Thermal protection and structure integrated rudder controller and forming method thereof

Abstract

This invention relates to an integrated thermal protection and structural servo controller and its molding method, belonging to the field of controller thermal protection technology. It solves the problem in existing servo controllers that cannot achieve long-duration operation in high-temperature environments without heat dissipation pathways. The servo controller of this invention includes: an outer thermal insulation sleeve, an inner thermal insulation sleeve, a controller housing, a control printed circuit board (PCB), and a power printed circuit board (PCB). The controller housing includes: an upper controller housing and a lower controller housing. The control PCB is fixedly mounted on the upper controller housing; the power PCB is fixedly mounted on the lower controller housing. Both the upper and lower controller housings are filled with PCM phase change material. The outer and inner thermal insulation sleeves cover the outside of the controller housing. This invention achieves excellent thermal protection for the controller by using thermal insulation sleeves and combining them with heat absorption by the phase change material.

Description

Technical Field

[0001] This invention relates to the field of controller thermal protection technology, and in particular to a servo controller integrating thermal protection and structure, and its molding method. Background Technology

[0002] Servo motors are a crucial component of an aircraft's attitude control system, used to control the oscillation of engine nozzles or the deflection of control surfaces. During launch and flight, servo motors must withstand harsh operating environments such as shock, vibration, and high temperatures. Especially as the flight distance and time increase, the external radiation and convection of the servo motor, as well as its internal heat generation, all increase significantly. Ensuring reliable operation of the servo motor under the simultaneous action of internal and external heat loads is a pressing issue that needs to be addressed.

[0003] Servo servos face the following thermal environments during operation: frictional heat from the outer surface of the servo mounting bay during flight; heat generation from the engine exhaust nozzle and aircraft battery within the confined space of the mounting bay; and additional heat from the components on the internal circuit board of the servo controller. Furthermore, the temperature generated by the servo controller's own heat is generally much lower than the ambient temperature, meaning the controller cannot reduce its own temperature by transferring heat to the external environment. Therefore, the servo controller requires appropriate thermal design measures to ensure that its internal components operate within a normal temperature range.

[0004] The servo controller interfaces with the aircraft's cabling network and the servo actuators, performing functions such as power filtering and isolation conversion, servo command signal acquisition, servo actuator position feedback, and sending servo actuator action signals. A typical controller includes signal processing chips, position acquisition chips, temperature acquisition chips, isolation chips, and power supply chips. These components are sensitive to high-temperature environments, requiring thermal design measures for protection during long-duration operation in high-temperature environments.

[0005] The thermal design of servo controllers often considers dissipating the high temperature inside the controller or using some low thermal conductivity materials for insulation, which cannot adapt to the high temperature environment during long-term operation. Summary of the Invention

[0006] Based on the above analysis, the present invention aims to provide a thermal protection and structurally integrated servo controller and its molding method, in order to solve the problem that the existing controllers have poor thermal protection performance and are difficult to achieve long-term operation in high-temperature environments.

[0007] The objective of this invention is mainly achieved through the following technical solutions: A thermal protection and structurally integrated servo controller includes: a thermal insulation sleeve, a controller housing, a control printed circuit board, and a power printed circuit board; the controller housing includes: an upper controller housing and a lower controller housing; the control printed circuit board is fixedly mounted on the upper controller housing; the power printed circuit board is fixedly mounted on the lower controller housing; the thermal insulation sleeve is disposed outside the controller housing.

[0008] Specifically, the heat insulation sleeve includes an outer heat insulation sleeve and an inner heat insulation sleeve. The inner heat insulation sleeve and the outer heat insulation sleeve are sequentially installed over the outside of the controller housing and are fixedly connected to the controller housing.

[0009] For example, the outer heat insulation sleeve, the inner heat insulation sleeve, and the controller housing are fixed together by adhesive bonding.

[0010] Furthermore, both the upper and lower housings of the controller are filled with PCM phase change material. PCM (Phase Change Material) refers to a substance that changes its state with temperature and can provide latent heat.

[0011] Furthermore, it also includes: an actuator communication electrical connector and an aircraft communication electrical connector; the aircraft communication electrical connector and the actuator communication electrical connector are respectively fixedly installed on both sides of the upper housing of the controller.

[0012] Furthermore, the controller housing is provided with a first boss and a second boss, and the control printed circuit board is fixedly mounted on the first boss and the second boss by screws.

[0013] Furthermore, a third boss and a fourth boss are provided on the lower housing of the controller; the power supply printed circuit board is fixedly mounted on the third boss and the fourth boss.

[0014] Furthermore, the upper housing and the lower housing of the controller are fixedly connected by screws.

[0015] Furthermore, a first phase change material filling area is provided on the upper housing of the controller; the first phase change material filling area is filled with the PCM phase change material.

[0016] Furthermore, a second phase change material filling area is provided on the lower housing of the controller; the second phase change material filling area is filled with the PCM phase change material.

[0017] Furthermore, the first phase change material filling area is encapsulated by welding a first cavity top plate; the second phase change material filling area is encapsulated by welding a second cavity top plate.

[0018] Furthermore, the heat insulation sleeve is a double-layer structure composed of an aluminum-plated thin film and a low thermal conductivity material.

[0019] Furthermore, the outer heat insulation sleeve and the inner heat insulation sleeve are made of the same material.

[0020] A molding method for a servo controller integrating thermal protection and structure includes the following steps: Step S1: The outer shape of the controller housing is formed, and the PCM phase change material is determined according to the thermal environment conditions of the servo controller. Step S2: PCM phase change material is filled and sealed in the first phase change material filling area on the upper housing of the controller and the second phase change material filling area on the lower housing of the controller; and the weld quality and pressure resistance test are checked. Step S3: Assemble the various components of the integrated thermal protection and structural servo controller; Step S4: Conduct a temperature resistance test on the integrated thermal protection and structural servo controller to verify the thermal protection effect.

[0021] The technical solution of this invention can achieve at least one of the following effects: 1. The present invention has an outer heat insulation sleeve and an inner heat insulation sleeve on the outside of the controller. The heat insulation is made of low thermal conductivity material and aluminum foil, which has a passive heat insulation effect. When the controller is in a thermal radiation environment, it can effectively prevent high temperature radiation and heat insulation; it can prevent the engine nozzle from transferring heat through radiation and isolate the high temperature air from transferring heat through convection.

[0022] 2. This invention discloses a thermal protection and structurally integrated servo controller. A first phase change material (PCM) filling area and a second PCM filling area are provided inside the controller housing. The controller housing is filled with PCM PCM for active heat absorption. This transforms the traditional controller housing into a thermal protection and structurally integrated design, further reducing the temperature inside the controller cavity. It achieves both structural support and active heat absorption within a limited space, solving the problem of long-duration operation of existing servo controllers in high-temperature environments without heat dissipation pathways. It can adapt to a 1000s long-duration operation and a 150℃ high-temperature environment.

[0023] 3. The present invention provides a servo controller integrating thermal protection and structure, which achieves passive heat insulation through an external heat insulation sleeve and active heat absorption through PCM phase change material in the internal controller housing, thus realizing two-stage thermal protection. It also features a compact structure, optimized process, and the ability to enable the internal circuitry of the servo controller to operate for extended periods in high-temperature environments where there is no heat dissipation path.

[0024] In this invention, the above-described technical solutions can be combined with each other to achieve more preferred combinations. Other features and advantages of this invention will be set forth in the following description, and some advantages may become apparent from the description or be learned by practicing the invention. The objects and other advantages of this invention can be realized and obtained from what is particularly pointed out in the description and drawings. Attached Figure Description

[0025] The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Throughout the drawings, the same reference numerals denote the same parts.

[0026] Figure 1 This is a schematic diagram of the integrated thermal protection and structural servo controller structure of Embodiment 1 of the present invention; Figure 2 This is a cross-sectional view along the AA direction of the integrated thermal protection and structural servo controller of Embodiment 1 of the present invention; Figure 3 This is a bottom view of a thermal protection and structural integrated servo controller according to Embodiment 1 of the present invention; Figure 4 This is a schematic diagram of the controller's upper housing; Figure 5 This is a cross-sectional view of the controller housing along the BB direction. Figure 6 This is a schematic diagram of the lower housing of the controller; Figure 7 Cross-sectional view of the lower housing of the controller in the CC direction. Figure 8 This is a flowchart of the molding method for the integrated thermal protection and structural servo controller of Embodiment 2 of the present invention.

[0027] Figure label: 1-Outer heat insulation sleeve; 2-Inner heat insulation sleeve; 3-Actuator communication electrical connector; 4-Aircraft communication electrical connector; 5-Controller mounting hole; 6-Controller upper housing; 7-Controller lower housing; 8-Controller printed circuit board; 9-Power printed circuit board; 10-First phase change material filling area; 11-Second phase change material filling area; 12-First fixing hole; 13-Second fixing hole; 14-First boss; 15-Second boss; 16-First threaded hole; 17-Second threaded hole; 18-Third boss; 19-Fourth boss; 20-First cavity top plate; 21-Second cavity top plate. Detailed Implementation

[0028] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, which constitute a part of the present invention and are used together with the embodiments of the present invention to illustrate the principles of the present invention, but are not intended to limit the scope of the present invention.

[0029] Example 1 One specific embodiment of the present invention discloses a servo controller integrating thermal protection and structure, such as... Figure 1 , Figure 2As shown, it includes: an outer heat insulation sleeve 1, an inner heat insulation sleeve 2, an actuator communication electrical connector 3, an aircraft communication electrical connector 4, a controller housing, a control printed circuit board 8, and a power printed circuit board 9.

[0030] The controller housing includes an upper controller housing 6 and a lower controller housing 7. The upper controller housing 6 and the lower controller housing 7 are fixedly connected; further, the upper controller housing 6 and the lower controller housing 7 are combined to form a controller compartment, such as... Figure 3 As shown, a controller mounting hole 5 is provided on the cabin body, and screws are installed in the controller mounting hole 5. The control printed circuit board 8 is fixedly installed on the controller cabin body by the screws.

[0031] The aircraft communication electrical connector 4 is used to realize communication with the aircraft; the actuator communication electrical connector 3 is used to realize communication with the actuator; the aircraft communication electrical connector 4 and the actuator communication electrical connector 3 are existing components, and no improvements are made to them in this application, and their internal structure and principle are not described in detail here.

[0032] Furthermore, the aircraft communication electrical connector 4 and the actuator communication electrical connector 3 are respectively fixedly installed on both sides of the upper housing 6 of the controller; the control printed circuit board 8 is fixedly installed on the upper housing 6 of the controller; the power printed circuit board 9 is fixedly installed on the lower housing 7 of the controller; the outer heat insulation sleeve 1 and the inner heat insulation sleeve 2 are covered on the outside of the controller housing; the outer heat insulation sleeve 1 and the inner heat insulation sleeve 2 are used to achieve thermal protection for the internal controller.

[0033] In one specific embodiment of the present invention, the upper housing 6 of the controller is provided with a first fixing hole 12 and a second fixing hole 13, and correspondingly, the lower housing 7 of the controller is provided with a first threaded hole 16 and a second threaded hole 17; the upper housing 6 and the lower housing 7 of the controller are connected by screws, and the screws pass through the first fixing hole 12 and the second fixing hole 13 and are fixed on the first threaded hole 16 and the second threaded hole 17 of the lower housing 7 of the controller, thereby realizing the fixed connection between the upper housing 6 and the lower housing 7 of the controller.

[0034] In one specific embodiment of the present invention, such as Figure 2 As shown, both the inner heat insulation sleeve 2 and the outer heat insulation sleeve 1 are U-shaped semi-enclosed structures; the outer surfaces of the controller upper housing 6 and the controller lower housing 7 are first wrapped with the inner heat insulation sleeve 2, and then wrapped with the outer heat insulation sleeve 1; the outer heat insulation sleeve 1 and the inner heat insulation sleeve 2 are symmetrically arranged, and the outer heat insulation sleeve 1 surrounds the inner heat insulation sleeve 2.

[0035] Specifically, such as Figure 2As shown, the two side plates of the inner heat insulation sleeve 2 are embedded inside the outer heat insulation sleeve 1. The outer surfaces of the two side plates of the inner heat insulation sleeve 2 are fitted with the inner surfaces of the two side plates of the outer heat insulation sleeve 1. In practice, the heat insulation sleeve is used to block external radiation and achieve thermal protection for the controller. This application achieves convenient installation of the heat insulation sleeve and enhances its sealing performance by setting up a double-layer heat insulation sleeve, with the two side plates of the U-shaped outer heat insulation sleeve 1 and inner heat insulation sleeve 2 overlapping each other. This improves the thermal protection effect.

[0036] Furthermore, both the inner heat insulation sleeve 2 and the outer heat insulation sleeve 1 are provided with openings for installing the aircraft communication electrical connector 4 and the actuator communication electrical connector 3; one set is provided on each side of the opening; the aircraft communication electrical connector 4 and the actuator communication electrical connector 3 are fixedly installed in the openings. Figure 2 As shown, the aircraft communication connector 4 and the actuator communication connector 3 are both fixed to the side wall of the controller housing 6 by screws.

[0037] In one specific embodiment of the present invention, such as Figure 4 As shown, a first boss 14 and a second boss 15 are provided inside the upper housing 6 of the controller; the control printed circuit board 8 is fixed to the first boss 14 and the second boss 15 inside the upper housing 6 of the controller by screws. Specifically, the first boss 14 and the second boss 15 are provided with control mounting holes 5, and the screws pass through the control printed circuit board 8 and are installed in the control mounting holes 5 on the first boss 14 and the second boss 15, so as to realize the fixed connection between the control printed circuit board 8 and the upper housing 6 of the controller.

[0038] like Figure 6 As shown, the lower housing 7 of the controller is provided with a third protrusion 18 and a fourth protrusion 19 inside; the power supply printed circuit board 9 is fixed to the third protrusion 18 and the fourth protrusion 19 inside the lower housing 7 of the controller by screws.

[0039] Furthermore, a first phase change material filling area 10 is provided inside the bottom plate of the upper housing 6 of the controller, such as... Figure 2 , Figure 5 As shown; a second phase change material filling area 11 is provided inside the bottom plate of the lower housing 7 of the controller, as... Figure 2 , Figure 7 As shown. Furthermore, the first phase change material filling area 10 and the second phase change material filling area 11 inside the bottom plate of the upper housing 6 and the lower housing 7 of the controller are both filled with PCM phase change material.

[0040] In one specific embodiment of the present invention, the upper housing 6 and the lower housing 7 of the controller are made of aluminum alloy, and the bottom plate is made into a cavity to form the first phase change material filling area 10 and the second phase change material filling area 11.

[0041] Specifically, a first phase change material filling area 10 is provided on the bottom plate of the upper housing 6 of the controller, and a first cavity top plate 20 is fixedly installed on the top of the first phase change material filling area 10; a second phase change material filling area 11 is provided on the bottom plate of the lower housing 7 of the controller, and a second cavity top plate 21 is fixedly installed on the top of the second phase change material filling area 11; the first cavity top plate 20 is used to seal the first phase change material filling area 10, and the second cavity top plate 21 is used to seal the second phase change material filling area 11.

[0042] The first cavity top plate 20 is fixed to the upper housing 6 of the controller, and the second cavity top plate 21 is fixed to the lower housing 7 of the controller by laser welding.

[0043] Furthermore, the upper housing 6 of the controller needs to reserve installation space for the aircraft communication electrical connector 4 and the actuator communication electrical connector 3.

[0044] In one specific embodiment of the present invention, both the inner heat insulation sleeve 2 and the outer heat insulation sleeve 1 are double-layer structures composed of an aluminum-plated thin film and a low thermal conductivity material.

[0045] Specifically, the aluminum-coated film prevents the engine exhaust nozzle from radiating heat to the servo controller; low thermal conductivity materials can insulate against high-temperature airflow inside the servo compartment. Low thermal conductivity materials can be selected based on environmental conditions; common low thermal conductivity materials for servo controllers include silicone rubber-based insulation materials, silica-type insulation materials, and carbon fiber reinforced carbon composite materials.

[0046] Furthermore, the bottom plates of both the upper housing 6 and the lower housing 7 of the controller are filled with PCM phase change material.

[0047] The operating range of phase change energy storage thermal control devices generally begins from the phase change point and continues until all internal materials have completed the phase change process. The duration of the entire process is related to the operating time of the servo controller and can be controlled by designing the total amount and thermal conductivity of the internal phase change material.

[0048] Currently, there are many types of phase change materials (PCMs). Based on their chemical properties, they can be divided into two categories: organic PCMs and inorganic PCMs. Organic PCMs mainly include paraffin wax, carboxylic acids, esters, and polyols; inorganic PCMs mainly include hydrated crystalline salts, molten salts, and metal alloys.

[0049] During implementation: This invention relates to a thermal protection and structurally integrated servo controller, which includes: an outer heat insulation sleeve 1, an inner heat insulation sleeve 2, an upper controller housing 6, a lower controller housing 7, a control printed circuit board 8, a power supply printed circuit board 9, an aircraft communication connector 4, and an actuator communication connector 3. The outer surfaces of the upper controller housing 6 and the lower controller housing 7 are covered with the inner heat insulation sleeve 2 and the outer heat insulation sleeve 1, respectively. The control printed circuit board 8 is fixed to the inside of the upper controller housing 6 by screws, and the power supply printed circuit board 9 is fixed to the inside of the lower controller housing 7 by screws. The aircraft communication connector 4 and the actuator communication connector 3 are both fixed to the side wall of the upper controller housing 6 by screws. The bottom plates of the upper controller housing 6 and the lower controller housing 7 are filled with PCM phase change material. The thermal protection and structural integrated servo controller of the present invention has an inner heat insulation sleeve 2 and an outer heat insulation sleeve 1 as heat insulation materials covering the outer surface of the controller housing, which isolates the controller housing from the external high-temperature airflow and protects the controller housing. It mainly plays the role of blocking heat radiation and heat insulation. After the controller housing reaches the phase change energy storage working temperature range, the phase change material stored inside the upper housing 6 and the lower housing 7 of the controller undergoes a phase change, melts from solid to liquid, and absorbs a large amount of heat, playing the role of active heat absorption.

[0050] This invention uses two thermal protection materials, heat insulation material and phase change material, to jointly protect the control printed circuit board and power printed circuit board inside the controller within the normal operating temperature range. It has a simple structure, compact space, can adapt to the high temperature environment of aircraft without heat dissipation path, and is easy to implement and highly reliable.

[0051] Example 2 A specific embodiment of the present invention provides a molding method for a servo controller integrating thermal protection and structure. Specifically, regarding the molding process of the servo controller integrating thermal protection and structure in Embodiment 1, the specific production process is as follows: Figure 8 As shown, it includes the following steps: Step S1: The outer shape of the controller housing is formed, and the PCM phase change material is determined according to the thermal environment conditions of the servo controller. Step S2: PCM phase change material is filled and sealed in the first phase change material filling area 10 on the upper housing 6 and the second phase change material filling area 11 on the lower housing 7 of the controller; and the weld quality and pressure resistance test are checked. Step S3: Assemble the various components of the integrated thermal protection and structural servo controller; Step S4: Conduct a temperature resistance test on the integrated thermal protection and structural servo controller to verify the thermal protection effect.

[0052] Specifically, in step S1, the selection of PCM phase change material needs to comprehensively consider factors such as phase change temperature range, latent heat of phase change (energy storage capacity), density, thermal conductivity, compatibility and cost.

[0053] Among these, the latent heat of phase change and the phase change temperature range are the most important selection parameters. PCM phase change materials with high latent heat of phase change and large phase change temperature ranges should be selected according to requirements. Furthermore, phase change materials with high density and good compatibility should be preferred to improve the overall operating efficiency of the system.

[0054] Based on the above parameters and environmental conditions, appropriate PCM phase change materials are selected. The phase change temperature range and energy storage capacity of different types of PCM phase change materials are shown in Table 1.

[0055] Table 1 - Phase change temperature range and energy storage capacity of different types of PCM phase change materials

[0056] Specifically, in a 1000s long-endurance, 150℃ high-temperature environment, the controller is protected by the inner heat insulation sleeve 2 and the outer heat insulation sleeve 1, and the controller housing temperature can reach 128℃; therefore, in this embodiment, the PCM phase change material is a polyol-based PCM phase change material, and the initial operating temperature range is 100℃.

[0057] In step S1, the forming process of the controller housing is as follows: Step S11: The controller housing is divided into an upper controller housing 6 and a lower controller housing 7, which are formed separately.

[0058] Step S12: Process the phase change material filling areas on the upper housing 6 and the lower housing 7 of the controller; specifically, process the first phase change material filling area 10 on the upper housing 6 of the controller and process the second phase change material filling area 11 on the lower housing 7 of the controller.

[0059] Step S13: Fabricate the first cavity top plate 20 and the second cavity top plate 21.

[0060] Step S14: The first fixing hole 12, the second fixing hole 13, the first boss 14 and the second boss 15 are machined on the upper housing 6 of the controller by means of machining, and the first threaded hole 16, the second threaded hole 17, the third boss 18 and the fourth boss 19 are machined on the lower housing 7 of the controller.

[0061] In step S2, the PCM phase change material filling and sealing process includes: Step S21: Fill the first phase change material filling region 10 and the second phase change material filling region 11 with PCM phase change material.

[0062] Step S22: Weld a first cavity top plate 20 above the first phase change material filling region 10; the first cavity top plate 20 encapsulates the PCM phase change material within the first phase change material filling region 10, such as... Figure 5As shown.

[0063] Step S23: Weld a second cavity top plate 21 above the second phase change material filling region 11; the second cavity top plate 21 encapsulates the PCM phase change material within the second phase change material filling region 11, such as... Figure 7 As shown.

[0064] In one specific embodiment of the present invention, in step S2, X-ray fluoroscopy is used to inspect the weld quality, and the inspection results should meet the following requirements: (1) The weld at the sealing end should be smooth and flat, and its shape should not exceed the maximum outer contour dimension; (2) The flatness of the product's mounting surface is better than 0.1mm; (3) The flatness of the contact surface of the product is better than 0.1mm.

[0065] In one specific embodiment of the present invention, in step S2, a helium mass spectrometry leak detection method is used to detect leaks in the phase change material filling area. The detection results should meet the following requirements: the overall leakage rate of the PCM phase change material in the controller housing should not exceed 5 × 10⁻¹⁰ Pa·m. 3 / s.

[0066] In step S3, the assembly process of the integrated thermal protection and structural servo controller includes combining and installing the controller upper housing 6, controller lower housing 7, control printed circuit board 8, power printed circuit board 9, aircraft communication electrical connector 4, actuator communication electrical connector 3, inner heat insulation sleeve 2 and outer heat insulation sleeve 1.

[0067] Specifically, in step S3, the assembly process of the integrated thermal protection and structural servo controller is as follows: Step S31: Fix the control printed circuit board 8 to the first boss 14 and the second boss 15 on the upper housing 6 of the controller with screws; fix the power printed circuit board 9 to the third boss 18 and the fourth boss 19 on the lower housing 7 of the controller with screws.

[0068] Furthermore, the aircraft communication connector 4 and the actuator communication connector 3 are fixedly installed on both sides inside the housing 6 of the controller, such as... Figure 2 As shown.

[0069] Step S32: The upper housing 6 and the lower housing 7 of the controller are fixedly connected by screws; specifically, the screws pass through the first fixing hole 12 and the second fixing hole 13 on the upper housing 6 of the controller, and are screwed into the first threaded hole 16 and the second threaded hole 17 on the lower housing 7 of the controller, so as to achieve the fixed connection between the upper housing 6 and the lower housing 7 of the controller.

[0070] Step S33: Install the inner heat insulation sleeve 2 on the outside of the controller housing, and install the outer heat insulation sleeve 1 on the outside of the inner heat insulation sleeve 2.

[0071] Specifically, such as Figure 2 As shown, the bottom plate of the inner heat insulation sleeve 2 is fitted with the bottom plate of the controller housing, and the two side plates of the inner heat insulation sleeve 2 are fitted with the side walls of the controller housing; the bottom plate of the outer heat insulation sleeve 1 is fitted with the top plate of the controller housing, and the inner surfaces of the two side plates of the outer heat insulation sleeve 1 are fitted with the outer surfaces of the two side plates of the inner heat insulation sleeve 2. This application, by setting up double-layer heat insulation sleeves and installing the U-shaped outer heat insulation sleeve 1 and the two side plates of the inner heat insulation sleeve 2 overlapping each other, not only achieves convenient installation of the heat insulation sleeves but also enhances their sealing performance and improves the thermal protection effect.

[0072] In one specific embodiment of the present invention, in step S4, after the design and production of the integrated thermal protection and structural servo controller are completed, the thermal protection performance is verified through a temperature resistance test. The temperature resistance test in step S4 is an induced high-temperature test.

[0073] Furthermore, the high-temperature induced test includes the following process: Step S41: Obtain the equivalent temperature: The thermal radiation conditions of the controller's operating environment are equivalent to the temperature conditions for inducing a high-temperature test. Specifically, the equivalent temperature is obtained as follows: Step S411: Use computational fluid dynamics (CFD) software to perform simulation calculations, establish a fluid dynamics model, set the flight speed, time, and flight environment of the aircraft, and obtain the aerodynamic thermal radiation of the flight cabin wall; Step S412: Obtain the engine nozzle operating temperature through the engine hot test results; Step S413: A temperature control experiment is conducted using the electrothermal characteristics of a quartz lamp. The thermal radiation of the quartz lamp simulates the combined effect of the aerodynamic thermal radiation of the flight cabin wall in step S411 and the working radiation of the engine nozzle in step S412. At the same time, the aircraft battery is used to power the servo motor and controller to obtain the working radiation environment of the aircraft battery. In step S414, the controller is placed in an environment under the combined effects of aerodynamic thermal radiation from the flight cabin wall, working radiation from the engine nozzle, and working radiation from the aircraft battery, as described in step S413 above; and a temperature sensor is attached to the surface of the controller to monitor the surface temperature of the controller, which is the equivalent temperature for inducing the high-temperature test.

[0074] Step S42: The high-temperature induced test can be carried out directly in the temperature chamber, and the temperature inside the temperature chamber is controlled to be the equivalent temperature obtained in step S41; the real-time temperature inside the integrated thermal protection and structural servo controller is collected in real time by controlling the temperature chip inside the printed circuit board 8; by comparing the equivalent temperature inside the temperature chamber with the real-time temperature collected by the temperature chip, the thermal protection performance of the integrated thermal protection and structural servo controller can be verified.

[0075] This invention simulates the working environment of the controller in step S41 to test the thermal protection performance of the controller; and obtains the equivalent temperature of the controller's working environment. Then, it verifies the thermal protection performance of the controller again through a heat resistance test in a temperature chamber. Through a double superposition test, a thermal protection and structural integrated servo controller with qualified thermal protection performance is obtained.

[0076] Furthermore, in one specific embodiment of the present invention, after the integrated thermal protection and structural servo controller has undergone a 1000s long-endurance, 150℃ high-temperature induced high-temperature test, if the real-time temperature inside the controller can be controlled within 80℃ throughout the test, then it is considered to meet the thermal protection performance standard, and the operating temperature range of all electronic components inside the controller is normal.

[0077] Compared with the prior art, the technical solution provided in this embodiment has at least one of the following beneficial effects: 1. The present invention provides an aluminum-plated thin film and a low thermal conductivity material on the outer surface of the controller housing as an outer heat insulation sleeve 1 and an inner heat insulation sleeve 2. The aluminum-plated thin film can effectively prevent high temperature radiation from the engine nozzle, and the low thermal conductivity material can effectively insulate heat; the two together provide the first layer of thermal radiation protection for the servo controller housing.

[0078] 2. In this invention, the traditional controller housing is replaced with a controller housing that integrates thermal protection and structure. The controller housing has a phase change material filling area and is filled with PCM phase change material. It achieves structural load-bearing, electromagnetic shielding and active heat absorption functions in a limited space. Under the protection of the external heat insulation sleeve, it plays a second layer of protection for the servo controller housing. Through the inherent properties of the phase change material, it stores a large amount of heat energy without causing the temperature to rise, which can solve the problem of long-term operation of existing servo controllers in high-temperature environments without heat dissipation paths.

[0079] 3. The integrated thermal protection and structural controller of the present invention has good heat protection effect in environments with thermal radiation, thermal conduction and thermal convection. At the same time, it can actively absorb heat by using phase change materials, and can adapt to the complex high-temperature environment of servo controllers.

[0080] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention.

Claims

1. A molding method for a servo controller integrating thermal protection and structure, characterized in that, Includes the following steps: Step S1: The outer shape of the controller housing is formed, and the PCM phase change material is determined according to the thermal environment conditions of the servo controller. Step S2: Fill and seal the PCM phase change material; and inspect the weld quality and compressive strength. Step S3: Assemble the various components of the integrated thermal protection and structural servo controller; Step S4: Conduct a temperature resistance test on the integrated thermal protection and structural servo controller to verify the thermal protection effect; Step S41: Obtain the equivalent temperature. The thermal radiation conditions of the controller's operating environment are equivalent to the temperature conditions for inducing a high-temperature test. Specifically, the equivalent temperature is obtained as follows: Step S411: Use computational fluid dynamics (CFD) software to perform simulation calculations, establish a fluid dynamics model, set the flight speed, time, and flight environment of the aircraft, and obtain the aerodynamic thermal radiation of the flight cabin wall; Step S412: Obtain the engine nozzle operating temperature through the engine hot test results; Step S413: A temperature control experiment is conducted using the electrothermal characteristics of a quartz lamp. The thermal radiation of the quartz lamp simulates the combined effect of the aerodynamic thermal radiation of the flight cabin wall in step S411 and the working radiation of the engine nozzle in step S412. At the same time, the aircraft battery is used to power the servo motor and controller to obtain the working radiation environment of the aircraft battery. In step S414, the controller is placed in an environment under the combined effects of aerodynamic thermal radiation from the flight cabin wall, working radiation from the engine nozzle, and working radiation from the aircraft battery, as described in step S413 above; and a temperature sensor is attached to the surface of the controller to monitor the surface temperature of the controller, which is the equivalent temperature for inducing the high-temperature test. Step S42: The high temperature induced test can be carried out directly in the temperature chamber, and the temperature inside the temperature chamber is controlled to be the equivalent temperature obtained in step S41; the real-time temperature inside the integrated thermal protection and structure servo controller is collected in real time by controlling the temperature chip inside the printed circuit board (8); by comparing the equivalent temperature inside the temperature chamber with the real-time temperature collected by the temperature chip, the thermal protection performance of the integrated thermal protection and structure servo controller can be verified. The integrated thermal protection and structural servo controller includes: a heat insulation sleeve, a controller housing, a control printed circuit board (8), and a power printed circuit board (9); the controller housing includes: an upper controller housing (6) and a lower controller housing (7); the control printed circuit board (8) is fixedly mounted on the upper controller housing (6); the power printed circuit board (9) is fixedly mounted on the lower controller housing (7); the heat insulation sleeve covers the outside of the controller housing; the heat insulation sleeve includes: an outer heat insulation sleeve (1) and an inner heat insulation sleeve (2), the inner heat insulation sleeve (2) and the outer heat insulation sleeve... All sleeves (1) are U-shaped semi-enclosed structures. The inner heat insulation sleeve (2) and the outer heat insulation sleeve (1) are successively covered on the outside of the controller housing and fixedly connected to the controller housing. The two side plates of the U-shaped outer heat insulation sleeve (1) and the inner heat insulation sleeve (2) are installed overlapping each other. The two side plates of the inner heat insulation sleeve (2) are embedded in the interior of the outer heat insulation sleeve (1). The outer side of the two side plates of the inner heat insulation sleeve (2) is in contact with the inner side of the two side plates of the outer heat insulation sleeve (1). The outer heat insulation sleeve (1) and the inner heat insulation sleeve (2) form a double heat insulation sleeve. The upper housing (6) of the controller is provided with a first phase change material filling area (10), and the lower housing (7) of the controller is provided with a second phase change material filling area (11). The bottom plates of the upper housing (6) and the lower housing (7) of the controller are hollow structures. The first phase change material filling area (10) and the second phase change material filling area (11) are both filled with PCM phase change material.

2. The molding method of the integrated thermal protection and structural servo controller according to claim 1, characterized in that, The integrated thermal protection and structural servo controller also includes: an actuator communication electrical connector (3) and an aircraft communication electrical connector (4).

3. The molding method of the integrated thermal protection and structural servo controller according to claim 2, characterized in that, The aircraft communication connector (4) and the actuator communication connector (3) are respectively fixedly installed on both sides of the upper housing (6) of the controller.

4. The molding method of the integrated thermal protection and structural servo controller according to claim 1, characterized in that, The controller housing (6) is provided with a first boss (14) and a second boss (15).

5. The molding method of the integrated thermal protection and structural servo controller according to claim 4, characterized in that, The control printed circuit board (8) is fixedly mounted on the first boss (14) and the second boss (15) by screws.

6. The molding method of the integrated thermal protection and structural servo controller according to any one of claims 1-5, characterized in that, The lower housing (7) of the controller is provided with a third boss (18) and a fourth boss (19).

7. The molding method of the integrated thermal protection and structural servo controller according to claim 6, characterized in that, The power supply printed circuit board (9) is fixedly mounted on the third boss (18) and the fourth boss (19).

8. The molding method of the integrated thermal protection and structural servo controller according to claim 1, characterized in that, The heat insulation sleeve is a double-layer structure composed of an aluminum-plated thin film and a low thermal conductivity material.

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