A health management system for a flight vehicle thermal protection system

Abstract

The present application relates to the field of aircraft health management, and discloses a health management system of a flight space vehicle thermal protection system, the functional architecture of which comprises four levels of data acquisition, data processing, fault diagnosis and maintenance assistance; the physical architecture comprises an onboard terminal, a ground terminal and a mobile terminal; the onboard terminal comprises a plurality of data acquisition nodes distributed at various positions of the vehicle body, which are used to acquire temperature data measured in the thermal protection system in a relatively harsh thermal environment and store the data for post-flight download; the ground terminal comprises a data receiving and storage module, a data processing module, a fault diagnosis module and a maintenance assistance module, which are used to diagnose and locate faults of the thermal protection system; and the mobile terminal is used for maintenance work, receives visual fault information provided by the maintenance assistance module, and updates the maintenance state, so that faults of the thermal protection system can be found in time, and the maintenance time and cost of the flight space vehicle are reduced.

Description

Technical Field

[0001] This invention relates to the field of aircraft health management, and more particularly to a health management system for the thermal protection system of a commercial space launch vehicle. Background Technology

[0002] A reusable launch vehicle is a space launch vehicle that takes off from the ground, completes its planned launch mission, returns fully or partially to its final location, and lands safely. After maintenance, it can quickly perform another launch mission. Unlike launch vehicles that are discarded after a single launch, reusable launch vehicles can be reused multiple times, thereby significantly reducing the launch cost per unit payload and achieving the goals of free and convenient access to space and efficient use of space.

[0003] Flight-oriented space launch vehicles need to perform round-trip flights between Earth and space. During flight, these vehicles face harsh thermal environments. To ensure that the spacecraft's metal structure and internal electronic equipment operate under suitable temperature conditions, large-area thermal protection systems need to be installed on the spacecraft's structural surfaces. Under extreme flight conditions, thermal protection systems are susceptible to various forms of damage, such as impact, loosening, and detachment, posing a potential threat to catastrophic accidents. Therefore, inspection and maintenance are required after each mission cycle. Currently, the condition monitoring of thermal protection systems mainly relies on ground-based non-destructive testing (NDT) methods. Although NDT techniques such as ultrasonic testing and infrared scanning can effectively detect various forms of damage to thermal protection systems from the ground, these methods have long testing cycles and require complex equipment, making it difficult to meet the rapid turnaround and maintenance requirements of flight-oriented space launch vehicles. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide a health management system for the thermal protection system of a flight-type space launch vehicle, including: an airborne terminal, a ground terminal, and a mobile terminal;

[0005] The airborne terminal is arranged on the body of the space launch vehicle. The airborne terminal includes several data acquisition nodes. Each data acquisition node includes a data acquisition module, a data storage module, a wireless communication module, and a power supply module.

[0006] The ground terminal includes a data receiving and storage module, a data processing module, a fault diagnosis module, a database, and a maintenance assistance module;

[0007] The mobile terminal is used for maintenance work, receives visualized fault information provided by the maintenance assistance module, and updates the maintenance status.

[0008] Furthermore, the data acquisition module is used to collect temperature data at the connection between the thermal protection system and the metal structure; the data storage module is used to store the raw data collected by the sensors; the wireless communication module operates after the flight of the spacecraft and transmits the collected data to the ground terminal wirelessly; and the power supply module provides a stable power supply for all components of the data acquisition node.

[0009] Furthermore, the ground terminal is located at the spaceport, launch site, and recovery site.

[0010] Furthermore, the data receiving and storage module includes a data receiving unit, a data management unit, and a data storage unit.

[0011] Furthermore, the data receiving unit is used to receive packaged data sent by the airborne terminal; the data management unit is used to classify and process the data according to different node addresses; and the data storage unit is used to partition and store the classified data.

[0012] Furthermore, the data processing module preprocesses and extracts features from the node temperature data.

[0013] Preferably, the preprocessing includes data cleaning, data settling, data summarization, and data transformation; the feature extraction refers to extracting fault-sensitive features from the preprocessed data.

[0014] Furthermore, the fault diagnosis module integrates temperature data, fault feature parameters after feature extraction, ground test data, and historical measurement data, and performs fault diagnosis through a threshold detection method.

[0015] Preferably, the fault diagnosis execution process includes: the fault diagnosis module determines the upper and lower thresholds of the threshold detection based on the ground test data and the historical measurement data; after receiving the data, the fault diagnosis module determines whether the data exceeds the upper and lower thresholds; when the data exceeds the upper and lower thresholds, the address information of the fault data is recorded.

[0016] Furthermore, the database is used to store historical data, data processing algorithms, and fault diagnosis algorithms.

[0017] Furthermore, the maintenance assistance module visualizes the fault area and transmits the fault information to the mobile terminal.

[0018] More preferably, data transmission between the plurality of data acquisition points and the ground terminal is achieved through a ZigBee wireless communication network.

[0019] Compared with the prior art, the beneficial effects of the present invention are:

[0020] (1) By setting up a fault diagnosis module, timely diagnosis, location and early warning of faults in the thermal protection structure of the spacecraft can be achieved.

[0021] (2) The data processing module is used to complete the data processing work. The relevant algorithms carried by the data processing module are used to preprocess the data and extract features for subsequent fault diagnosis.

[0022] (3) By cooperating with the airborne terminal, the ground terminal and the mobile terminal, a reliable and real-time monitoring method is provided so that the failure of the thermal protection system can be detected in time, reducing the maintenance time and cost of the flight-type carrier. Attached Figure Description

[0023] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings:

[0024] Figure 1 This invention provides a functional framework for a health management system of a flight-oriented space launch vehicle thermal protection system.

[0025] Figure 2 This invention provides a physical framework for a health management system of a flight-oriented space launch vehicle thermal protection system.

[0026] Figure 3 This is a diagram showing the data acquisition node layout of a fuselage-covered thermal protection system according to the present invention.

[0027] Figure 4 This is a diagram showing the data acquisition node layout of an integrated rigid connection thermal protection system for the machine head cone according to the present invention.

[0028] Figure 5 This is a schematic diagram of a data packet composition according to the present invention;

[0029] Figure 6 This is a fault diagnosis flowchart of the present invention;

[0030] Figure 7 This is a schematic diagram of the components of a mobile terminal according to the present invention.

[0031] Figure Labels

[0032] 1: Data acquisition node; 2: Data acquisition node at the gap; 3: Rigid heat-resistant tile. Detailed Implementation

[0033] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0034] Those skilled in the art will understand that, unless specifically stated otherwise, the singular forms “a,” “an,” “the,” and “the” used herein may also include the plural forms. It should be further understood that the term “comprising” as used in this specification means the presence of the stated features, integers, steps, operations, elements, and / or components, but does not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0035] At present, the condition monitoring of thermal protection systems mainly relies on ground-based non-destructive testing methods. Although non-destructive testing technologies such as ultrasonic testing and infrared scanning can effectively detect various forms of damage to thermal protection systems on the ground, these methods have long testing cycles and require complex instruments and equipment, making it difficult to meet the rapid turnover and maintenance requirements of commercial space launch vehicles.

[0036] In summary, this embodiment aims to develop a reliable and real-time monitoring method for the thermal protection system of flight-type space launch vehicles, so as to detect faults in the thermal protection system in a timely manner and reduce the maintenance time and cost of flight-type launch vehicles.

[0037] Example 1

[0038] The health management system of the flight-type aerospace launch vehicle thermal protection system in this embodiment includes an airborne terminal, a ground terminal, and a mobile terminal;

[0039] The airborne terminal is located on the body of the space launch vehicle. The airborne terminal includes several data acquisition nodes, and each data acquisition node includes a data acquisition module, a data storage module, a wireless communication module, and a power supply module.

[0040] Furthermore, the ground terminal is located in the spaceport, launch site, and recovery site, and the ground terminal includes a data receiving and storage module, a data processing module, a fault diagnosis module, a database, and a maintenance assistance module;

[0041] Furthermore, the mobile terminal is used for maintenance work, receiving visualized fault information provided by the maintenance assistance module to update the maintenance status.

[0042] like Figure 1The diagram illustrates the functional framework of the flight-based space launch vehicle health management system in this embodiment. This framework comprises four functional modules: data acquisition, data processing, fault diagnosis, and maintenance assistance. Data acquisition is implemented by several data acquisition nodes deployed on the launch vehicle, while data processing, fault diagnosis, and maintenance assistance are performed from the ground.

[0043] The data acquisition module is used to collect temperature data at the connection between the thermal protection system and the metal structure; the data storage module is used to store the raw data collected by the sensors; the wireless communication module operates after the flight of the spacecraft and transmits the collected data to the ground terminal wirelessly; and the power supply module provides a stable power supply for all components of the data acquisition node.

[0044] Specifically, in this embodiment, data acquisition relies on the sensors, signal conditioning circuits, and data acquisition circuits within the data acquisition module. The working principle is as follows: first, the sensors detect the measured physical quantity and convert it into an electrical signal; then, the signal processing circuit performs noise reduction, conditioning, transformation, and conversion operations on the electrical signal; finally, the data acquisition circuit records the data and transmits it to the data storage unit.

[0045] Furthermore, the data receiving and storage module includes a data receiving unit, a data management unit, and a data storage unit.

[0046] The data receiving unit is used to receive packaged data sent by the airborne terminal; the data management unit is used to classify the data according to different node addresses; and the data storage unit is used to partition and store the classified data.

[0047] Furthermore, the data processing module preprocesses and extracts features from the node temperature data.

[0048] Specifically, in this embodiment, the data processing work is completed by the data processing module. The relevant algorithms carried by the data processing module are used to preprocess and extract features from the data. Preprocessing includes data cleaning, data integration, data reduction and data transformation. Feature extraction refers to extracting sensitive features that can reflect the current state of the launch vehicle's thermal protection system from the preprocessed data, which are used to realize subsequent fault diagnosis.

[0049] Furthermore, the fault diagnosis module integrates temperature data, fault feature parameters after feature extraction, ground test data, and historical measurement data, and performs fault diagnosis through a threshold detection method.

[0050] The maintenance assistance work relies on the maintenance assistance module and the mobile terminal to complete the maintenance process. Based on the fault diagnosis results and fault location results, the maintenance process of the whole machine's thermal protection system is generated to guide ground maintenance personnel to complete the maintenance of the thermal protection system.

[0051] Specifically, in this embodiment, the execution process of the fault diagnosis includes: the fault diagnosis module determines the upper and lower thresholds of the threshold detection based on the ground test data and the historical measurement data; after the fault diagnosis module receives the data, it determines whether the data exceeds the upper and lower thresholds; when the data exceeds the upper and lower thresholds, it records the address information of the fault data.

[0052] Figure 2 This paper demonstrates the physical framework of a health management system for a flight-oriented space launch vehicle thermal protection system that implements the aforementioned functions. The main focus is on the distribution of the physical components of the health management system. The health management system consists of an airborne terminal, a ground terminal, and a mobile terminal. The airborne terminal collects and transmits data to the ground terminal, and the ground terminal transmits maintenance information to the mobile terminal, all via wireless communication.

[0053] Specifically, in this embodiment, the airborne terminal consists of several data acquisition nodes. These nodes are arranged in sections between the thermal protection system and the carrier's metal structure, and are installed on the metal structure. They are used to collect temperature data from the surface of the metal structure after thermal protection treatment and to store and record the data. The thermal protection system is divided into a fuselage-covered thermal protection system and a nose cone-integrated rigid connection thermal protection system. The data acquisition node arrangement is as follows: Figure 3 and Figure 4 As shown.

[0054] After the launch vehicle completes its flight mission and returns to land, the monitoring data from the data acquisition nodes is downloaded to the ground terminal via a ZigBee wireless communication network. The wireless communication module of the data acquisition node reads the data from the data storage module and packages the data for transmission to the ground terminal. The data packet format is "node address-time-temperature data," and the specific format of the data packet is as follows: Figure 5 As shown, the first four bits of the data packet contain the address information of the data acquisition node, the fifth to eighth bits contain the acquisition time information, and the ninth to eleventh bits contain the acquisition temperature information. The data receiving and storage module at the ground end receives the node monitoring data, classifies and stores the received data according to the node address information in the first four bits of the data packet, and then transmits it to the data processing module.

[0055] Furthermore, in this embodiment, the data processing module performs data preprocessing and feature extraction for single-node data. Data preprocessing mainly involves operations such as filling in missing values, deleting duplicate values, and removing outliers in the temperature data; data feature extraction mainly involves extracting feature information such as peak value, mean value, and kurtosis of the temperature data, thereby reducing the dimensionality of the time-domain temperature data.

[0056] In addition, the fault diagnosis module acquires preprocessed temperature data, feature extraction data, and historical data, calculates the correlation between the detected temperature data and historical temperature data, and determines whether the peak value, mean value, kurtosis, and correlation coefficient of the temperature detection data exceed the upper and lower thresholds through threshold detection, thereby completing the fault diagnosis of the thermal protection system at the node.

[0057] Furthermore, such as Figure 6 The diagram shows the execution flow of the fault diagnosis module in this embodiment. The maintenance assistance module obtains the fault location result, visualizes the area to be repaired, generates the corresponding maintenance process according to the maintenance manual, and transmits the fault area and maintenance process to the mobile terminal via WIFI wireless transmission to guide ground maintenance personnel to complete the maintenance work of the thermal protection system.

[0058] Furthermore, such as Figure 7 The diagram shows the components of the mobile terminal in this embodiment. The terminal includes a Wi-Fi communication module, a central processing chip, storage components, a power supply, and external measuring equipment, used to receive and store maintenance information and procedures transmitted from the ground terminal. The external measuring equipment assists maintenance personnel in performing further non-destructive testing on the ground.

[0059] As described above, the design process of a thermal protection system health management system provided in this embodiment is as follows:

[0060] STEP 1: Typical Failure Modes of Statistical Thermal Protection Systems;

[0061] STEP2: Analyze the failure phenomena of the thermal protection system through simulation calculations and ground test verification, and determine the variation characteristics of the health status and characteristic parameters of different failure modes;

[0062] STEP3: Based on the heat flow calculation results of the launch vehicle, determine the areas with more severe thermal environment of the launch vehicle, and deploy airborne data acquisition nodes in the areas with more severe thermal environment;

[0063] STEP4: Determine the upper and lower thresholds of the temperature characteristic parameters;

[0064] STEP5: According to Figure 1 and Figure 2 Establish a health management system;

[0065] In summary, the health management system solution for the thermal protection system of the flight-type carrier provided in this embodiment has a functional architecture comprising four layers: data acquisition, data processing, fault diagnosis, and maintenance assistance; and a physical architecture comprising an airborne terminal, a ground terminal, and a mobile terminal. The airborne terminal includes several data acquisition nodes distributed throughout the carrier fuselage. Each data acquisition node includes a data acquisition module, a data storage module, a data transmission module, and a power supply. These nodes are used to collect temperature data measured within the thermal protection system in areas with harsh thermal environments and store the data for post-flight download. The ground terminal contains a data receiving and storage module, a data processing module, a fault diagnosis module, and a maintenance assistance module. The data receiving and storage module receives, classifies, and stores data. The data processing module preprocesses and extracts features from the classified data. The fault diagnosis module deploys a threshold diagnosis method based on temperature feature data to diagnose and locate faults in the thermal protection system. The maintenance assistance module provides visualization of the maintenance area and generates maintenance procedures. The mobile terminal is used to share ground-based fault diagnosis information with ground maintenance personnel, assisting them in their maintenance work.

[0066] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principle of the present invention should also be considered within the scope of protection of the present invention. The technical features of the above embodiments can be combined arbitrarily. For the sake of brevity, not all possible combinations of the technical features in the above embodiments have been described. However, as long as the combination of these technical features does not contradict each other, it should be considered within the scope of this specification.

Claims

1. A health management system for a flight-qualified space vehicle thermal protection system, characterized by, include: Airborne, ground-based, and mobile terminals; The airborne terminal is arranged on the body of the space launch vehicle. The airborne terminal includes several data acquisition nodes. Each data acquisition node includes a data acquisition module, a data storage module, a wireless communication module, and a power supply module. The data acquisition module is used to collect temperature data at the connection between the thermal protection system and the metal structure; the data storage module is used to store the raw data collected by the sensors; the wireless communication module operates after the flight of the spacecraft and transmits the collected data to the ground terminal wirelessly; the power supply module provides a stable power supply for all components of the data acquisition node. The ground terminal includes a data receiving and storage module, a data processing module, a fault diagnosis module, a database, and a maintenance assistance module; The ground terminals are located at spaceports, launch sites, and recovery sites; The data receiving and storage module includes a data receiving unit, a data management unit, and a data storage unit; The data receiving unit is used to receive packaged data sent by the airborne terminal; the data management unit is used to classify and process the data according to different node addresses. The data storage unit is used to partition and store the classified data. The data processing module preprocesses and extracts features from the node temperature data; The preprocessing includes data cleaning, data settling, data summarization, and data transformation; The feature extraction refers to extracting fault-sensitive features from the preprocessed data; The fault diagnosis module integrates temperature data, fault feature parameters after feature extraction, ground test data, and historical measurement data, and performs fault diagnosis through a threshold detection method. The fault diagnosis execution process includes: the fault diagnosis module determines the upper and lower thresholds of the threshold detection based on the ground test data and the historical measurement data; after receiving the data, the fault diagnosis module determines whether the data exceeds the upper and lower thresholds; when the data exceeds the upper and lower thresholds, the address information of the fault data is recorded. The mobile terminal is used for maintenance work, receives visualized fault information provided by the maintenance assistance module, and updates the maintenance status.

2. The health management system for the thermal protection system of a flight-oriented space launch vehicle according to claim 1, characterized in that, The database is used to store historical data, data processing algorithms, and fault diagnosis algorithms.

3. The health management system for the thermal protection system of a flight-oriented space launch vehicle according to claim 1, characterized in that, The maintenance assistance module visualizes the fault area and transmits the fault information to the mobile terminal.

4. The health management system for the thermal protection system of a flight-oriented space launch vehicle according to claim 1, characterized in that, Data transmission between the data acquisition points and the ground terminal is achieved through a ZigBee wireless communication network.

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