Laser Alignment Of Rocket Launch Rails

Rocket Launch Rails Case Study

The Challenge

NASA T-slot rail system needed to be installed on Pad 1 AML 20K launcher at KTF. The rail system needed to be precisely aligned, but there was no access for the standard alignment tools (wire and machinist scales) and accuracy needed to be improved.

The Solution

KTF, at the suggestion of Hovey Corbin, purchased a Pinpoint Laser System Model 2000 to align the 450 inches of NASA T-slot rails on the launcher. Hovey, then, designed and commissioned fixtures to mount the Model 2000 laser and its receiver/target to the NASA T-slot rails.

The Results

Successful alignment along the entire length of the 450 inches of rail to within .012” TIR (total indicator reading) from forward to aft on the launcher sail and forward extension.

Lessons Learned

• The Pinpoint Laser System Model 2000 outperformed the “wire and machinist scale” technique significantly. Both in time and accuracy,
  and the 0-Sigma actual impact results were much better. -The repeatability of measurements was improved.
• The process of mounting the laser and moving the target was developed.
• No wire tension deviation, vibration, breakage or movement during measurement process.
• Realtime adjustment capability.
• Easy to read hand-held LCD receiver display. Had to manually
  record data and coordinate with each bolt station in rail flanges, identify highest point on launcher boom and then calculate shim heights for alignment.
• Wire connecting single-axis target to the hand-held display was open for damage.

Advantages Of The New 2023 Microgage 2d and Pro Plus System

• New color screen for the hand-held display. (Pro Plus Only)
• Wireless connection between dual-axis ( X and Y ) target and display. (Pro Plus Only)
• Internal batteries for the hand-held display, the dual axis digital receiver/target and the laser, making the entire system wireless without the problem of connecting cables.
• Long battery run time for all units.
• Up to 120+ feet operating distance without losing accuracy.
• Better repeatability and performance with enhanced fixturing and target mounting.
• Can use the laser mount for immediate calibration of launcher elevation after aligning the rails. Done using a 45-degree angle mounting plate and a digital clinometer.
• The NEW Pinpoint Laser Microgage PRO Plus System can capture and store 10,000 data points which can then be used to create a quantitative Excel data map complete with custom graphs of the collected data.
• Self-centering dual-axis target fixture to enhance accuracy of both X and Y measurements.
• Entire Rail Mapping with just a single-pass for complete alignment measurement determining the highest point of the rails, saving time and providing precise rail alignments up to 120+ feet in length.
• Process positioning movement minimized (time savings).

Time Saving For

• New assembly setup and alignment of rails.
• Pre-launch validation after world-wide shipment.
• Fast, accurate and intuitive

Future Test Possibilities

• Check and, if needed, align existing rails on all launchers now in use for better 0-Sigma accuracy.
• Possibility of using Microgage Pro Plus System for precise jackscrew shaft alignment with elevation drive housing to jackscrew for long and reliable operation.

Conclusion

After recently visiting the Pinpoint Laser System facility late in December 2022 and meeting with management and engineering personnel, I was given a comprehensive and very informative 2-day tour of the facility. Plant Manager Mory Creighton and Sales Manager Craig Eliot introduced me to the most recent additions to the Pinpoint Laser Systems product line, and explained, at length, the technological advancements found in each system family. I am now convinced that the Microgage Pro Plus or 2D systems with dual-axis digital target receiver modules should become the industry standard for precise Sounding Rocket Launch Rail alignments as used by the world-wide Sounding Rocket Launch Community. The Pinpoint Laser Systems Microgage Pro Plus and 2D systems will provide Sounding Rocket Divisions world-wide, the “means to a superior technology” allowing these divisions to quickly and precisely align Sounding Rocket Launch Rails. Straight and true Sounding Rocket Launch Rails will improve actual impact points with respect to predicted 0-Sigma impact points and a “velvet smooth ride” on a precisely aligned set of Sounding Rocket Launch Rails will assure a much better rocket system launch with no spurious rates introduced into the system flight path when the shoes release from the launch rail cleanly, and the system flies away straight-and-true toward the predicted 0-Sigma impact point. Flight Safety Officers and Program Managers are only a few who will appreciate the use of this “superior technology” with respect to flight safety and mission success.

Respectfully submitted for your consideration and review,

Hovey D. Corbin

Addendum

This papers author, Hovey Corbin worked at Sandia National Laboratories in Albuquerque, NM for 40 years. After spending 8 plus years in the design and engineering group at Sandia, Hovey spent 30 plus years in the Sandia Laboratories Sounding Rocket Group. While in this group, he participated in launching rockets from Alaska to Africa with many missions at Kauai Test Facility (KTF)/PMRF Kauai, Wallops Island VA, Vandenberg CA, Poker Flats Research Range AK, AADC Kodiak AK, Wahmonie Site at NTS, Malindi Kenya, Eglin AFB, FL and other sites worldwide.

Pinpoint’s experience with precision laser and alignment systems that operate over long distances and deliver high precision measuring and alignment capability provide a solid fit for this project. Working closely with GasTOPS, Ltd., Pinpoint adapted one of its standard
measuring systems, called the Microgage 2D, to fit onto the Sea King and essentially replace the conventional string and wire alignment method with laser light.

The first system was delivered in February of 2003 to the Shearwater Military Facility in Dartmouth, Nova Scotia, Canada, and run through an extensive trial and evaluation process. Lessons learned from this testing were helpful in making modifications and improving the system’s ease of use. By June of 2003, approximately six months after the first design meeting, the laser alignment system had been improved upon and was returned to the customer and put into additional testing trials and regular use.

Over the last three years, this Sea King Laser Alignment system has been tested and evaluated extensively by the Canadian Military Forces. Additional systems have been purchased and are in regular use in Nova Scotia and British Columbia. The laser system has been used successfully to align Sea King tail rotor shafts in the Persian Gulf theater in May of 2003 and more recent alignments on the deck of a destroyer in the North Sea in February of 2005.

Product improvements and advances continue and this Laser Alignment system has proven to save time and significantly improve the shaft alignment accuracy on the Sea King. Present alignment results include: