A new micro-flow control system with Tesla-like valve structure for satellites

Abstract

The present invention provides a novel micro-flow control system for satellites using a Tesla-like valve structure, comprising a xenon gas path control system and a circuit control system. The xenon gas path control system includes a novel micro-flow controller using a Tesla-like valve structure for satellites. The novel micro-flow controller includes a sealed cavity with a xenon gas inlet and outlet, and multiple flow channels within the sealed cavity connecting the xenon gas inlet and outlet. The present invention utilizes the Tesla valve structure's progressive throttling characteristics during reverse flow to design the flow channels of the micro-channel flow controller. Theoretically, this design can achieve near-perfect, precise control of xenon gas pressure and flow. The successful implementation of this invention is of strategic significance for improving xenon gas management in space Hall-effect electric thrusters, enhancing the precision of micro-flow distribution and coordinated control, and increasing their maneuverability.

Description

Technical Field

[0001] The present invention relates to the field of space propulsion technology, in particular to a novel micro-flow control system with a Tesla valve-like structure for satellites. Background Art

[0002] Hall-effect propulsion is a typical spacecraft electric propulsion system, offering advantages such as a high thrust-to-power ratio, high thrust density, high specific impulse, and a simple and reliable system (Zhang Guangke, Shan Shihua, and Fan Chao, "Overview of Satellite Propellant Technology Development Trends," Chemical Propellants and Polymer Materials, 2012, 10:71-74). Xenon (high-purity Xe), the most commonly used propellant in Hall-effect thrusters, offers numerous advantages, including being pollution-free, non-toxic, and chemically non-reactive with spacecraft surface materials. To improve storage efficiency, the xenon gas storage pressure in space electric propulsion systems is approximately 15 MPa, and the inlet pressure of the flow control module in the propellant supply unit is relatively low, typically around 0.2 MPa. Hall-effect thrusters have very stringent requirements for propellant flow control. The inlet pressure is high, and the output flow is very small. Reducing the outlet pressure to 5-10 kPa while ensuring an outlet flow rate of 0.1-20 mg / s is key to the stable operation of Hall-effect thrusters (Hou Xiao, Li Yong, Wu Zhiwen, Lin Qingguo, Wang Xiaowei, Geng Hai, Huang Tiankun, "Reflections and Suggestions on the Development of Space Propulsion Technology in my country," China Engineering Science, 2024, 26:217-225).

[0003] At present, electric propulsion systems at home and abroad mostly use micro-flow controllers such as metal capillaries and porous metal materials for flow control. For example: SH Collicott, Convergence behavior of surface evolver applied to agenic propellant-management device, Journal of Propulsion and Power 2001, 17: 845-851, Wang Xiaoyong, Zhang Hongpeng, Hu Jing, Li Xingkun, Development of propellant supply technology for foreign electric propulsion systems, Vacuum & Cryogenics 2022, 28: 497-506, J. Cassady, B. Boyce, B. Kearney, D. Herman, P.Peterson, Development of 12 kw hall thrusters for NASA lunar gateway power and propulsion element, Space Propulsion 2022, Estoril, Portugal | 09 – 13 May 2022. Capillary micro-flow controllers use capillaries as throttling elements, achieving micro-flow control by precisely controlling the diameter and length of the capillary tubes, and monitoring and regulating parameters such as the pressure and temperature of the fluid within the capillary tubes. Porous metal micro-flow controllers utilize the properties of porous metal materials to precisely control and monitor the parameters of the fluid as it passes through the material, achieving micro-flow control. Although adjusting the inlet pressure and temperature can correct the on-orbit flow of xenon gas, it suffers from fundamental flaws such as flow resistance and suboptimal flow control. Improving the xenon gas regulation capabilities of flow controllers is crucial to enhancing the distribution and control of space propellant.

[0004] The Tesla valve structure has the excellent performance of achieving unidirectional fluid conduction without any auxiliary structure (FK Forster, RL Bardell, M. Afromowitz, NR Sharma, A. Blanchard, Design, fabrication and testing of fixed-valve micro-pumps, Proceedings of the ASME Fluids Engineering Division 1995, 234: 39–44.). Tesla valve structures are typically used in liquid fluids, but the application of Tesla valve structures in Hall effect thrusters has not been found in the prior art. Summary of the Invention

[0005] In order to solve the problems of the prior art, the present invention provides a new micro-flow control system with a Tesla valve-like structure for satellites. Based on the step-by-step throttling characteristics of the Tesla valve structure during reverse flow, it is used in the flow channel design of a microfluidic flow controller. In theory, it can achieve nearly perfect precise regulation of xenon pressure and flow. The successful implementation of the present invention is of great strategic significance for improving the xenon management level of space Hall electric thrusters, enhancing the accuracy of micro-flow distribution and coordinated control, and enhancing their maneuverability.

[0006] The present invention provides a novel micro-flow control system with a Tesla-like valve structure for satellites, comprising a xenon gas path control system and a circuit control system. The xenon gas path control system comprises a novel micro-flow controller with a Tesla-like valve structure for satellites connected between a xenon gas storage tank and a Hall thruster. The xenon gas storage tank is sequentially connected to the inlet of the novel micro-flow controller with a Tesla-like valve structure for satellites via a filter and a stop valve. The outlet of the novel micro-flow controller with a Tesla-like valve structure for satellites is respectively connected to the anode and cathode of the Hall thruster via two controllable stop valves. Low-pressure gas valves are respectively provided in the anode and cathode of the Hall thruster. The novel micro-flow controller with a Tesla-like valve structure for satellites comprises a sealed cavity with a xenon gas inlet and a xenon gas outlet. A plurality of flow channels connecting the xenon gas inlet and the xenon gas outlet are present in the sealed cavity. The flow channels utilize an array of Tesla valve wing-shaped structural units. The xenon gas inlet pressure is 0.1-0.3 MPa, the xenon gas outlet pressure is 5-10 kPa, and the flow channel flow rate is 0.1-30 mg / s.

[0007] The circuit control system is respectively connected to the filter, the stop valve, the controllable stop valve, and the low-pressure gas valve. The low-pressure gas valve is provided inside the anode and cathode of the Hall thruster. The flow rate at the inlet of the new micro-flow controller with a Tesla valve structure used for the satellite is controlled by the filter and the stop valve. The high-pressure gas flow entering the cathode and anode of the Hall thruster is controlled by the controllable stop valve. The low-pressure gas flow entering the cathode and anode of the Hall thruster is controlled by the low-pressure gas valve.

[0008] As a further improvement, the number of Tesla valve wing-shaped structural unit arrays in the novel micro-flow controller for satellites imitating Tesla valve structure is 3 to 10 groups.

[0009] As a further improvement, the Tesla valve wing-shaped structural unit array in the novel micro-flow controller with Tesla valve-like structure for satellite is a plurality of Tesla valve wing-shaped structures arranged in an array, and the array modes include single-sided array, double-sided array, single-sided and double-sided combination, and positive and negative combination array, the connection modes include divergent and convergent types, and the combination forms include single-column or multi-column combinations.

[0010] As a further improvement, the Tesla valve wing-shaped structural unit array includes 1 to 10 Tesla valve wing-shaped structural units, and the Tesla valve wing-shaped structural unit includes an entrance and exit position, a wing front position, a wing rear position and a wingspan angle.

[0011] As a further improvement, the cross-sectional shape of the entrance and exit is rectangular, the width and depth of the entrance and exit are 0.2~2mm, and the width and depth of the wing front and wing rear are 0.2~2mm.

[0012] As a further improvement, the cross-section of the entrance and exit is circular, the diameter of the entrance and exit is 0.2~2mm, and the wingspan angle is 20~70°.

[0013] The present invention also provides a method for manufacturing and packaging a novel micro-flow control system with a Tesla-like valve structure for satellites, characterized in that: the novel micro-flow controller with a Tesla-like valve structure for satellites is manufactured using diffusion welding packaging technology and 3D printing technology, and the novel micro-flow controller with a Tesla-like valve structure for satellites is connected between a xenon gas storage tank and a Hall thruster; the diffusion welding packaging technology specifically includes the following steps:

[0014] a) Surface pretreatment: The micro flow controller mainly consists of two parts: the upper and lower substrates. The substrate material can be made of metal materials such as 304 stainless steel or TC4 titanium alloy. The upper and lower substrate samples are polished with 120#, 100#, 60#, 36#, and 24# metallographic sandpaper respectively, and then polished with a grinding and polishing machine to ensure that the surface roughness Ra is below 50nm;

[0015] b) Tesla valve structure processing: Using micromachining, micro-electrolysis, and laser etching methods, a new micro-flow control system structure imitating the Tesla valve structure for satellites is processed on the lower substrate surface. The dimensional error of the processed structure is controlled within 10%;

[0016] c) Fixing hole processing: Use mechanical drilling method to process bolt holes on the upper and lower base plates. The specific number is determined according to the brazing effect and the overall structural size of the micro flow controller;

[0017] d) Surface polishing: Use a grinding and polishing machine to polish the surface to ensure that the surface roughness is below Ra50nm;

[0018] e) Surface coating preparation: Ti thin films are deposited on the upper and lower substrates using magnetron sputtering technology or physical vapor deposition as intermediate layers for subsequent diffusion welding. The film thickness is controlled at 3-10 nm, and the film roughness is less than 5 nm.

[0019] f) Diffusion welding packaging: Press the upper and lower substrates together and place them in a vacuum or protective atmosphere furnace for heating and pressurization. The surfaces to be welded will produce micro plastic deformation and close contact to achieve micro flow controller packaging;

[0020] g) Bolt connection reinforcement: For the packaged micro flow controller, the bolt holes processed in step c) are connected with fine thread bolts.

[0021] The present invention also provides a working method of a new micro-flow control system with a Tesla-like valve structure for satellites, comprising the following steps: connecting the new micro-flow control system with a Tesla-like valve structure for satellites between a xenon storage tank and a Hall thruster, allowing xenon gas output from the xenon storage tank to enter the new micro-flow control system with a Tesla-like valve structure for satellites through a filter and a stop valve, regulating the pressure and flow of the xenon gas, and allowing the xenon gas to flow into the anode and cathode of the Hall thruster through two controllable stop valves, thereby realizing xenon gas supply; and automatically controlling the filter, stop valve, and controllable stop valve through a circuit control system during operation.

[0022] The beneficial effects of this invention lie in: leveraging the Tesla valve structure's superior unidirectional flow characteristics without any auxiliary structures, a novel micro-flow control system for satellites, imitating the Tesla valve structure, is designed to enhance the regulation of xenon (Xe) gas pressure and flow, better meeting the operational requirements of the Hall propulsion system for the entire satellite. Theoretically, near-perfect precision control of xenon gas pressure and flow can be achieved. The successful implementation of this invention is of strategic significance for improving xenon gas management in space Hall electric thrusters, enhancing the precision of micro-flow distribution and coordinated control, and enhancing their maneuverability. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0024] Figure 1 It is a characteristic of Tesla's valve-wing-shaped structural unit;

[0025] Figure 2 Design of the array, connection and combination of structural units;

[0026] Figure 3 Manufacturing and packaging of a new micro flow controller with Tesla valve structure;

[0027] Figure 4 This is a schematic diagram of a new micro-flow control system that imitates the Tesla valve structure. DETAILED DESCRIPTION

[0028] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0029] The technical implementation plan for the new micro-flow controller with Tesla-like valve structure mainly includes the following core parts: Tesla valve wing-shaped structural unit design, array, connection and combination design, manufacturing and packaging of the new micro-flow controller with Tesla-like valve structure, and control method implementation. The specific technical details are as follows:

[0030] 1) Tesla valve wing structure unit design:

[0031] Tesla valve wing structure unit such as Figure 1 As shown, its characteristic parameters include key positions such as the inlet / exit position, the front / rear position of the wing, and the wingspan angle. For the structural unit with a rectangular cross-section, the width and depth of the inlet / exit position are guaranteed to be 0.2~2mm, and the width and depth of the front / rear position of the wing are guaranteed to be 0.2~2mm. For the structural unit with a circular cross-section, the diameter size of the above positions is guaranteed to be 0.2~2mm, and the wingspan angle is 20~70°.

[0032] 2) Tesla valve wing structure unit array, connection and combination design:

[0033] Taking the xenon propellant parameters in the Hall electric thrusters of different types of small satellites as the target (specifically including: inlet pressure 0.1~0.3MPa, outlet pressure 5~10kPa, flow rate 0.1~30mg / s), based on the Tesla valve wing structure unit dimensions obtained in step 1), the Tesla valve wing structure unit array, connection and combination methods are designed, such as Figure 2 As shown, the number of wing-shaped structural units is controlled at 1 to 10, the wing-shaped structure array modes include single-sided array, double-sided array, single / double-sided combination and forward and reverse combination array, the connection modes include divergent and convergent types, and the combination forms include single-row or multi-row combination (3 to 10 groups). The specific structural parameters are determined according to the actual needs of the use and control of xenon propellant in the Hall electric thruster in the small satellite.

[0034] 3) Micro flow controller manufacturing and packaging:

[0035] There are two types of manufacturing and packaging: 1. Processing the structure obtained in step 2) on the surface of a metal substrate and encapsulating it using diffusion bonding technology; 2. Using 3D printing technology, the Tesla valve wing structure obtained in step 2) is printed in an integrated manner. Here, we will only elaborate on the technical details of the first manufacturing and packaging method, as follows:

[0036] a) Surface pretreatment: The micro flow controller mainly consists of two parts: the upper and lower substrates. The substrate material can be made of metal materials such as 304 stainless steel or TC4 titanium alloy. Since the surface roughness of the substrate has a great influence on the final packaging effect, the upper and lower substrate samples are polished with 120#, 100#, 60#, 36#, and 24# metallographic sandpaper respectively, and then polished with a grinding / polishing machine to ensure that the surface roughness Ra is below 50nm;

[0037] b) Tesla valve structure processing: using micromachining, micro electrolysis, laser etching and other processing methods, such as Figure 3 As shown, the specific structure obtained in step 2) is processed on the lower substrate surface, and the dimensional error of the processed structure is controlled within 10%;

[0038] c) Fixing hole processing: Use mechanical drilling method to drill holes on the upper and lower substrates Figure 3 Bolt holes (maximum M4 bolts) are machined at the positions shown. The specific number is determined by the brazing effect and the overall structural dimensions of the micro-flow controller (the maximum size of the controller is determined by the Hall effect electric thrusters used in the specific model of satellite, and the number is 8 to 20);

[0039] d) Surface polishing: Since steps b) and c) will produce machining burrs on the surface, the surface is further polished using a grinding / polishing machine to ensure that the surface roughness is below Ra50nm;

[0040] e) Surface coating preparation: Using magnetron sputtering technology (physical vapor deposition), a Ti film is deposited on the upper and lower substrate surfaces as an intermediate layer for subsequent diffusion welding. The film thickness is controlled to be 3-10 nm, and the film roughness is less than 5 nm to improve the diffusion welding effect;

[0041] f) Diffusion welding packaging: Press the upper and lower substrates together and place them in a vacuum or protective atmosphere furnace for heating and pressurization. The surfaces to be welded will produce micro plastic deformation and close contact to achieve micro flow controller packaging;

[0042] g) Bolt connection reinforcement: Considering the possibility of package interface instability caused by extreme working conditions such as impact during satellite launch and space service, fine-threaded bolts are used to connect the bolt holes processed in step c) of the packaged micro-flow controller to ensure controller stability.

[0043] At this point, the micro flow controller is manufactured and packaged, and its structure is shown as follows: Figure 3 shown.

[0044] 4) Control method implementation:

[0045] Figure 4The diagram below shows a schematic diagram of a new micro-flow control system with a Tesla-like valve structure. It primarily consists of a xenon gas path control system and a circuit control system. The operating principle is as follows: Xenon gas in the xenon storage tank flows through a filter and a shutoff valve into a new micro-flow controller with a Tesla-like valve structure. The Tesla-like valve structure regulates pressure and flow, and then flows through controllable shutoff valves A / B into the anode and cathode of the Hall thruster, completing the xenon supply. The control circuit, primarily powered by the satellite's solar panels, automatically controls the filter, shutoff valve, controllable shutoff valves A / B, the anode and cathode of the Hall thruster, and the low-pressure gas valve according to instructions. The main components function as follows:

[0046] Filter: used to filter micro-nano particles in storage tanks and pipelines;

[0047] Shut-off valve: cuts off the propeller (xenon) supply in special circumstances;

[0048] Controllable stop valve A / B: controls the propellant (xenon) supply to the Hall anode and cathode;

[0049] Solar panels: provide power for the system;

[0050] Control system: perform corresponding operations according to instructions;

[0051] Low-pressure gas valve: acts as the second gas valve after the controllable stop valve A / B to control the propellant (xenon) supply to the Hall anode and cathode;

[0052] Hall thruster: The final execution unit, which completes the propulsion function based on the Hall effect.

[0053] Each embodiment in this specification is described in a progressive manner, and the same or similar parts between the embodiments can be referred to each other, and each embodiment focuses on the differences from other embodiments. In particular, for the device embodiment, the above is only a preferred embodiment of the present invention. Since it is basically similar to the method embodiment, the description is relatively simple, and the relevant parts can be referred to the partial description of the method embodiment. The above is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited to this. Any technical personnel familiar with this technical field is within the technical scope disclosed by the present invention. For ordinary technical personnel in this technical field, changes or replacements that can be easily thought of should be covered within the protection scope of the present invention without departing from the principle of the present invention. Therefore, the protection scope of the present invention should be based on the protection scope of the claims.

Claims

1. A novel micro-flow control system with a Tesla-like valve structure for satellites, comprising a xenon gas path control system and a circuit control system, characterized by: The xenon gas path control system includes a satellite-use Tesla-like valve structure novel micro-flow controller connected between a xenon gas storage tank and a Hall thruster. The xenon gas storage tank is connected to the inlet of the satellite-use Tesla-like valve structure novel micro-flow controller through a filter and a stop valve in sequence. The outlet of the satellite-use Tesla-like valve structure novel micro-flow controller is respectively connected to the anode and cathode of the Hall thruster through two controllable stop valves. A low-pressure gas valve is respectively provided in the anode and cathode of the Hall thruster. The satellite-use Tesla-like valve structure novel micro-flow controller includes a sealed cavity with a xenon gas inlet and a xenon gas outlet. There are multiple flow channels connecting the xenon gas inlet and the xenon gas outlet in the sealed cavity. The flow channels adopt an array of several Tesla valve wing-shaped structural units. The xenon gas inlet pressure is 0.1-0.3 MPa, and the xenon gas outlet pressure is 5-10 kPa, and the flow rate of the flow channel is 0.1~30mg / s; the Tesla valve wing-shaped structural unit array in the novel micro-flow controller imitating the Tesla valve structure for satellites is a plurality of Tesla valve wing-shaped structures arranged in an array, and the array modes include single-side array, double-side array, single-side and double-side combination, and positive and negative combination array, the connection modes include divergent and convergent types, and the combination forms include single-row or multi-row combination; The circuit control system is respectively connected to the filter, the stop valve, the controllable stop valve, and the low-pressure gas valve. The low-pressure gas valve is provided inside the anode and cathode of the Hall thruster. The flow rate at the inlet of the new micro-flow controller with a Tesla valve structure used for the satellite is controlled by the filter and the stop valve. The high-pressure gas flow entering the cathode and anode of the Hall thruster is controlled by the controllable stop valve. The low-pressure gas flow entering the cathode and anode of the Hall thruster is controlled by the low-pressure gas valve.

2. The novel micro-flow control system with Tesla-like valve structure for satellites according to claim 1 is characterized by: The number of Tesla valve wing-shaped structural unit arrays in the novel micro-flow controller with Tesla valve-like structure for satellites is 3 to 10 groups.

3. The novel micro-flow control system with Tesla-like valve structure for satellites according to claim 1 is characterized by: The Tesla valve wing-shaped structural unit array includes 1 to 10 Tesla valve wing-shaped structural units, and the Tesla valve wing-shaped structural unit includes an entrance and exit position, a wing front position, a wing rear position and a wingspan angle.

4. The novel micro-flow control system with Tesla-like valve structure for satellites according to claim 3 is characterized by: The cross-section of the entrance and exit is rectangular, the width and depth of the entrance and exit are 0.2~2 mm, and the width and depth of the wing front and wing rear are 0.2~2 mm.

5. The novel micro-flow control system with Tesla-like valve structure for satellites according to claim 3 is characterized by: The cross-section of the entrance and exit is circular, the diameter of the entrance and exit is 0.2~2 mm, and the wingspan angle is 20~70°.

6. A method for manufacturing and packaging a novel micro-flow control system with a Tesla-like valve structure for satellites as claimed in any one of claims 1 to 5, characterized in that: A new micro-flow controller with a Tesla-like valve structure for satellites is manufactured using diffusion welding packaging and 3D printing technology, and the new micro-flow controller with a Tesla-like valve structure for satellites is connected between a xenon gas storage tank and a Hall thruster. The diffusion welding packaging specifically includes the following steps: a) Surface pretreatment: The micro flow controller mainly consists of two parts: the upper and lower substrates. The substrate material is selected from metal materials. The upper and lower substrate samples are polished with 120#, 100#, 60#, 36#, and 24# metallographic sandpaper respectively, and then polished with a grinding and polishing machine to ensure that the surface roughness Ra is below 50 nm; b) Tesla valve structure processing: Using micromachining, micro-electrolysis, and laser etching methods, a new micro-flow control system structure imitating the Tesla valve structure for satellites is processed on the lower substrate surface. The dimensional error of the processed structure is controlled within 10%; c) Fixing hole processing: Use mechanical drilling method to process bolt holes on the upper and lower base plates. The specific number is determined according to the brazing effect and the overall structural size of the micro flow controller; d) Surface polishing: Use a grinding and polishing machine to polish the surface to ensure that the surface roughness is below Ra 50 nm; e) Surface coating preparation: Ti thin films are deposited on the upper and lower substrates using magnetron sputtering or physical vapor deposition technology as intermediate layers for subsequent diffusion welding. The film thickness is controlled to be 3-10 nm, and the film roughness is less than 5 nm. f) Diffusion welding packaging: Press the upper and lower substrates together and place them in a vacuum or protective atmosphere furnace for heating and pressurization. The surfaces to be welded will produce micro plastic deformation and close contact to achieve micro flow controller packaging; g) Bolt connection reinforcement: For the packaged micro flow controller, the bolt holes processed in step c) are connected with fine thread bolts.

7. A method for operating a novel micro-flow control system for satellites using a Tesla-like valve structure as claimed in any one of claims 1 to 5, characterized in that The following steps are involved: A new micro-flow control system with a Tesla-like valve structure for satellites is connected between the xenon storage tank and the Hall thruster. The xenon gas output from the xenon storage tank enters the new micro-flow control system with a Tesla-like valve structure for satellites through a filter and a stop valve. The new micro-flow control system with a Tesla-like valve structure for satellites regulates the pressure and flow of the xenon gas, and flows into the anode and cathode of the Hall thruster through two controllable stop valves to realize the xenon supply. During the working process, the filter, stop valve, controllable stop valve and low-pressure gas valve are automatically controlled by the circuit control system.

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