CN110171584B - Vacuum thermal test method for mass production of satellite constellation system - Google Patents
Vacuum thermal test method for mass production of satellite constellation system Download PDFInfo
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Abstract
The invention provides a vacuum thermal test method for a satellite constellation system produced in batch, which is characterized in that a plurality of satellites are simultaneously placed in a space environment simulation device, a heat balance star and a heat vacuum star are respectively selected, and the heat control state of the heat balance star is worse than that of the heat vacuum star; carrying out a heat balance test on the heat balance star; in the process of the heat balance test, equipment on the heat balance satellite is powered up according to an on-orbit set working mode, and meanwhile, each surface of the heat balance satellite is applied according to external heat flow design parameters; simulating the external heat flow influence of the heat balance satellite brought by the mutual shielding condition of each satellite, and correcting the external heat flow of the heat balance satellite in real time; in the process of the thermal balance test, equipment on the thermal vacuum satellite is powered up according to an on-orbit set working mode, but external heat flow is not applied; and after the thermal balance test is finished, determining the high and low temperature maintaining range of the thermal vacuum test of the satellite system according to the thermal balance test result, and performing the thermal vacuum test of the satellite system.
Description
Technical Field
The invention relates to the technical field of aerospace, in particular to a vacuum thermal test method for a satellite constellation system in batch production.
Background
With the continuous development of aerospace technology, the functional density of the spacecraft is higher and higher, and the miniaturization, batch development and production capacity of the spacecraft are realized at present. The satellite constellation is a set of a plurality of or a plurality of satellites which can normally work when being launched into orbit and have similar functions and are combined in a certain mode. For completing tasks such as global communication, navigation, environmental monitoring and the like, any place on the earth and any time can be covered by a satellite, and the situation that one satellite is used is far from enough, and a plurality of satellites are required to form a satellite network according to a certain mode so as to realize the functions. At the present stage, miniaturized satellite constellations are widely applied to the fields of internet communication, remote sensing, navigation, environment monitoring and the like, with the promotion of national military and civil fusion policies in recent years, the development and launching costs of spacecrafts are further reduced, and the satellite constellations produced in batches at present show a rapid development situation.
The task of the spacecraft thermal control system is to ensure that all instruments and equipment on the satellite meet the temperature index requirements under the conditions of a set orbit, attitude and working mode. In order to verify the overall function of the spacecraft in a space environment and ensure the on-orbit reliable operation of the spacecraft, all the spacecrafts are required to be examined in a vacuum thermal test in a ground development stage, wherein the most important and complex test with the longest period is the whole-satellite vacuum thermal test in space environment simulation equipment. The spacecraft ground vacuum thermal test is divided into a thermal balance test and a thermal vacuum test, wherein the thermal balance test and the thermal vacuum test are mainly used for verifying the correctness of thermal control design, the capability of a thermal control system for maintaining each instrument and equipment on a satellite in a specified working temperature range is mainly examined, the working performance of a satellite-mounted thermal control product and the effectiveness of various thermal control measures are examined, a thermal analysis physical model is perfected, and a high-low temperature holding range of the thermal vacuum test is predicted; the later tests mainly examine the capability of each instrument on the satellite to resist high temperature, low temperature and temperature alternation under the vacuum condition, expose single machines, raw materials, components and process defects on the satellite in advance, and obtain test data under different temperature environment conditions.
The low-orbit satellite constellation at the present stage has the characteristics of light weight, small volume, large quantity, dense one-rocket multi-satellite launching and rapid networking, and the traditional test method can not meet the requirement of task development progress. Therefore, it is urgently needed to provide a method for massively producing a satellite constellation multi-satellite parallel vacuum thermal test for the ground vacuum thermal test of the satellite constellation massively produced at the present stage.
In order to ensure the capability of the spacecraft in resisting space vacuum and high and low temperature environments, all the spacecrafts are required to be subjected to vacuum thermal test examination in the ground development stage. For a single satellite or a single serial developed satellite, a thermal balance test is generally carried out on the satellite firstly, then a thermal vacuum test is carried out, and the thermal vacuum test condition is determined according to the thermal balance test result, namely, one satellite enters space environment simulation equipment once to complete two test verification contents. And only one satellite which is produced in batch and has the same thermal control state is selected to be subjected to a thermal balance test, and the other satellites are subjected to a thermal vacuum test according to the thermal balance test result, so that the two test processes are mutually connected in series. However, when the thermal control state of the subsequent satellite changes, the test verification needs to be performed independently, the existing test method needs to perform the test at least twice independently, the satellite needs to enter and exit space environment simulation equipment at least twice, the implementation process is complex and time-consuming, and the test mode of mass production of a large number of satellites can seriously restrict the development progress and the launching plan of the mass production of the satellites.
The existing test method has the following defects:
firstly, the existing test method requires that a single-star thermal balance test is firstly carried out, then a multi-star thermal vacuum test is carried out, and the two test processes need to be successively carried out in series, which is equivalent to carrying out two vacuum thermal tests, and the test period is longer;
secondly, the existing test method requires that the vacuum thermal test is carried out at least twice on the satellites in batch production, namely, one satellite is selected to carry out a single-satellite thermal balance test, and then a multi-satellite thermal vacuum test is carried out, so that the test cost is high;
the existing test method needs at least twice in-and-out space environment simulation equipment, has higher requirements on preparation work before the test, test equipment operation and thermal control process implementation, and can carry out turnover, hoisting and transferring operation on the satellite to be tested for multiple times when the satellite is in and out of the test equipment for multiple times, so that the damage probability of the satellite is greatly increased;
the existing test method requires at least two times of entering and exiting the space environment simulation equipment for testing, and wastes more thermal control materials, test consumables and the like required by the test;
fifthly, the existing test method requires that a single-satellite thermal balance test is firstly carried out in small test equipment, and a subsequent multi-satellite thermal vacuum test is carried out in large test equipment. Therefore, the requirements on the type and the index of the test equipment are complex, and a plurality of matched units are required to jointly bear the research;
and sixthly, the conventional test method seriously restricts the test period, development progress, development cost and task completion of the satellite constellation mass production, and the conventional development requirement of the satellite constellation mass production is not met.
Disclosure of Invention
The invention aims to provide a vacuum thermal test method for a satellite constellation system produced in batch, which aims to solve the problem that the conventional test mode for producing the satellite constellation in batch seriously restricts the development progress and the launching plan of the satellite produced in batch.
In order to solve the technical problems, the invention provides a vacuum thermal test method for batch production of a satellite constellation system, wherein the satellite constellation system comprises a plurality of satellites with the same or similar thermal control states, and the vacuum thermal test method for the satellite constellation system comprises the following steps:
simultaneously placing the plurality of satellites into space environment simulation equipment, selecting one satellite as a heat balance satellite, and using the other satellites as heat vacuum satellites, wherein the heat control state of the heat balance satellite is worse than that of the heat vacuum satellites;
carrying out a heat balance test on the heat balance star;
in the process of the heat balance test, equipment on the heat balance star is powered up according to an on-orbit set working mode, and external heat flows are applied to the outer surfaces of the heat balance star according to external heat flow design parameters;
in the thermal balance test process, simulating the external heat flow influence brought to the thermal balance satellite by the mutual shielding condition of each satellite, and correcting the external heat flow applied to the thermal balance satellite in real time according to the simulation result;
in the process of the thermal balance test, the equipment on the thermal vacuum star is powered up according to an on-orbit set working mode;
and after the thermal balance test of the thermal balance satellite is finished, determining the temperature holding range of the thermal vacuum test of the satellite constellation system according to the thermal balance test result, and performing the thermal vacuum test of the satellite constellation system according to the temperature holding range.
In the invention, the terms "the thermal control states are the same or similar" mean that the factors influencing the thermal control state of the whole satellite, such as the flight orbit parameters of the satellite, the configuration layout, the thermal power consumption, the working mode, the thermal control scheme and the like, are the same or similar. The "the thermal control state of the first satellite is worse than that of the second satellite" means that through analysis of the above parameters, the selected thermal balance satellite has certain representativeness and worse thermal control parameters, for example, the satellite which is not favorable for thermal control design and heat dissipation of the whole satellite is used as the thermal balance satellite if the heat flow result outside the flight orbit is bad, the heat power consumption of the whole satellite is larger than that of other satellites, the working time is longer, and the other satellites are used as the thermal vacuum satellites, that is, the parameter represented by the thermal control state of the first satellite is worse than that represented by the thermal control state of the second satellite, that is, the difference from the ideal parameter is larger or less ideal.
Optionally, in the vacuum thermal test method for a satellite constellation system, the vacuum thermal test method for a satellite constellation system further includes:
selecting the space environment simulation equipment according to the size and the number of each satellite in the satellite constellation system, wherein the space environment simulation equipment is usually a vertical cylinder or a horizontal cylinder;
the direction of each satellite is placed according to the minimum test unit, and an electric test cable and a temperature measurement and control cable are connected, wherein the electric test cable is used for electrifying equipment on the satellite, and the temperature measurement and control cable is used for applying external heat flow to the outer surface of the heat balance satellite;
and designing a thermal test tool according to the position and the placing direction of each satellite so that the structural strength and the rigidity of the thermal test tool meet the requirements of the vacuum thermal test, wherein the thermal test tool comprises a guide rail, a support rod and a lifting appliance, the support rod and the lifting appliance are in direct contact with each satellite for temperature compensation, and the guide rail, the support rod and the lifting appliance are subjected to active temperature control in the vacuum thermal test process.
Optionally, in the vacuum thermal test method for a satellite constellation system, the vacuum thermal test method for a satellite constellation system further includes:
the outer surface of the heat balance star is provided with a main radiating surface and an auxiliary radiating surface;
when the plurality of satellites are placed into the space environment simulation equipment, the main radiating surface is opposite to the inner surface of the space environment simulation equipment, and the auxiliary radiating surface is opposite to the inner surface of the space environment simulation equipment or the non-radiating surface of the hot vacuum star, so that the heat balance star is minimally influenced by the shielding of the hot vacuum star.
Optionally, in the vacuum thermal test method for the satellite constellation system, the thermal equilibrium test includes, but is not limited to, a thermal equilibrium test low-temperature operating condition and a thermal equilibrium test high-temperature operating condition,
the thermal balance test low-temperature working condition comprises a steady-state low-temperature working condition, a quasi-steady-state low-temperature working condition, a periodic transient low-temperature working condition and a transient low-temperature working condition;
the high-temperature working condition of the thermal balance test comprises a steady-state high-temperature working condition, a quasi-steady-state high-temperature working condition, a periodic transient high-temperature working condition and a transient high-temperature working condition.
Optionally, in the vacuum thermal test method for the satellite constellation system,
the external heat flow of the high-temperature working condition of the heat balance test is set according to the final service life of the heat balance star, the vicinity of the winter solstice and the maximum heat flow orbit parameter simulation result, and is corrected according to the shielding condition of each satellite, so that the heat balance star works according to the maximum heat consumption mode, and the high-temperature working condition temperature result of the heat balance test is obtained;
the external heat flow of the low-temperature working condition of the heat balance test is set according to the simulation result of the minimum heat flow orbit parameter near summer solstice in the initial service life of the heat balance satellite, and is corrected according to the shielding condition of each satellite, so that the heat balance satellite works in the minimum heat loss mode, and the low-temperature working condition temperature result of the heat balance test is obtained.
Optionally, in the vacuum thermal test method for a satellite constellation system, the thermal vacuum test performs a plurality of high and low temperature cycles according to the temperature maintaining range, and in the high and low temperature cycle process of the thermal vacuum test:
the heat balance star and the heat vacuum star are subjected to heating operation by arranging an auxiliary heating heater and an external heat flow simulation heat source, and each satellite is set to be in the same power-on state and the same thermal control state in the heating and cooling process;
the highest temperature in the temperature keeping range is determined according to the high-temperature working condition temperature result of the thermal balance test, and the lowest temperature in the temperature keeping range is determined according to the low-temperature working condition temperature result of the thermal balance test;
cooling the heat balance star and the hot vacuum star by turning off the auxiliary heating heater and the external heat flow simulation heat source;
and collecting, comparing and analyzing the test state and the remote measurement parameters of each satellite, judging whether the satellite state and the performance of each satellite are consistent, finding and positioning abnormal data and parameters, and processing potential faults.
Optionally, in the vacuum thermal test method for the satellite constellation system, in a high-low temperature cycle process of the thermal vacuum test:
in the high-temperature maintaining stage of the thermal vacuum test, the temperature of more than 80 percent of the temperature measuring point is 10-15 ℃ higher than the temperature result of the high-temperature working condition of the thermal balance test and is lower than the highest test temperature of the acceptance grade;
in the low-temperature maintaining stage of the thermal vacuum test, the temperature of more than 20 percent of the temperature measuring point is 5-15 ℃ lower than the result of the low-temperature working condition temperature of the thermal balance test and is higher than the lowest test temperature of the acceptance grade.
Optionally, in the vacuum thermal test method for a satellite constellation system, the vacuum thermal test method for a satellite constellation system further includes:
before the thermal balance test is carried out, carrying out initial test on the satellite constellation system, wherein the initial test comprises a low-pressure test working condition, a thermal control software test working condition and a whole satellite high-temperature air outlet working condition;
and after the thermal vacuum test is finished, performing a vacuum aging test on the satellite constellation system.
Optionally, in the vacuum thermal test method for the satellite constellation system,
and under the low-pressure test working condition, vacuumizing the space environment simulation equipment, keeping the minimum system equipment of each satellite in a power-on state, so that the vacuum degree in the space environment simulation equipment is reduced to 0.1Pa from 1000Pa, monitoring the power-on state and the remote measurement parameters of each satellite, wherein the minimum system equipment is the power-on equipment during satellite transmission.
Optionally, in the vacuum thermal test method for the satellite constellation system, under the test condition of the thermal control software, determining each satellite temperature control interval according to the temperature control threshold of the thermal control software module and the lowest temperature allowed by the auxiliary heating heater;
testing the ability of the thermal control software module to maintain the temperature of the whole satellite;
performing a switch control logic test and a proportional control logic test of the thermal control software module;
carrying out a whole satellite safety mode and a minimum function test of a thermal control software module;
and carrying out open-loop test and closed-loop test on the auxiliary heating heater.
Optionally, in the vacuum thermal test method for the satellite constellation system, under the working condition of high-temperature air outlet of the whole satellite, the auxiliary temperature-raising heater, the external heat flow simulation heat source and the satellite body active thermal control heater are used for raising the temperature of the satellite constellation system, so that the temperature of the satellite constellation system is 5-10 ℃ higher than the simulation result of the maximum heat flow orbit parameter and is maintained, the maintenance time is longer than 24 hours, and the structure plate, the satellite single-machine, the cable and the satellite auxiliary material of each satellite are deflated.
Optionally, in the vacuum thermal test method for a satellite constellation system, the vacuum aging test includes: in the space environment simulation equipment, the temperature of each satellite is adjusted through the auxiliary heating-up heater, and meanwhile, each satellite is powered up according to an on-orbit set working mode, so that the electrical performance of each satellite is tested, and aging-simulating accelerated test is realized.
Optionally, in the vacuum thermal test method for the satellite constellation system, the satellite constellation system includes a satellite using a star sensor to fix the attitude, a star map simulator is installed on the satellite using the star sensor to fix the attitude, a closed-loop attitude control software test is performed on the star map simulator, and active temperature control and temperature monitoring are performed on the star map simulator.
Optionally, in the vacuum thermal test method for the satellite constellation system, a movable radiation screen is arranged at the main radiating surface of the heat balance star and the heat vacuum star;
a resistance silicon tube and an ionization silicon tube are arranged at the high-power equipment of the satellite constellation system;
and arranging a heat sink device at the heat balance star.
According to the vacuum thermal test method for the satellite constellation system, the thermal balance test is carried out on the thermal balance satellite, the external heat flow applied to the thermal balance satellite is corrected in real time, after the thermal balance test of the thermal balance satellite is completed, the temperature holding range of the thermal vacuum test of the satellite constellation system is determined according to the thermal balance test result, the thermal vacuum test of the satellite constellation system is carried out according to the temperature holding range, the batch satellite development and test period can be obviously shortened, and the test cost is reduced. The purpose of a thermal balance test can be realized through one-time vacuum thermal test operation, the assessment requirement of the thermal vacuum test can be met, a plurality of satellites can be subjected to the vacuum thermal test in parallel, the test time of the satellites in batch production in the thermal vacuum environment can be quickly accumulated, and the method is very suitable for large-scale development of the satellites in batch production; the device has the advantages that the test period is short, the test cost is low, only one time of entering and exiting of the space environment simulation equipment is needed, the implementation requirements on preparation work before the test, test equipment operation and thermal control process are low, the repeated turning-over, hoisting and transferring operations of the participating satellites are avoided, the damage probability of the satellites is reduced, the thermal control materials and test consumables required by the test are saved, and the requirements on the type and indexes of the test equipment are simple.
With the increasing maturity of spacecraft thermal control analysis software, the accuracy is gradually improved, the thermophysical model is corrected in a mode of combining test and simulation analysis, and the corrected thermophysical model is applied to predict the on-orbit temperature range and the change rule of each instrument and equipment on the satellite. The purpose of the thermal balance test can be realized by one-time operation of the space environment simulation equipment, the thermal vacuum test examination requirement is met, and the requirement of satellite development task in batch production is met.
The invention relates to a method for verifying a multi-satellite parallel ground vacuum thermal test of a batch production satellite (spacecraft). The satellites should have the same or similar thermal control states, and the invention can be widely applied to the field of commercial aerospace in which the thermal control states of the satellites are more consistent by adopting a one-arrow-multi-satellite emission mode, wherein the vacuum thermal test can be carried out on the satellites in batch production such as low-earth-orbit communication satellite constellations, remote sensing satellite constellations, navigation satellite constellations and internet satellite constellations simultaneously or in batches.
Drawings
Fig. 1 is a schematic diagram of a satellite placement with a minimum test unit of two stars in a horizontal space environment simulation device according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of a satellite placement with a minimum test unit of samsung in the horizontal space environment simulation device according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a satellite placement with a minimum test unit of four stars in the horizontal space environment simulation apparatus according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of a satellite placement with a minimum test unit of two stars in the vertical space environment simulation device according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of a satellite placement with a minimum test unit of samsung in the vertical space environment simulation device according to an embodiment of the present invention;
fig. 6 is a schematic diagram of a satellite placement with a minimum test unit of four stars in the vertical space environment simulation device according to the embodiment of the present invention;
FIG. 7 is a schematic diagram of a parallel vacuum thermal test process for each satellite according to an embodiment of the present invention;
shown in the figure: 0-space environment simulation equipment; 1-heat balance star; 2-hot vacuum star; 3-hot vacuum star; 4-hot vacuum star; 10-initial testing; 11-heat balance test; 12-thermal vacuum test; 13-vacuum aging test; 101-low pressure test working condition; 102-testing working conditions by thermal control software; 103-whole star high-temperature air outlet working condition; 104-high temperature working condition of heat balance test; 105-low temperature working condition of heat balance test; 106-thermal vacuum test cycle 1; 107-thermal vacuum test cycle 2; 108-thermal vacuum test cycle 3; 109-thermal vacuum test cycle 4; 110-thermal vacuum test n cycle; 111-vacuum aging test.
Detailed Description
The vacuum thermal test method for the satellite constellation system provided by the invention is further described in detail with reference to the accompanying drawings and specific embodiments. Advantages and features of the present invention will become apparent from the following description and from the claims. It is to be noted that the drawings are in a very simplified form and are not to precise scale, which is merely for the purpose of facilitating and distinctly claiming the embodiments of the present invention.
The core idea of the invention is to provide a vacuum thermal test method for batch production of satellite constellation systems, so as to solve the problem that the conventional batch production of satellite constellation test mode seriously restricts the development progress and emission plan of batch production of satellites.
In order to realize the idea, the invention provides a vacuum thermal test method for batch production of a satellite constellation system, wherein the satellite constellation system comprises a plurality of satellites with the same or similar thermal control states, and the vacuum thermal test method for the satellite constellation system comprises the following steps: simultaneously placing the plurality of satellites into space environment simulation equipment, selecting one satellite as a heat balance satellite, and using the other satellites as heat vacuum satellites, wherein the heat control state of the heat balance satellite is worse than that of the heat vacuum satellites; carrying out a heat balance test on the heat balance star; in the process of the heat balance test, equipment on the heat balance star is powered up according to an on-orbit set working mode, and external heat flows are applied to the outer surfaces of the heat balance star according to external heat flow design parameters; in the thermal balance test process, simulating the external heat flow influence brought to the thermal balance satellite by the mutual shielding condition of each satellite, and correcting the external heat flow applied to the thermal balance satellite in real time according to the simulation result; in the process of the thermal balance test, the equipment on the thermal vacuum star is powered up according to an on-orbit set working mode; and after the thermal balance test of the thermal balance satellite is finished, determining the temperature holding range of the thermal vacuum test of the satellite constellation system according to the thermal balance test result, and performing the thermal vacuum test of the satellite constellation system according to the temperature holding range.
The invention provides a vacuum thermal test method for a satellite constellation system produced in batch, as shown in figures 1-7, the satellite constellation system comprises a plurality of satellites with the same or similar thermal control states, and the vacuum thermal test method for the satellite constellation system comprises the following steps: putting the satellites into a space environment simulation device 0 at the same time, selecting one satellite as a heat balance star 1, and the other satellites as heat vacuum stars 2, 3 and 4, wherein the heat control state of the heat balance star 1 is worse than the heat control states of the heat vacuum stars 2, 3 and 4; carrying out a heat balance test 11 on the heat balance star 1; in the process of the heat balance test 11, the equipment on the heat balance star 1 is powered up according to an on-orbit set working mode, and external heat flows are applied to the outer surfaces of the heat balance star 1 according to external heat flow design parameters; in the process of the thermal balance test 11, simulating the external heat flow influence brought to the thermal balance star 1 by the mutual shielding condition of each satellite, and correcting the external heat flow applied to the thermal balance star 1 in real time according to the simulation result; in the process of the thermal balance test 11, the devices on the thermal vacuum stars 2, 3 and 4 are powered up according to an on-orbit set working mode; after the thermal balance test 11 of the thermal balance star 1 is completed, determining the temperature holding range of the thermal vacuum test 12 of the satellite constellation system according to the result of the thermal balance test 11, and performing the thermal vacuum test 12 of the satellite constellation system according to the temperature holding range.
Specifically, in the vacuum thermal test method for a satellite constellation system, the vacuum thermal test method for a satellite constellation system further includes: selecting the space environment simulation equipment 0 according to the size and the number of each satellite in the satellite constellation system, wherein the space environment simulation equipment 0 is a vertical cylinder or a horizontal cylinder; the method comprises the following steps of placing the directions of all satellites according to a minimum test unit, carrying out level adjustment operation on all satellites, and connecting an electric test cable and a temperature measurement and control cable, wherein the electric test cable is used for electrifying equipment on the satellites, and the temperature measurement and control cable is used for applying external heat flow to the outer surface of the heat balance satellite 1; designing a thermal test tool according to the position and the placing direction of each satellite so that the structural strength and the rigidity of the thermal test tool meet the requirements of the vacuum thermal test, wherein the thermal test tool comprises a guide rail, a supporting rod and a lifting appliance, the supporting rod and the lifting appliance which are in direct contact with each satellite are subjected to temperature compensation, the temperature of the tool is controlled to be consistent with the temperature of a neighboring satellite in the test process, and the influence of heat leakage of a system on a thermal balance test result is reduced; in the vacuum thermal test process, the guide rail, the support rod and the lifting appliance are subjected to active temperature control, namely, the guide rail, the support tool, the lifting rod and other parts with slow temperature return process of the test equipment are subjected to active heating control in the thermal test process, and active thermal control is performed in the temperature return process, so that the thermal test time is reduced;
fig. 1 is a schematic diagram of a test state of a horizontal device double-star unit, fig. 2 is a schematic diagram of a test state of a horizontal device triple-star unit, fig. 3 is a schematic diagram of a test state of a horizontal device four-star unit, fig. 4 is a schematic diagram of a test state of a vertical device double-star unit, fig. 5 is a schematic diagram of a test state of a vertical device triple-star unit, fig. 6 is a schematic diagram of a test state of a vertical device four-star unit, fig. 0 is a space environment simulation device, 1 is a satellite participating in both a thermal balance test and a thermal vacuum test (i.e., a thermal balance star), 2, 3 and 4 are satellites participating only in the thermal vacuum test (i.e., a thermal vacuum star), fig. 1 to fig. 3 are diagrams for selecting a horizontal test device to perform a test, a left side diagram represents a minimum test. Fig. 4 to 6 are diagrams showing a combination of minimum test units in a test state, in which a vertical test apparatus is selected for a test, and the left side diagram shows the minimum test unit to be tested.
Further, in the vacuum thermal test method for a satellite constellation system, the vacuum thermal test method for a satellite constellation system further includes: the outer surface of the heat balance star 1 is provided with a main radiating surface and an auxiliary radiating surface; when the plurality of satellites are placed into the space environment simulation equipment 0, the main radiating surface is opposite to the inner surface of the space environment simulation equipment 0, and the auxiliary radiating surface is opposite to the inner surface of the space environment simulation equipment 0 or the non-radiating surfaces of the thermal vacuum stars 2, 3 and 4, so that the thermal balance star 1 is shielded by the thermal vacuum stars 2, 3 and 4 to be minimally influenced. In fig. 1 to 6, 1 represents a heat balance star in the test, and 2, 3 and 4 represent heat vacuum stars participating in the test. The thick solid line of the star represents the primary radiating surface, the thick dotted line of the star represents the secondary radiating surface, and the thin solid line of the star represents the non-radiating area. In the position arrangement process of the heat balance star and the thermal vacuum star, the position space of the heat balance star is ensured as much as possible, the auxiliary main radiating surface of the heat balance star is enabled to be opposite to the inner surface of the test equipment and is not influenced by other stars, when the main radiating surface and the auxiliary radiating surface can not be simultaneously ensured to be opposite to the inner surface of the equipment, the main radiating surface is preferentially ensured, the auxiliary radiating surface can face to other star non-radiating areas, the heat balance star is enabled to be minimally influenced by shielding, and the shielded area is subjected to external heat flow correction through simulation analysis.
The test units of the horizontal test equipment can be arranged according to the figures 1 to 3, and the test units of the vertical test equipment can be arranged according to the figures 4 to 6, but not limited to the orientation relationship of the test units in the figures, and also includes other star body placing position relationships which are deduced according to the orientation relationship of the figures 1 to 6. In the implementation process, the heat balance star should be preferentially ensured to have sufficient position space and orientation, and a low-temperature heat sink can be additionally arranged around the heat balance star when necessary.
And starting the multi-satellite parallel thermal test, completing self-checking of the test equipment, closing a gate of the test equipment after the satellite is powered on for testing, and starting the multi-satellite parallel vacuum thermal test. The test process is divided into four stages, namely an initial test stage, a thermal balance test stage, a thermal vacuum test stage and a vacuum aging test stage. But are not limited to, the above four phases, including a recombination of the above four phases;
as shown in fig. 7, in the vacuum thermal test method for a satellite constellation system, the thermal balance test 11 includes, but is not limited to, a thermal balance test low temperature condition 105 and a thermal balance test high temperature condition 104, where the thermal balance test low temperature condition 105 includes a steady state low temperature condition, a quasi-steady state low temperature condition, a periodic transient state low temperature condition, and a transient state low temperature condition; the thermal balance test high temperature conditions 104 include steady state high temperature conditions, quasi-steady state high temperature conditions, periodic transient state high temperature conditions, and transient state high temperature conditions. The external heat flow of the high-temperature working condition 104 of the heat balance test is set according to the final service life of the heat balance star 1, the vicinity of the winter solstice and the maximum heat flow orbit parameter simulation result, and is corrected according to the shielding condition of each satellite, so that the heat balance star 1 works according to the maximum heat consumption mode, and the high-temperature working condition temperature result of the heat balance test is obtained; the external heat flow of the low-temperature working condition 105 of the heat balance test is set according to the simulation result of the minimum heat flow orbit parameter near the summer solstice in the initial service life of the heat balance satellite 1, and is corrected according to the shielding condition of each satellite, so that the heat balance satellite 1 works according to the minimum heat consumption mode, and the temperature result of the low-temperature working condition of the heat balance test is obtained. The rest satellites (thermal vacuum stars) which do not participate in the thermal balance test during the thermal balance test are set according to the same working mode as the thermal balance star, the satellite power-on test time is increased by maintaining the temperature of the star body, and external heat flow is not applied.
In addition, in the vacuum thermal test method for the satellite constellation system, the thermal vacuum test 12 performs a plurality of high and low temperature cycles according to the temperature maintaining range, for example, in fig. 7, 106 indicates the 1 st cycle of the thermal vacuum test; 107 denotes cycle 2 of the thermal vacuum test; 108 denotes the thermal vacuum test cycle 3; 109 represents cycle 4 of the thermal vacuum test; possibly further cycles (110, …) may follow; during the high and low temperature cycles of the thermal vacuum test 12: the heat balance star 1 and the hot vacuum stars 2, 3 and 4 are subjected to heating operation by arranging an auxiliary heating heater and an external heat flow simulation heat source, and each satellite is set to be in the same power-on state and heat control state in the heating and cooling process; the highest temperature in the temperature keeping range is determined according to the high-temperature working condition temperature result of the thermal balance test, and the lowest temperature in the temperature keeping range is determined according to the low-temperature working condition temperature result of the thermal balance test; cooling the heat balance star 1 and the hot vacuum stars 2, 3 and 4 by turning off the auxiliary heating heater and the external heat flow simulation heat source; and collecting, comparing and analyzing the test state and the remote measurement parameters of each satellite, judging whether the satellite state and the performance of each satellite are consistent, finding and positioning abnormal data and parameters, and processing potential faults.
The thermal vacuum test stage can be divided into a plurality of high-low temperature cycle processes according to requirements, wherein a high-temperature holding range is determined according to a high-temperature working condition test result of a thermal balance test of the thermal balance star, a low-temperature holding range is determined according to a low-temperature working condition test result of the thermal balance test of the thermal balance star, rapid heating can be carried out in a mode of arranging an auxiliary heater and an external heat flow simulation heat source in the temperature cycle heating process, the cooling process is realized by closing a corresponding temperature control area heat source heater, a platform and a load equipment main backup on-duty machine state can be set according to requirements in the cycle starting stage every time, and then the test and the full coverage of the main stand-. In the thermal vacuum test stage, the test state and the remote measurement parameters of each satellite need to be collected, compared and analyzed, whether the states and the performances of the satellites to be tested are consistent or not is confirmed, all the satellites to be tested are set to be in the same power-on state and the same thermal control state in the temperature rising and reducing process, abnormal data and parameters in the test process are located, and a potential fault mode is found and processed in time.
Specifically, in the vacuum thermal test method for the satellite constellation system, in the high-temperature cycle process of the thermal vacuum test 12: in the high-temperature maintaining stage of the thermal vacuum test 12, the temperature of more than 80 percent of the temperature measuring point is 10-15 ℃ higher than the temperature result of the high-temperature working condition of the thermal balance test and is lower than the highest test temperature of the acceptance grade; in the low-temperature maintaining stage of the thermal vacuum test 12, the temperature of more than 20% of the temperature measuring points is 5-15 ℃ lower than the result of the low-temperature working condition temperature of the thermal balance test and is higher than the minimum test temperature of the acceptance level, the maximum test temperature of the acceptance level is determined according to design indexes and specification requirements, and the high-temperature working condition maintaining temperature of the thermal vacuum test is not higher than the maximum test temperature of the acceptance level (the maximum temperature allowed under the condition of ensuring the safe working of equipment) or is set as the lower limit of the design indexes; and the acceptance level minimum test temperature is the minimum test temperature allowed under the condition of ensuring the safe working of equipment, which is determined according to the design index specification requirement that the low-temperature working condition keeping temperature of the thermal vacuum test is not lower than the acceptance level minimum test temperature. (the highest/low test temperature of the acceptance level refers to the highest/low temperature generally allowed by normal operation of the equipment, damage to the equipment can be caused when the temperature is beyond the range, and the temperature is not allowed to be beyond the range in the test process.)
Further, in the vacuum thermal test method for a satellite constellation system, the vacuum thermal test method for a satellite constellation system further includes: before the thermal balance test 11 is carried out, carrying out an initial test 10 on the satellite constellation system, wherein the initial test 10 comprises a low-pressure test working condition 101, a thermal control software test working condition 102 and a whole satellite high-temperature air outlet working condition 103; but the method is not limited to the setting of three working conditions, and also comprises the combination of the above test working conditions. After the thermal vacuum test 12 is completed, a vacuum burn-in test 13 is performed on the satellite constellation system. The vacuum aging test stage determines the star temperature holding range according to the general technical requirements to carry out a power-on test for a period of time.
Under the low-pressure test condition 101, vacuumizing the space environment simulation equipment 0, and keeping minimum system equipment of each satellite in a power-on state, so that the vacuum degree in the space environment simulation equipment 0 is reduced from 1000Pa to 0.1Pa, monitoring the power-on state and remote measurement parameters of each satellite, wherein the minimum system equipment is power-on equipment during satellite transmission, and checking the low-pressure resistance of the power-on equipment on the satellite during the transmission process; the method comprises the following steps of carrying out a thermal control software module test working condition (102) in a stage of establishing a low-temperature environment (most on-board equipment is not powered) in a thermal test, wherein the stage comprises a heater open-loop test, a closed-loop test (a switch control logic test and a proportional control logic test) and the capability of a thermal control system for maintaining the temperature of the whole satellite in the stage; under the thermal control software test condition 102, determining each satellite temperature control interval according to a thermal control software module temperature control threshold and the lowest temperature allowed by the auxiliary heating heater; testing the ability of the thermal control software module to maintain the temperature of the whole satellite; performing a switch control logic test and a proportional control logic test of the thermal control software module; carrying out a whole satellite safety mode and a minimum function test of a thermal control software module; and carrying out open-loop test and closed-loop test on the auxiliary heating heater. Under the whole satellite high-temperature air outlet working condition 103, the auxiliary temperature-rising heater, the external heat flow simulation heat source and the satellite body active heat control heater are used for rising the temperature of the satellite constellation system, so that the temperature of the satellite constellation system is 5-10 ℃ higher than the maximum heat flow orbit parameter simulation result and is kept for more than 24 hours, and the vacuum air release treatment is carried out on the structural plate, the satellite single machine, the cable and the satellite auxiliary material of each satellite. Vacuum degassing refers to removing organic macromolecular gas or other polluted gas components in a structural plate or single-machine equipment in a heating and vacuumizing mode.
In addition, in the vacuum thermal test method of the satellite constellation system, after the thermal vacuum test is finished, a vacuum aging test can be additionally arranged according to the requirement of model development progress, the temperature of the whole satellite is maintained at a certain level by using an auxiliary heater, the normal-temperature power-on time of the satellite is accelerated in an equivalent manner, and the subsequent normal-temperature aging time is shortened; the vacuum aging test 13 includes: in the space environment simulation equipment 0, the temperature of each satellite is adjusted through the auxiliary heating-up heater, and meanwhile, each satellite is powered up according to an on-orbit set working mode, so that the electrical performance of each satellite is tested, and aging-simulating accelerated test is realized. The vacuum aging test is determined whether to be carried out or not according to the development requirement of the satellite, if the vacuum aging test is carried out, the temperature holding interval of the whole satellite and the state of power-on working equipment in the vacuum aging stage are firstly determined, generally, the vacuum aging is considered to play a role in accelerating the test time, the acceleration factor is related to the temperature level (generally, 1.3-1.5), but the temperature of the vacuum aging test is not selected to be too high so as to avoid influencing the safety of the whole satellite.
In addition, in the vacuum thermal test method of the satellite constellation system, the satellite constellation system comprises a satellite using a star sensor to fix the attitude, a star map simulator is installed on the satellite using the star sensor to fix the attitude, closed-loop attitude control software testing is carried out on the star map simulator, and active temperature control and temperature monitoring are carried out on the star map simulator. For the satellite using the star sensor attitude determination scheme, a star model (star map simulator) can be installed for closed-loop attitude control software testing during a thermal test, and active temperature control needs to be carried out on the star model (star map simulator) in test equipment at the moment. A vacuum gauge and an ionization gauge can be arranged in the thermal balance star body to measure the vacuum degree in the whole process, so that the safety of the startup and use processes of high-power equipment in the star is ensured.
A movable radiation screen is arranged on the main radiating surface of the heat balance star 1 and the heat vacuum stars 2, 3 and 4; under the condition that test conditions allow, movable radiation screens are additionally arranged in the areas of the heat balance star and the main radiating surface of the heat vacuum star, so that the accuracy of the heat balance test result and the cooling rate of the heat vacuum star are improved; a resistance silicon tube and an ionization silicon tube are arranged at the high-power equipment of the satellite constellation system; in the thermal test process, a vacuum gauge tube (comprising a resistance silicon tube and an ionization silicon tube) is additionally arranged near the star body high-power equipment to realize the measurement of the vacuum degree in the whole test process; a heat sink device is arranged at the heat balance star 1.
In the vacuum thermal test method for the satellite constellation system, the thermal balance test 11 is carried out on the thermal balance satellite 1, the external heat flow applied to the thermal balance satellite 1 is corrected in real time, after the thermal balance test 11 of the thermal balance satellite 1 is completed, the temperature holding range of the thermal vacuum test 12 of the satellite constellation system is determined according to the result of the thermal balance test 11, the thermal vacuum test 12 of the satellite constellation system is carried out according to the temperature holding range, the batch satellite development and test period can be obviously shortened, and the test cost is reduced. The purpose of a thermal balance test 11 can be realized through one-time vacuum thermal test operation, the assessment requirements of a thermal vacuum test 12 can be met, a plurality of satellites are subjected to the vacuum thermal test in parallel, the test time of the satellites in batch production in the thermal vacuum environment can be quickly accumulated, and the method is very suitable for large-scale development of the satellites in batch production; the device has the advantages that the test period is short, the test cost is low, only one time of entering and exiting of the space environment simulation equipment is needed, the implementation requirements on preparation work before the test, test equipment operation and thermal control process are low, the repeated turning-over, hoisting and transferring operations of the participating satellites are avoided, the damage probability of the satellites is reduced, the thermal control materials and test consumables required by the test are saved, and the requirements on the type and indexes of the test equipment are simple.
The heat balance star carries out heat flow simulation outside a heat dissipation area and a non-heat dissipation area according to relevant standard requirements, the thermal control implementation state is consistent with the on-orbit state, and the accuracy of the thermal balance test result is improved; the hot vacuum star does not carry out external heat flow simulation, and the thermal control implementation state is simplified compared with the on-orbit state, thereby reducing the complexity of process operation, the implementation period and the test cost. The thermal balance star multilayer assembly carries out external heat flow correction through simulation analysis and test process temperature measurement results, accuracy is gradually improved along with increasing maturity of spacecraft thermal control analysis software, a thermal physical model is corrected in a mode of combining the test with the simulation analysis, and the corrected thermal physical model is applied to predict the on-orbit temperature range and the change rule of each instrument and equipment on the star. The purpose of the thermal balance test 11 can be realized by one-time operation of the space environment simulation equipment, the thermal balance test has the assessment requirement of the thermal vacuum test 12, and the requirement of the satellite development task in batch production is met.
The invention relates to a method for verifying a multi-satellite parallel ground vacuum thermal test of a batch production satellite (spacecraft). The satellites should have the same or similar thermal control states, and the invention can be widely applied to the field of commercial aerospace in which the thermal control states of the satellites are more consistent by adopting a one-arrow-multi-satellite emission mode, wherein the vacuum thermal test can be carried out on the satellites in batch production such as low-earth-orbit communication satellite constellations, remote sensing satellite constellations, navigation satellite constellations and internet satellite constellations simultaneously or in batches.
In summary, the above embodiments have described in detail different configurations of the vacuum thermal test method for satellite constellation systems, and it is understood that the present invention includes, but is not limited to, the configurations listed in the above embodiments, and any modifications made on the configurations provided in the above embodiments are within the scope of the present invention. One skilled in the art can take the contents of the above embodiments to take a counter-measure.
The above description is only for the purpose of describing the preferred embodiments of the present invention, and is not intended to limit the scope of the present invention, and any variations and modifications made by those skilled in the art based on the above disclosure are within the scope of the appended claims.
Claims (13)
1. A vacuum thermal test method for producing satellite constellation systems in batch is disclosed, wherein the satellite constellation systems comprise a plurality of satellites with the same or similar thermal control states, and the satellite flight orbit parameters, configuration layout, thermal power consumption, working modes and thermal control schemes of the satellites with the same or similar thermal control states are the same or similar; the vacuum thermal test method for the satellite constellation system is characterized by comprising the following steps:
simultaneously placing the satellites with the same or similar thermal control states into space environment simulation equipment, selecting one satellite as a thermal balance satellite and the other satellites as thermal vacuum satellites, wherein the thermal control state of the thermal balance satellite is worse than that of the thermal vacuum satellites;
carrying out a heat balance test on the heat balance star;
in the process of the heat balance test, equipment on the heat balance star is powered up according to an on-orbit set working mode, and external heat flows are applied to the outer surfaces of the heat balance star according to external heat flow design parameters;
in the thermal balance test process, simulating the external heat flow influence brought to the thermal balance satellite by the mutual shielding condition of each satellite, and correcting the external heat flow applied to the thermal balance satellite in real time according to the simulation result;
in the process of the thermal balance test, the equipment on the thermal vacuum star is powered up according to an on-orbit set working mode;
after the thermal balance test of the thermal balance satellite is finished, determining the temperature holding range of the thermal vacuum test of the satellite constellation system according to the thermal balance test result, and performing the thermal vacuum test of the satellite constellation system according to the temperature holding range;
the outer surface of the heat balance star is provided with a main radiating surface and an auxiliary radiating surface;
when the satellites with the same or similar thermal control states are placed in the space environment simulation equipment, the main radiating surface faces the inner surface of the space environment simulation equipment, and the auxiliary radiating surface faces the inner surface of the space environment simulation equipment or the non-radiating surface of the thermal vacuum star, so that the thermal balance star is shielded by the thermal vacuum star to the minimum.
2. The satellite constellation system vacuum thermal test method of claim 1, wherein the satellite constellation system vacuum thermal test method further comprises:
selecting the space environment simulation equipment according to the size and the number of each satellite in the satellite constellation system, wherein the space environment simulation equipment is a vertical cylinder or a horizontal cylinder;
the direction of each satellite is placed according to the minimum test unit, and an electric test cable and a temperature measurement and control cable are connected, wherein the electric test cable is used for electrifying equipment on the satellite, and the temperature measurement and control cable is used for applying external heat flow to the outer surface of the heat balance satellite;
and designing a thermal test tool according to the position and the placing direction of each satellite so that the structural strength and the rigidity of the thermal test tool meet the requirements of the vacuum thermal test, wherein the thermal test tool comprises a guide rail, a support rod and a lifting appliance, the support rod and the lifting appliance are in direct contact with each satellite for temperature compensation, and the guide rail, the support rod and the lifting appliance are subjected to active temperature control in the vacuum thermal test process.
3. The vacuum thermal test method for satellite constellation systems as in claim 1, wherein the thermal equilibrium test includes but is not limited to a thermal equilibrium test low temperature condition and a thermal equilibrium test high temperature condition,
the thermal balance test low-temperature working condition comprises a steady-state low-temperature working condition, a quasi-steady-state low-temperature working condition, a periodic transient low-temperature working condition and a transient low-temperature working condition;
the high-temperature working condition of the thermal balance test comprises a steady-state high-temperature working condition, a quasi-steady-state high-temperature working condition, a periodic transient high-temperature working condition and a transient high-temperature working condition.
4. The satellite constellation system vacuum thermal test method of claim 3,
the external heat flow of the high-temperature working condition of the heat balance test is set according to the final service life of the heat balance star, the vicinity of the winter solstice and the maximum heat flow orbit parameter simulation result, and is corrected according to the shielding condition of each satellite, so that the heat balance star works according to the maximum heat consumption mode, and the high-temperature working condition temperature result of the heat balance test is obtained;
the external heat flow of the low-temperature working condition of the heat balance test is set according to the simulation result of the minimum heat flow orbit parameter near summer solstice in the initial service life of the heat balance satellite, and is corrected according to the shielding condition of each satellite, so that the heat balance satellite works in the minimum heat loss mode, and the low-temperature working condition temperature result of the heat balance test is obtained.
5. The vacuum thermal test method for satellite constellation systems as in claim 4, wherein the thermal vacuum test is performed for a plurality of high and low temperature cycles according to the temperature maintaining range, and during the high and low temperature cycles of the thermal vacuum test:
the heat balance star and the heat vacuum star are subjected to heating operation by arranging an auxiliary heating heater and an external heat flow simulation heat source, and each satellite is set to be in the same power-on state and the same thermal control state in the heating and cooling process;
the highest temperature in the temperature keeping range is determined according to the high-temperature working condition temperature result of the thermal balance test, and the lowest temperature in the temperature keeping range is determined according to the low-temperature working condition temperature result of the thermal balance test;
cooling the heat balance star and the hot vacuum star by turning off the auxiliary heating heater and the external heat flow simulation heat source;
and collecting, comparing and analyzing the test state and the remote measurement parameters of each satellite, judging whether the satellite state and the performance of each satellite are consistent, finding and positioning abnormal data and parameters, and processing potential faults.
6. The satellite constellation system vacuum thermal test method of claim 5, wherein during high and low temperature cycles of the thermal vacuum test:
in the high-temperature maintaining stage of the thermal vacuum test, the temperature of more than 80% of temperature measuring points is 10-15 ℃ higher than the temperature result of the high-temperature working condition of the thermal balance test and is lower than the highest test temperature of the acceptance level;
in the low-temperature maintaining stage of the thermal vacuum test, the temperature of more than 20% of the temperature measuring points is 5-15 ℃ lower than the temperature result of the low-temperature working condition of the thermal balance test and is higher than the lowest test temperature of the acceptance grade.
7. The satellite constellation system vacuum thermal test method of claim 5, wherein the satellite constellation system vacuum thermal test method further comprises:
before the thermal balance test is carried out, carrying out initial test on the satellite constellation system, wherein the initial test comprises a low-pressure test working condition, a thermal control software test working condition and a whole satellite high-temperature air outlet working condition;
and after the thermal vacuum test is finished, performing a vacuum aging test on the satellite constellation system.
8. The satellite constellation system vacuum thermal test method of claim 7,
and under the low-pressure test working condition, vacuumizing the space environment simulation equipment, keeping the minimum system equipment of each satellite in a power-on state, so that the vacuum degree in the space environment simulation equipment is reduced to 0.1Pa from 1000Pa, monitoring the power-on state and the remote measurement parameters of each satellite, wherein the minimum system equipment is the power-on equipment during satellite transmission.
9. The satellite constellation system vacuum thermal test method of claim 7, wherein under the thermal control software test condition, each satellite temperature control interval is determined according to a thermal control software module temperature control threshold and a lowest temperature allowed by the auxiliary warming heater;
testing the ability of the thermal control software module to maintain the temperature of the whole satellite;
performing a switch control logic test and a proportional control logic test of the thermal control software module;
carrying out a whole satellite safety mode and a minimum function test of a thermal control software module;
and carrying out open-loop test and closed-loop test on the auxiliary heating heater.
10. The satellite constellation system vacuum thermal test method of claim 7, wherein under a whole satellite high-temperature air outlet working condition, the auxiliary temperature-rising heater, the external heat flow simulation heat source and the satellite active thermal control heater are used for rising the temperature of the satellite constellation system, so that the temperature of the satellite constellation system is 5-10 ℃ higher than the maximum heat flow orbit parameter simulation result and is kept for more than 24 hours, and the structure plate, the satellite single-machine, the cable and the satellite auxiliary material of each satellite are deflated.
11. The satellite constellation system vacuum thermal test method of claim 7, wherein the vacuum burn-in test comprises: in the space environment simulation equipment, the temperature of each satellite is adjusted through the auxiliary heating-up heater, and meanwhile, each satellite is powered up according to an on-orbit set working mode, so that the electrical performance of each satellite is tested, and aging-simulating accelerated test is realized.
12. The method according to claim 1, wherein the satellite constellation system comprises a satellite using a star sensor for attitude determination, and a star map simulator is installed on the satellite using the star sensor for attitude determination, and is subjected to closed-loop attitude control software testing, and is subjected to active temperature control and temperature monitoring.
13. The vacuum thermal test method for the satellite constellation system as recited in claim 1, wherein a movable radiation screen is arranged at the main radiating surface of the heat balance star and the heat vacuum star;
a resistance silicon tube and an ionization silicon tube are arranged at the high-power equipment of the satellite constellation system;
and arranging a heat sink device at the heat balance star.
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