RU2269457C2 - Method of manufacture of payload module for spacecraft - Google Patents

Abstract

FIELD: space engineering; manufacture of communication satellites.

SUBSTANCE: proposed method includes testing the payload for serviceability. To this end, technological compensating device is connected to module before and after tests. Gas cavity of this device is preliminarily filled with gas under pressure and definite amount of heat-transfer agent is drained from liquid cavity. Pressure and amount of liquid being drained are selected in definite ratio.

EFFECT: reduction of rejects, hidden rejects inclusive.

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Description

The invention relates to space technology, in particular to connected satellites, and was created by the authors in the order of performance of a job.

Currently, communication satellites are initially made of two separate parts: a payload module (MPN), where repeater devices are installed on thermostatic panels with a liquid path, and a service system module (MSS), where, in particular, a temperature control system (CTP) is installed with liquid circuit, which provides the required thermal regime of MPN under conditions of orbital functioning.

During the manufacturing process, each module undergoes autonomous performance tests, in particular, when testing the MPN, the hydraulic connectors of the temperature control system simulator (ISTR) are attached to its hydraulic connectors of the liquid path (see patents of the Russian Federation No. 2144893, 2200689, 2139228), previously undocked from hydraulic connector MPN technological volume compensator (TCU - technological compensation device).

The experience in the manufacture of such MPNs shows that as a result of operator errors in the MPN liquid path, it is possible to create unacceptably high pressure, which can lead to the destruction of the MPN before the launch of the spacecraft or to the hidden defect of the MPN liquid path (to premature failure of the MPN liquid path and the connected satellite in conditions of orbital functioning due to the presence of the liquid path of the MPN at unacceptably high pressures during the manufacture of MPN).

An analysis of the sources of information on patent and scientific and technical literature showed that the closest in technical essence to the proposed technical solution is the manufacturing method described in patent materials No. 2200689.

Currently implemented in the production method of manufacturing MPN based on patent No. 2200689 includes the following basic operations (see figure 2):

- starting position: they attach to the hydraulic connector 1.2 of the MPN 1 liquid path filled with liquid coolant 1 hydraulic connector 2.1 TKU 2, the liquid cavity 2.2 of which is charged with the same coolant, and the gas cavity 2.3, separated from the liquid cavity by bellows 2.4, is charged with gas with atmospheric pressure ≈1 kgf / cm ² (communicated with the atmosphere);

- undock the hydraulic connector 2.1 TKU 2 from the hydraulic connector 1.2 MPN 1 and then dock the hydraulic connectors 3.1, 3.2 ISTR 3 to the hydraulic connectors 1.1, 1.2 MPN 1; ISTR 3 includes ENA 3.3, refrigerator 3.5, volume compensator 3.4. a gas cavity 3.4.1 which is filled with gas with a certain increased (higher than atmospheric) pressure (the gas cavity of the ISTR volume compensator is filled with a high gas pressure to maintain an increased pressure of the coolant at the inlet of the ENA to ensure its cavitation-free (stable) operation and to exclude vaporization in the liquid paths when tests of MPN at elevated temperatures of the coolant at its inlet and outlet (up to 55 ° C): for example, the gas cavity of the volume compensator of the existing ISTR to meet this Slovenia is charged with gas at a pressure of 1.59 kgf / cm ² at a filling temperature of 20 ° C);

- include ISTR 3;

- include in the work of MPN 1 and check its performance:

- excess heat released during the operation of the MPN is removed to the ISTR;

- after the performance tests are completed, ISTR 3 is undocked from MPN 1, and then after that they are docked to MPN 1 TKU 2 and transferred to MPN (with TKU) for temporary storage or to the assembly shop where MPN will be docked with MSS.

As the analysis of the use of the well-known technical solution in the production of MPN showed, in the case of an error - violation of the undocking and docking of ISTR hydraulic connectors from MPN and TKU to MPN, the liquid cavity of the TCU can be completely filled: in the case when the second ISTR hydraulic connector 3.2 is disconnected from MPN and before another is undocked (first) of its hydraulic connector 3.1 from MPN to the second hydraulic connector 1.2 MPN docked hydraulic connector 2.1 TKU, then in this case, the liquid coolant flows from the liquid cavity of the compensator volume 3.4 ISTR 3 in the liquid the volume compensator 2.2 TCU, as a result of which it is completely filled with coolant, the bellows 2.4 is compressed to the stop and the TCU loses its compensating ability, and after undocking the first hydraulic connector 3.1 ISTR from the MPN in the liquid path of the latter, the coolant pressure rises significantly above the permissible temperature ( up to destructive fluid path pressure).

Thus, a significant drawback of the known technical solution is the insufficiently high reliability of the production of the MPN, which leads to the destruction of the liquid path of the MPN or to a hidden defect leading to premature failure under the conditions of the orbital functioning of the liquid path of the MPN and the spacecraft as a whole.

The aim of the proposed technical solution is to eliminate the above significant drawback.

This goal is achieved by the manufacture of MPN in such a way that they are docked to MPN TKU, the gas cavity of which is filled with gas with pressure satisfying the condition:

P _g.p.TKU = P _{g.p. ISTR} ± _ΔР ,

where P _g.TKU - gas pressure in the gas cavity of the TKU at its refueling temperature, Pa;

P _{g. ISTR} - gas pressure in the gas cavity ISTR at the same temperature of refueling it, Pa;

ΔР is the permissible deviation of the gas pressure in the gas cavity of the TCU from the gas pressure in the gas cavity of the ISTR volume compensator, Pa,

and the fluid carrier dose drained from the liquid cavity, determined from the ratio:

where V _SL - the volume of the fused dose of the coolant, m ³ ;

m is the total mass of the coolant in the liquid circuit of the payload module and the liquid cavity of the technological compensation device after draining the dose of the coolant, kg;

ρ, ρ _cl - the density of the coolant at a specific current temperature T and at the discharge temperature of the dose of coolant T _sl , kg / m ³ (ρ ≠ ρ _sl );

R _SL , R - gas pressure in the gas cavity of the compensator volume of the simulator of the temperature control system at the temperature of the discharge of the dose of coolant T _SL and at a specific current temperature T, Pa (R _SL ≠ P);

T, T _SL - specific current gas temperature in the gas cavity and gas temperature in the gas cavity when draining the coolant dose, ° K (P _{sl сл} P);

V _G.min - the minimum possible volume of the gas cavity before draining the coolant dose, m ³ ;

ΔV - technological tolerance, m ³ ,

which, according to the authors, are the essential distinguishing features of the technical solution proposed by the authors.

As a result of the analysis carried out by the authors of the well-known patent and scientific and technical literature, the proposed combination of significant distinguishing features of the claimed technical solution was not found in the known information sources and, therefore, the known technical solutions do not exhibit the same properties as in the claimed method of manufacturing the MPN of the spacecraft.

A schematic diagram of the implementation of the proposed method for the manufacture of MPN is shown in figure 1.

The proposed method of manufacturing MPN includes the following basic operations:

1) In the initial state, before the start of the MPN tests for operability, they attach to the hydraulic connector 1.2 MPN 1 hydraulic connector 2.1 TKU 2, the gas cavity 2.1 of which through the filling valve 2.4 is charged with gas with pressure satisfying the condition:

P _g.p.TKU = P _{g.p. ISTR} ± _ΔР ,

where P _g.TKU - gas pressure in the gas cavity of the TKU at its refueling temperature, Pa;

P _{g. ISTR} - gas pressure in the gas cavity ISTR at the same temperature of refueling it, Pa;

ΔР is the permissible deviation of the gas pressure in the gas cavity of the TCU from the gas pressure in the gas cavity of the ISTR volume compensator, Pa,

and a dose of coolant is drained from its liquid cavity, providing at the maximum possible operating ambient temperature the pressure in the gas cavity is lower than the maximum allowable, determined from the ratio:

where V _SL - the volume of the fused dose of the coolant, m ³ ;

m is the total mass of the coolant in the liquid circuit of the payload module and the liquid cavity of the technological compensation device after draining the dose of the coolant, kg;

ρ, ρ _cl - the density of the coolant at a specific current temperature T and at the discharge temperature of the dose of coolant T _sl , kg / m ³ (ρ ≠ ρ _sl );

R _SL , R - gas pressure in the gas cavity of the compensator volume of the simulator of the temperature control system at the temperature of the discharge of the dose of coolant T _SL and at a specific current temperature T, Pa (R _SL ≠ P);

T, T _SL - the specific current temperature of the gas in the gas cavity and the temperature of the gas in the gas cavity when draining the coolant dose, K (P _sl Р P);

V _G.min - the minimum possible volume of the gas cavity before draining the coolant dose, m ³ ;

ΔV - technological tolerance, m ³ ;

2) undock TKU 2 from MPN 1;

3) dock ISTR 3 to MPN 1;

4) include the ISTR;

5) include in the work of MPN;

6) after completion of the MPN tests for performance, the ISTR is undocked from it;

7) dock to the MPN TKU, the gas cavity of which is filled according to claim 1 and the dose is drained from its liquid cavity in accordance with claim 1;

8) transfer MPN with docked TKU for temporary storage or in the assembly shop, where MPN will be docked with MSS.

As can be seen from the above proposed method of manufacturing MPN, even if the operators make a mistake in the procedure for undocking and docking ISTR, TKU, ingress of excess liquid coolant into the TKU liquid cavity is guaranteed to be excluded, thereby excluding the presence of the MPN liquid path at unacceptable coolant pressures during its manufacture, t .e. thereby achieving the objectives of the invention.

Thus, the technical solution proposed by the authors eliminates the defect (including hidden) in the manufacture of MPN, thereby ensuring improved quality and production efficiency of MPN.

The technical solution proposed by the authors is reflected in the technical documentation of our enterprise, according to which the MPN of the newly created communications satellite will be produced.

Claims (1)

A method of manufacturing a payload module of a spacecraft, the liquid path of which is charged with a coolant, including connecting to the hydraulic connector of this path a hydraulic connector of a technological compensation device before and after testing the module for operability using a temperature control system simulator, characterized in that the gas cavity of the technological compensation device being connected is filled with gas under pressure satisfying the condition: P _g.p.TKU = P _{g.p. ISTR} ± _ΔР , where P _g.TKU - gas pressure in the gas cavity of the technological compensation device at the temperature of its refueling, Pa; P _{g. ISTR} - gas pressure in the gas cavity of the compensator volume of the simulator of the temperature control system at the same temperature of its refueling, Pa; ΔР - permissible deviation of the gas pressure in the gas cavity of the technological compensation device from the gas pressure in the gas cavity of the compensator volume of the simulator of the temperature control system, Pa, and from the liquid cavity of the specified compensation device, the dose of the coolant is determined, determined from the ratio:

where V _SL - the volume of the fused dose of the coolant, m ³ ; m is the total mass of the coolant in the liquid circuit of the payload module and the liquid cavity of the technological compensation device after draining the dose of the coolant, kg; ρ, ρ _sl - the density of the coolant at the current temperature T and at the temperature of the discharge of the dose of coolant T _sl , kg / m ³ ; R _SL , R - gas pressure in the gas cavity of the compensator volume of the simulator of the temperature control system at the temperature of the discharge of the dose of the coolant T _SL and at the current temperature T, Pa; T, T _SL - the above, not equal to each other temperature, K; V _G.min - the minimum possible volume of the gas cavity before draining the coolant dose, m ³ ; ΔV - technological tolerance, m ³ .

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