CN114420378A - 星上低频电缆网防污染加工方法 - Google Patents
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Abstract
本发明公开了星上低频电缆网防污染加工方法,具体步骤如下:步骤一、下料;步骤二、绑线:采用22DPTH绑扎线;步骤三、焊接;步骤四、自检;步骤五、互检:焊点检验合格后焊点处涂B706黑色标志漆;步骤六、装配;步骤七、交检:检验合格后壳体螺钉处涂B706黑色标志漆;步骤八、真空除气实验:试验条件要求36h内石英天平的平均频率变化速率小于1HZ/h,石英天平灵敏度不低于1*10E‑9g.cm^2/Hz;制备得到TML<1%,CVCM<0.1%的星上低频电缆网。低频电缆网加工完成后满足搭载光学仪器的卫星防污染指标要求,保证星上不存在有机污染源。
Description
技术领域
本发明涉及电缆网加工方法,具体涉及一种星上低频电缆网防污染加工方法,应用于航天系统搭载光学仪器中。
背景技术
光学卫星上搭载的光学仪器对颗粒、有机分子等污染物极为敏感,为了避免仪器受污染影响仪器性能。光学卫星要求非金属部件及材料(含热控膜、电缆线、喷漆、镀膜、胶、真空油脂等)释气总质量损失TML、可凝挥发物CVCM尽可能低,至少满足TML小于1%,CVCM小于0.1%;卫星平台及其他载荷的非金属部件应进行高温真空烘烤,保证除气、排污充分,避免产生大量排气。
去除星体内部的污染源是确保星上光学遥感仪器免受污染的重要技术措施之一。目前,低频电缆网加工工艺没有考虑防污染情况,在加工过程中误选用了一些放气率高、挥发性大、易污染光学遥感仪器的非金属材料,在星上形成有机物污染源,卫星入轨后在宇宙空间高真空环境条件下释放,污染物质存在于光学镜头表面,会减少信号通量,降低光学部件性能,导致任务失败。
低频电缆网是卫星的重要组成部分之一,保证卫星各单机之间能源及信息通路的安全可靠并实现卫星的统一接地。低频电缆网主要由电连接器、低频电缆线、辅料组成,目前的加工工艺涉及的元器件和原材料清单详见表1。
电缆网制作工艺一般顺序为:下料、绑线、焊接、自检、互检、装配、交检。具体流程如图1所示。在自检、互检和交检阶段,红色醇酸磁漆作为标志漆点涂在焊点和螺钉处用来标记焊点检验合格和电缆网检验合格。在绑线阶段,热收缩膜和热收缩套管每隔200mm~300mm分段热缩,用于线束成型制作。但是,红色醇酸磁漆、热收缩膜和热收缩套管在防污染要求下均存在缺陷,具体分析如下。
C04-2红色醇酸磁漆由醇酸树脂、颜料、有机溶剂、助剂等组成。具有漆膜光润丰满,色泽清新,附着力好,遮盖力强,机械性能高的特点。红漆的主要特性参数:不挥发物占比为60%,即挥发物占比40%,贮存稳定性为50±2℃。因此在90℃真空高温情况下,其有机溶剂等极易挥发,挥发出来有机分子以直线运动的方式在真空中运动,直至与其他物质发生碰撞,附着在物体表面,引起低频电缆网污染问题,进而污染光学仪器。
吉林吉福热收缩膜主要成分为辐射交联聚乙烯高分子基材和热熔胶层复合而成,具有机械强度高、耐环境开裂应力大、耐化学介质腐蚀和粘接力强的特点;长春热缩套管是一种特制的聚烯烃材质热缩套管。外层采用优质柔软的交联聚烯烃材料及内层热熔胶复合加工而成的,外层材料有绝缘防蚀、耐磨等特点,内层有低熔点、防水密封和高粘接性。相较于低频电缆网其他组成部分,红漆挥发物容易附着在上述两种材料表面,形成二次污染源。
表1
发明内容
本发明的目的是为了保证星上光学遥感仪器免受有机分子污染,在低频电缆网设计、工艺、加工过程严格控制污染源。从而提供星上低频电缆网防污染加工方法及其制备得到的星上低频电缆网,解决上述至少一个问题。
本发明的技术方案是:星上低频电缆网防污染加工方法,具体步骤如下:
步骤一、下料;
步骤二、绑线:采用22DPTH绑扎线;
步骤三、焊接;
步骤四、自检:
步骤五、互检:焊点检验合格后焊点处涂B706黑色标志漆;
步骤六、装配;
步骤七、交检:检验合格后螺钉处涂B706黑色标志漆;
步骤八、真空除气实验:试验条件要求36h内石英天平的平均频率变化速率小于1HZ/h,石英天平灵敏度不低于1*10E-9g.cm^2/Hz;
制备得到TML<1%,CVCM<0.1%的星上低频电缆网。
进一步的,步骤八中所述真空除气实验,试验条件还包括:
真空度:优于1.3×10-3Pa;
除气温度:星体电缆网表面最高温度外扩10~15度;
升降温速率:平均不高于1℃/min;
除气时间:不少于120h。
进一步的,所述除气温度为70℃~75℃。
进一步的,步骤二中所述绑线,线束按每200mm~300mm绑扎一处,绑扎宽度5mm~10mm,绑扎宽度与线束直径相当。
本发明还提供根据所述的星上低频电缆网防污染加工方法制备得到的星上低频电缆网, TML<1%,CVCM<0.1%。
本发明的有益效果是:为了保证星上光学遥感仪器免受有机分子污染,在低频电缆网设计、工艺、加工过程严格控制污染源。(1)在设计阶段,选择放气率低、挥发性小且满足指标要求(TML小于1%,CVCM小于0.1%)的元器件和原材料,选择B706黑色标志漆替代红醇酸磁漆,选择22DPTH绑扎线替代热收缩膜和热缩套管;(2)绑线工艺由吸附力强的热缩套管更改为22DPTH绑扎线(满足TML<1%,CVCM<0.1%指标要求),线束按每200mm~ 300mm绑扎一处,绑扎宽度5mm~10mm,绑扎宽度与线束直径相当;(3)检验工艺采用航空航天用黑漆B706替代挥发性强红色醇酸磁漆;(4)在电缆组件加工完成后,进行真空除气试验,除气要求36h内石英天平的平均频率变化速率小于1HZ/h,石英天平灵敏度不低于1*10E-9g.cm^2/Hz。经过上述措施,低频电缆网加工完成后满足搭载光学仪器的卫星防污染指标要求,保证星上不存在有机污染源。
附图说明
图1为现有技术中电缆网工艺流程图;
图2为本申请实施例中星上低频电缆网防污染加工方法流程图。
具体实施方式
下面结合附图对本发明做进一步的说明。
为了避免星上光学遥感仪器免受有机分子污染,影响仪器性能,甚至导致整个卫星研制任务的失败。在低频电缆网设计、工艺、加工过程严格控制污染源。本发明针对传统加工工艺对防污染要求存在的缺陷对检验工艺和绑线工艺进行改进,选择B706黑色标志漆替代红醇酸磁漆,选择22DPTH绑扎线替代热收缩膜和热缩套管,最后对整束电缆进行真空除气试验,满足防污染指标求(TML小于1%,CVCM小于0.1%)要求。
在工艺设计阶段,选择放气率低、挥发性小的元器件和原材料,选择B706黑色标志漆替代红醇酸磁漆,选择22DPTH绑扎线替代热收缩膜和热缩套管。
其中绑线工艺由吸附力强的热缩套管更改为22DPTH绑扎线(满足TML<1%, CVCM<0.1%指标要求);22DPTH绑扎线具有在轨飞行经验,并且满足防污染指标要求,具体物理特性见表2。线束按每200mm~300mm绑扎一处,绑扎宽度5mm~10mm,绑扎宽度与线束直径相当。
表2
检验工艺采用航空航天用黑漆B706替代挥发性强红色醇酸磁漆。焊点检验合格后焊点处涂B706黑色标志漆。电缆验收合格后螺钉处涂B706黑色标志漆。B706黑色标志漆TML<1.0%,CVCM<0.02%,满足TML<1.0%,CVCM<0.1%的防污染指标要求,具体技术指标见表3。
表3
在电缆组件加工完成后,进行真空除气试验,保证最后交付的低频电缆网不存在有机污染源。真空除气试验条件为:
1.真空度:优于1.3×10-3Pa;
2.除气温度:70℃~75℃;(具体温度范围取决于星体电缆网表面最高温度外扩10~15 度)
3.升降温速率:不高于1℃/min(平均);
4.除气时间:不少于120h,参考标准:36h内石英天平的平均频率变化速率小于1HZ/h,石英天平灵敏度不低于1*10E-9g.cm^2/Hz。
制备得到TML<1%,CVCM<0.1%的星上低频电缆网。
具体如图2所示,一种星上低频电缆网防污染加工方法,具体步骤如下:
步骤一、下料;按照电缆加工图要求选择导线的型号规格、长度、数量,下料时按照图纸尺寸加上工艺余量下料,其它材料在装配过程中按需要下料。
步骤二、绑线:采用22DPTH绑扎,线线束按每200mm~300mm绑扎一处,绑扎宽度5mm~10mm,绑扎宽度与线束直径相当。
步骤三、焊接;焊接过程主要包括搪锡、焊接、焊点清洗、焊点检验、多媒体记录和函电保护。
步骤四、自检:所有焊点在焊接完成后使用热缩套管热缩保护,以释放焊接处应力,同时提高线路间电绝缘性能
步骤五、互检:焊接完成后由检验人员对焊接效果进行专检,保证焊接质量,焊点检验合格后焊点处涂B706黑色标志漆;
步骤六、装配;主要包括尾部线束整理、线束固定、壳体(尾罩)安装、灌胶、尾部线束紧固等装配过程。
步骤七、交检:检验人员对加工完成后的电缆网外观、电性能进行检验。检验合格后壳体螺钉处涂B706黑色标志漆;
步骤八、真空除气实验,试验条件如前所述。
最终得到的星上低频电缆网TML为0.211%,CVCM为0.034%,满足TML<1%, CVCM<0.1%的指标要求。
以上所述仅是本发明的优选实施方式,应当指出,对于本技术领域的普通技术人员来说,在不脱离本发明原理的前提下,还可以做出若干改进和润饰,这些改进和润饰也应视为本发明的保护范围。
Claims (4)
1.星上低频电缆网防污染加工方法,其特征在于:具体步骤如下:
步骤一、下料;
步骤二、绑线:采用22DPTH绑扎线;
步骤三、焊接;
步骤四、自检:
步骤五、互检:焊点检验合格后焊点处涂B706黑色标志漆;
步骤六、装配;
步骤七、交检:检验合格后螺钉处涂B706黑色标志漆;
步骤八、真空除气实验:试验条件要求36h内石英天平的平均频率变化速率小于1HZ/h,石英天平灵敏度不低于1*10E-9g.cm^2/Hz;
制备得到TML<1%,CVCM<0.1%的星上低频电缆网。
2.根据权利要求1所述的星上低频电缆网防污染加工方法,其特征在于:步骤八中所述真空除气实验,试验条件还包括:
真空度:优于1.3×10-3Pa;
除气温度:星体电缆网表面最高温度外扩10~15度;
升降温速率:平均不高于1℃/min;
除气时间:不少于120h。
3.根据权利要求2所述的星上低频电缆网防污染加工方法,其特征在于:所述除气温度为70℃~75℃。
4.根据权利要求1所述的星上低频电缆网防污染加工方法,其特征在于:步骤二中所述绑线,线束按每200mm~300mm绑扎一处,绑扎宽度5mm~10mm,绑扎宽度与线束直径相当。
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