A high-voltage high-power satellite main power cable high-reliability contact point distribution method

Abstract

The application provides a high-reliability contact point distribution method for a high-voltage and high-power satellite main power cable, and aims at a power supply controller using a power connector for output, and comprises the following steps: S1, identifying single machines needing power supply controllers for power distribution, and identifying single machines needing power supply controllers for direct power distribution of a whole satellite platform and a communication cabin; S2, counting power distribution requirements, and further analyzing the single machines identified in step S1; and S3, contact point distribution, matching the output capacity of the power supply controller and the power distribution requirements of the load single machines, and completing the distribution. The method can realize redundant backup of the contact point distribution mode, and improve the reliability and safety of an energy system.

Description

Technical Field

[0001] This invention relates to the field of GEO orbit satellites, and more particularly to a method for allocating highly reliable contacts in high-voltage, high-power satellite main power cables. Background Technology

[0002] The power control unit (PCU) of the previous DFH-4 platform communication satellites used a busbar + M4 distribution stud method to supply power to the high-power loads of the entire satellite platform and payload. The disadvantage of this power distribution method is that special power solder joints are required at the M4 distribution stud locations, placing extremely high demands on cable manufacturing and installation processes, insulation protection, and reliability. This area is also a key inspection point during the satellite's AIT (Automatic In-Process) phase. Another drawback of this traditional power distribution method is the limited diameter of the available power cables. To achieve high-power kilowatt-level power distribution, dozens of wires are often required, increasing the difficulty of ensuring installation quality and reliability.

[0003] With the development of new communication satellite platforms, the power supply and distribution subsystem of the new generation of high-power communication satellites has adopted a new generation of PCUs. Although the new generation of PCUs inherits the features of the previous generation PCU in terms of functional architecture, they are quite different from the previous generation PCUs in terms of power, interfaces, etc. Summary of the Invention

[0004] To address the aforementioned issues, this invention proposes a high-reliability connection point allocation method for high-voltage, high-power satellite main power cables. This method refines power distribution to the smallest level of power terminals, flexibly meeting the PCU direct power distribution requirements of high-voltage, high-power communication satellite platforms while significantly reducing the number of main power cables and improving their redundancy backup capabilities. This enhances the reliability and security of the energy system.

[0005] To achieve the above objectives, the present invention adopts the following solution:

[0006] This invention provides a high-reliability contact distribution method for high-voltage, high-power satellite main power cables, specifically for power controllers using power connector outputs, comprising the following steps:

[0007] S1: Identify individual units that require power distribution from the power controller, and identify individual units in the entire satellite platform and communication cabin that require direct power distribution from the power controller;

[0008] S2: Statistical analysis of power distribution demand, and further analysis of the individual units identified in step S1;

[0009] S3: Contact allocation, which matches the power controller's output capacity with the power distribution requirements of the individual load unit to complete the allocation.

[0010] Furthermore, in step S1, the single units that require direct power distribution from the power controller include high-power single units that need to be turned on for extended periods, single units with power distribution functions, single units with the function of supplying power to heaters, and power processors used in the electric propulsion subsystem.

[0011] Furthermore, the high-power single unit that needs to be kept running for extended periods has a power requirement exceeding the maximum output capacity that other power distribution units on the platform or in the communication module can provide; the single unit with power distribution function has a large power requirement, generally above the kW level, and this type of single unit has the function of distributing power to other single units on the platform or in the communication module; the single unit with the function of supplying power to the heater has a large power requirement, generally above the kW level, and this type of single unit has the function of supplying power to the heaters on the platform or in the communication module; the power processor used in the electric propulsion subsystem is responsible for providing power to the electric propulsion ignition, with a power requirement above the kW level, characterized by high power consumption, high voltage, and a large instantaneous current at the moment of electric propulsion ignition.

[0012] Further, in step S2, the analysis includes the following steps:

[0013] S2-1: Analysis of the maximum power demand P of a single unit during steady-state operation in orbit 单机 ;

[0014] S2-2: Analyze the layout of a single machine.

[0015] Furthermore, in step S2-2, the layout location is generally a platform, a communication module, or a satellite or other special module.

[0016] Furthermore, step S3 specifically includes the following steps:

[0017] S3-1: Analyze the maximum power output capacity P of a single module in the power controller's power output module. 单模块MAX and the number of modules;

[0018] S3-2: Consider the distribution of each power output module inside the power controller unit;

[0019] S3-3: Based on the overall satellite layout, the individual units that require power distribution are initially grouped;

[0020] S3-4: Calculate the number of groups and the total power demand of each unit in step S3-3;

[0021] S3-5: Combining steps S3-1, S3-2 and S3-4, group the output modules of the power controller. The number of groups corresponds to the number of groups in step S3-3. The total power of each group of output modules is greater than or equal to the total power of each individual unit in each group in step S3-4.

[0022] S3-6: Analyze the number of output power interface electrical connectors on a single power output module of the power controller, and the power output capacity of each electrical connector;

[0023] S3-7: Analyze the maximum power output capability P of each terminal of the electrical connector 单个端子 ;

[0024] S3-8: Number the power terminals of the electrical connectors of all power output modules in the same group, according to n×P 单个端子 ≥P 单机 Calculate the number of power terminals n required for power distribution of each single unit;

[0025] S3-9: Calculate the total output power of all power terminals on a single module. The total output power ≤ the maximum power output capacity of the single module P. 单模块MAX ;

[0026] S3-10: Compare the output power of each module and try to make the output power comparable to ensure power balance among the modules.

[0027] Further, in step S3-3, the grouping includes platform units: unit 1, unit 2, unit 3; communication cabin north panel units: unit 4, unit 5; communication cabin south panel units: unit 6, unit 7.

[0028] Furthermore, in steps S3-4, the total power demand P of each group of individual machines... 组单机功率总和 =P 单机1 +P 单机2+… .

[0029] Furthermore, in steps S3-5, the power output modules in each group should be as close as possible to each other in the individual distribution of the power controller to facilitate the routing of the main power cable.

[0030] Furthermore, in steps S3-8, considering the principle of redundancy backup, n cannot all be distributed on a single power output module, and the number of distributed power output modules is ≥2.

[0031] The beneficial effects of this invention are:

[0032] This invention proposes a main power cable contact allocation method based on high-voltage, high-power satellites, which can achieve redundancy backup of the contact allocation method and improve the reliability and security of the energy system. This method can be extended to high-voltage, high-power high-orbit communication satellite platforms. Attached Figure Description

[0033] Figure 1 This is a block diagram showing the connection relationship of the power controller in an embodiment of the present invention.

[0034] Figure 2This is a schematic diagram of the overall structure of the power controller in an embodiment of the present invention.

[0035] Figure 3 This is a schematic diagram of the power output electrical connector contacts in an embodiment of the present invention.

[0036] Figure 4 This is a diagram showing different power configurations of the power controller in an embodiment of the present invention. Detailed Implementation

[0037] To make the technical solutions and advantages of the present invention clearer, the technical solutions of the embodiments of the present invention will be fully described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0038] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0039] With the development of new communication satellite platforms, the power supply and distribution subsystem of the new generation of high-power communication satellites has adopted a new generation of PCUs. While the new generation PCU inherits the functional architecture of its predecessor, it differs significantly in power output and interfaces. In terms of high-power power distribution across the entire satellite, the new generation PCU's power output module uses high-power connectors, replacing the traditional busbar + M4 distribution stud method. This saves space on individual unit panels, significantly reduces the number of distribution cables, increases the current capacity of individual cables, improves the overall reliability of satellite power distribution, and ensures convenient and reliable installation and protection.

[0040] To address the power output characteristics of high-voltage, high-power communication satellite power controllers that utilize high-power electrical connectors for power distribution, a highly reliable connection allocation method for the main power cable of high-voltage, high-power satellites is proposed. This method considers power output balance between modules and power distribution redundancy backup to improve power distribution reliability.

[0041] Depending on the overall power requirements of the satellite, the power controller can accommodate power output expansion from 7.2kW to 21.6kW through different combinations of modules. The power controller is configured with varying numbers of power output modules based on the power output requirements. Each power output module has the same number of positive and negative power output connectors, and the cable output from these connectors is defined as the main power cable.

[0042] This invention proposes a highly reliable contact allocation method for the main power cable of a high-voltage, high-power communication satellite. This scheme is designed for power controllers using power connector outputs, considering power output balance between modules and power distribution redundancy backup to improve power distribution reliability.

[0043] 1) Identify the individual units that require power distribution from the power controller.

[0044] The individual units of the entire satellite platform and communication module that require direct power supply from the power controller were identified. The characteristics of these individual units are as follows:

[0045] ① High-power single unit that needs to be turned on for a long time: Its power requirement is greater than the maximum output capacity that other power distribution single units on the platform or in the communication cabin can provide.

[0046] ② Standalone units with power distribution function: These standalone units have a large power requirement, generally above kW. These standalone units have the function of distributing power to other standalone units on the platform or in the communication cabin.

[0047] ③ Standalone units with power supply function for heaters: These standalone units have a large power requirement, generally above kW. These standalone units have the function of power supply for platform or communication cabin heaters.

[0048] ④ Power processor used in electric propulsion subsystem: This type of unit is responsible for providing power to electric propulsion ignition. The power requirement is above kW. It has the characteristics of high power consumption and high voltage. The instantaneous current is also large during electric propulsion ignition.

[0049] 2) Statistics on power distribution demand

[0050] Further analysis is conducted on the single-machine statistics compiled in the previous step. The analysis content is as follows:

[0051] ① Maximum power requirement of a single unit: The maximum power P of a single unit during steady-state operation in orbit. 单机 ;

[0052] ②Single unit layout location: The single unit is located on the platform, communication compartment, or other special compartments of the satellite;

[0053] 3) Contact allocation

[0054] A power matching process is required based on the output capacity of the power controller and the power distribution requirements of the individual load unit. The process is as follows:

[0055] ①Analyze the maximum power output capacity P of a single module of the power controller's power output module. 单模块MAX and the number of modules;

[0056] ②Consider the distribution location of each power output module inside the power controller unit;

[0057] ③ Based on the overall satellite layout, the individual units requiring power distribution are initially grouped, for example: platform units: unit 1, unit 2, unit 3; communication module north panel units: unit 4, unit 5; communication module south panel units: unit 6, unit 7, etc.

[0058] ④ Calculate the number of groups and the total power demand of each unit in step ③, P. 组单机功率总和 =P 单机1 +P 单机2+。。。 ;

[0059] ⑤ Combining ①②④, group the output modules of the power controller. The number of groups should correspond to ③, and the total power of each group's output modules should be ≥ the total power of each individual unit in ④. 组单机功率总和 In each group, the power output modules should be placed as close as possible to each other in the individual distribution of the power controller to facilitate the routing of the main power cables.

[0060] ⑥ Analyze the number of output power interface electrical connectors on a single power output module of the power controller, and the power output capacity of each electrical connector;

[0061] ⑦ Analyze the maximum power output capability P of each terminal of the electrical connector. 单个端子 ;

[0062] ⑧ Number the power terminals of the electrical connectors of all power output modules in the same group, according to n×P 单个端子 ≥P 单机 Calculate the number of power terminals n required for power distribution of each single unit. Considering the principle of redundancy backup, n cannot all be distributed on one power output module. The number of distributed power output modules must be ≥2.

[0063] ⑨ Calculate the total output power of all power terminals on a single module. The total output power ≤ the maximum power output capacity P of the single module. 单模块MAX ;

[0064] ⑩ Compare the output power of each module and try to make the output power comparable to ensure power balance among the modules.

[0065] The technical solution of the present invention will be described below using a 14.4kW power controller of a certain platform as an example.

[0066] 1.1 Overview

[0067] The power controller in the high-voltage, high-power high-orbit communication satellite platform adopts a motherboard + module combination design concept, with a high degree of modularity. Different module combinations can be used to expand the overall output power from 7.2kW to 21.6kW. The types and positions of modules configured for different power levels are as follows: Figure 4 As shown.

[0068] 1.2 Statistics of individual power distribution units

[0069] The power output of the power controller is achieved through the shunt regulator module (SUN). The shunt regulator module provides a stable 100V bus voltage to the load unit. The power controller's direct power distribution units are divided into the following categories:

[0070] ①Platform Integrated Business Unit: Responsible for telemetry and remote control of each individual load on the platform, 100V power distribution, and heater power distribution;

[0071] ② Load Integrated Service Unit: Responsible for telemetry and remote control of each individual load unit, and power distribution of heaters;

[0072] ③ Load power distribution unit: responsible for the 100V power supply of each individual unit of the load;

[0073] ④ Power processing unit: The power controller of the electric propulsion system is responsible for converting 100V voltage into kilovolt high voltage.

[0074] The overall satellite connection diagram of the power controller is attached. Figure 1 .

[0075] 1.3 Power Distribution Demand Statistics

[0076] Power requirements and layout grouping both take into account satellites of a certain platform.

[0077]

[0078]

[0079] 1.4 Contact Allocation Method

[0080] A schematic diagram of the overall structure of the 14.4kW power controller is attached. Figure 2 As shown, the entire unit has six shunt regulator modules, each with one positive and one negative electrical connector. Each connector has three contacts, resulting in a total of 18 positive power contacts and 18 negative power contacts for the power controller's 100V bus output. Since power distribution generally requires an equal number of positive and negative lines (i.e., one unit has two positive power lines and two negative power lines), the contact allocation is only considered for the positive power connectors; the negative power connectors are allocated in the same way.

[0081] ① Power distribution capacity

[0082] The maximum current that a single contact terminal of the power distribution output connector can carry, after considering Class I derating, is 20A. Therefore, the power distribution current of a single contact terminal does not exceed 20A, and the maximum output current of a single SUN module is 45A.

[0083] ② Power distribution unit grouping

[0084] See the table in Section 1.3 for grouping; groups with the same group number are grouped together.

[0085] ③Number

[0086] The six SUN modules are numbered SUN1 to SUN6; the electrical connectors are numbered as follows: the positive power connector is numbered SUN... n -X1, power negative connector part number SUN n -X2, n = 1 to 6. The three contacts of each electrical connector are numbered 1 to 3 according to the electrical connector type specification. See attached diagram. Figure 3 .

[0087] ④Statistics on power distribution demand for individual units

[0088]

[0089]

[0090] ⑤ Contact point allocation

[0091] Contact allocation follows these principles:

[0092] 1. From the perspective of reliability and safety, the number of positive or negative power distribution contacts allocated to the load should be even, and the number should be at least 2 (if one fails, the other is a redundant backup).

[0093] 2. When allocating power contacts for the six SUN modules, redundancy and backup between SUN modules should be considered. Positive or negative contacts for the same device should come from different SUN modules.

[0094] 3. Consider that the output capacity of a SUN module is 45A, and the single point does not exceed 20A. That is, the actual current that each contact of the electrical connector will carry after connecting the load should not exceed 20A, and the total output current of the three points of an electrical connector should be less than 45A.

[0095] 4. Considering power balance, the output current of each SUN module is roughly balanced.

[0096] Table 6-1 shows the contact allocation method for a certain communication satellite, which has been verified in orbit.

[0097] Table 6-1 Distribution Method of Main Power Cable Connection Points for a Communication Satellite

[0098]

[0099]

[0100] In the description of this specification, references to terms such as "an embodiment" and "example" refer to specific features, structures, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms are not necessarily intended to refer to corresponding embodiments or examples in a suitable manner.

[0101] It must be pointed out that the above description of the embodiments is not intended to limit the invention but only to help understand the core idea of ​​the invention. For those skilled in the art, any improvements to the invention and equivalent alternatives made to the invention without departing from the principle of the invention are also within the scope of protection of the claims of the invention.

Claims

1. A high-reliability contact distribution method for high-voltage, high-power satellite main power cables, specifically for power controllers using power connector outputs, characterized in that... Includes the following steps: S1: Identify individual units that require power distribution from the power controller, and identify individual units in the entire satellite platform and communication cabin that require direct power distribution from the power controller; The single units that require direct power distribution from the power controller include high-power single units that need to be kept on for a long time, single units with power distribution functions, single units with the function of supplying power to heaters, and power processors used in electric propulsion subsystems. S2: Statistical analysis of power distribution demand, focusing on the individual units identified in step S1; The analysis includes the following steps: S2-1: Analysis of the maximum power demand P of a single unit during steady-state operation in orbit 单机 ; S2-2: Analysis of single-machine layout; S3: Contact allocation, which matches the power controller's output capacity with the power distribution requirements of the individual load unit to complete the allocation; Step S3 specifically includes the following steps: S3-1: Analyze the maximum power output capacity P of a single module in the power controller's power output module. 单模块MAX and the number of modules; S3-2: Consider the distribution of each power output module inside the power controller unit; S3-3: Based on the overall satellite layout, the individual units requiring power distribution are grouped; the grouping includes platform units, communication module north panel units, and communication module south panel units. S3-4: Calculate the number of groups and the total power demand of each unit in step S3-3; S3-5: Combining steps S3-1, S3-2 and S3-4, group the output modules of the power controller. The number of groups corresponds to the number of groups in step S3-3. The total power of each group of output modules is greater than or equal to the total power of each individual unit in each group in step S3-4. S3-6: Analyze the number of output power interface electrical connectors on a single power output module of the power controller and the power output capability of each electrical connector; S3-7: Analyze the maximum power output capability P of each terminal of the electrical connector 单个端子 ; S3-8: Number the power terminals of the electrical connectors of all power output modules in the same group, according to n×P 单个端子 ≥P 单机 Calculate the number of power terminals n required for power distribution of each single unit; S3-9: Calculate the total output power of all power terminals on a single module. The total output power ≤ the maximum power output capacity of the single module P. 单模块MAX ; S3-10: Compare the output power of each module to make the output power similar and ensure power balance among modules.

2. The method according to claim 1, characterized in that, The high-power single unit that needs to be kept running for a long time has a power requirement greater than the maximum output capacity that other power distribution units on the platform or in the communication module can supply; the single unit with power distribution function has a large power requirement, in the kW range or above, and this type of single unit has the function of distributing power to other single units on the platform or in the communication module; the single unit with the function of supplying power to the heater has a large power requirement, in the kW range or above, and this type of single unit has the function of supplying power to the heaters on the platform or in the communication module; the power processor used in the electric propulsion subsystem is responsible for providing power to the electric propulsion ignition, with a power requirement in the kW range or above, and is characterized by high power consumption, high voltage, and large instantaneous current at the moment of electric propulsion ignition.

3. The method according to claim 1, characterized in that, In step S2-2, the layout location is a platform, a communication module, or a satellite or other special modules.

4. The method according to claim 1, characterized in that, In steps S3-5, the power output modules in each group should be kept adjacent to each other in the individual distribution of the power controller to facilitate the routing of the main power cable.

5. The method according to claim 1, characterized in that, In steps S3-8, considering the principle of redundancy backup, n power terminals cannot all be distributed on one power output module, and the number of distributed power output modules is ≥2.

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