A further understanding of the nature and advantages of the present disclosure may be realized by reference to the remaining portions of the specification and the drawings, which forms a part of this disclosure. BRIEF DESCRIPTION OF THE DRAWINGS The description will be more fully understood with reference to the following figures, which include various embodiments of the disclosure and should not be construed as a complete recitation of the scope of the disclosure, wherein: FIG. 1 illustrates barrel manufacturing methods and fixturing devices in accordance with various aspects of the prior art. FIGS. 2A through 2C illustrate common manufacturing and alignment errors in accordance with some embodiments. FIG. 3 depicts a flow chart for an example method of fixturing for a barrel in accordance with the disclosure. FIG. 4 illustrates fixturing configured to hang panels, in accordance with some embodiments. FIG. 5 illustrates fixturing towers, rail, and support elements in accordance with some embodiments. FIG. 6 illustrates a hanging alignment and fixturing configuration in accordance with some embodiments. FIGS. 7A through 7D illustrate a clamping alignment and fixturing configuration in accordance with some embodiments. FIG. 8 illustrates a slotted panel alignment and fixturing configuration in accordance with some embodiments. FIGS. 9A and 9B illustrate an example hanging panel alignment and fixturing configuration for friction stir welding in accordance with some embodiments. FIG. 10 illustrates aligning and joining the last panel in accordance with some embodiments. FIGS. 11A and 11B illustrate lifting and alignment brackets in accordance with some embodiments. FIG. 12 illustrates an example large panel alignment and assembly apparatus in accordance with some embodiments. FIG. 13 illustrates the removal of a finished barrel from the fixture structure in accordance with some embodiments. FIG. 14 illustrates an example friction stir welding tower in accordance with some embodiments. FIG. 15 illustrates an example circular rail in accordance with some embodiments. FIG. 16 illustrates an example cart in accordance with some embodiments. FIGS. 17A through 17C illustrate loading and aligning panels and brackets in accordance with some embodiments. FIGS. 18A and 18B illustrate example upper clamps in accordance with some embodiments. FIG. 19 illustrates example lower clamps in accordance with some embodiments. FIG. 20 illustrates an example removable rail section in accordance with some embodiments. FIG. 21 illu