High-reliability spacecraft-rocket separation test method based on spacecraft-rocket separation elements

Abstract

This invention relates to a highly reliable satellite-rocket docking and separation test method based on satellite-rocket separation elements, comprising: refining satellite-rocket separation elements; designing various unlocking and separation test conditions according to different combinations of satellite-rocket separation elements, causing the satellite-rocket separation elements to be pulled to their limits in a direction unfavorable to normal separation, thus completing a satellite-rocket separation unlocking margin test; comparing and determining the influence weight of each satellite-rocket separation element on the separation result based on the test results and the state of the satellite-rocket separation elements; optimizing the satellite-rocket docking and separation test according to the influence weight of each satellite-rocket separation element on the separation result, setting satellite-rocket separation elements with influence weights higher than a preset threshold to a state favorable to normal separation. This invention solves the problem of high probability of test anomalies caused by the designer system and optimizes and improves the satellite-rocket docking and separation test method, thereby improving test reliability.

Description

Technical Field

[0001] This invention belongs to the field of overall launch vehicle technology and relates to a highly reliable test method for satellite-rocket docking and separation based on satellite-rocket separation elements. Background Technology

[0002] To ensure the correctness of the mechanical interface design, a series of large-scale ground tests need to be conducted for verification, the most important of which is the spacecraft docking and separation test.

[0003] Before their official launch missions, both domestic and international launch vehicles undergo satellite-rocket docking and separation tests. These tests are ground-based interface tests between large systems, designed to verify and mitigate risks associated with these interfaces. High-density launch vehicles, with their numerous launch missions, short launch cycles, rapid production schedules, and tight delivery plans, require a large number of satellite-rocket docking and separation tests. Given the long-standing lack of comprehensive and in-depth understanding of satellite-rocket docking and separation tests and their influencing factors within the design system, coupled with the frequency of tests, the probability of abnormal phenomena increases with the number of tests, negatively impacting launch missions and exposing a series of problems in testing methods.

[0004] Therefore, in order to solve the problem of frequent abnormal phenomena in experiments due to incomplete and superficial understanding of the factors affecting the experiment, it is urgent to explore and identify the various factors affecting the satellite-rocket docking and separation experiment, clarify the actual impact and weight of each factor, thereby optimizing the experimental method, reducing the probability of abnormal phenomena from the root, forming a highly reliable satellite-rocket docking and separation experimental method based on the factors of satellite-rocket separation, and achieving high reliability of the experiment and eliminating abnormal phenomena. Summary of the Invention

[0005] The technical problem solved by this invention is to overcome the shortcomings of the prior art, propose a highly reliable satellite-rocket docking and separation test method based on the elements of satellite-rocket separation, solve the problem of the high probability of abnormal phenomena in the test caused by the designer's insufficient understanding of the satellite-rocket docking and separation test and its influencing factors, and optimize and improve the satellite-rocket docking and separation test method to improve the reliability of the test.

[0006] The solution of this invention is: a highly reliable satellite-rocket docking and separation test method based on satellite-rocket separation elements, comprising the following steps:

[0007] Based on the structural characteristics of the strap-type connection unlocking device and the reasons for quality problems arising from historical failure tests of satellite-rocket docking and separation, the satellite-rocket separation elements are extracted. These elements include the action of the satellite-rocket separation spring, the matching of the V-shaped locking block and the end frame, the detonation form of the explosive bolts, the installation status of the connecting bolts of the V-shaped locking block, the magnitude of the strap preload, the loading method of the strap preload, and the axial dimension of the satellite end frame.

[0008] Based on different combinations of star-rocket separation elements, various unlocking and separation test conditions are designed to make the star-rocket separation elements be pulled to the extreme in a direction that is not conducive to normal separation, so as to complete the star-rocket separation unlocking margin test.

[0009] Based on the status of the separation elements and the corresponding test results in the historical failure test of the separation of the satellite and rocket, and the status of the separation elements and the corresponding test results in the separation unlocking margin test of the satellite and rocket under different working conditions, the influence weight of each separation element on the separation result is compared and judged.

[0010] Based on the influence weight of each star-rocket separation element on the separation result, the star-rocket docking and separation test is optimized, and star-rocket separation elements with influence weights higher than the preset threshold are set to a state that is conducive to normal separation.

[0011] Furthermore, the unlocking and separation test conditions include Condition 1: The three star-rocket separation factors—the action of the separation spring, the magnitude of the strap preload, and the axial dimension of the satellite end frame—are subjected to extreme pulling in a direction unfavorable to normal separation. Specifically:

[0012] The star-rocket separation spring actuates;

[0013] The preload of the strapping tape is pulled to the lower limit, so that the preload of the strapping tape is in a half-load state;

[0014] The axial dimension of the satellite end frame is not the dimension specified in the "Satellite and Launch Vehicle Docking Dimensions".

[0015] The V-shaped clips were matched with the end frame before the test;

[0016] The explosive bolts are detonated via a double-sided, double-headed normal initiation method.

[0017] All connecting bolts of the V-shaped clamp were installed correctly.

[0018] The preload of the strapping is applied uniformly.

[0019] Under operating condition one, a satellite-rocket separation and unlocking margin test was conducted, and the satellite support descended normally.

[0020] Furthermore, the unlocking and separation test conditions include condition two: all star-rocket separation elements are extreme-directed in a direction unfavorable to normal separation, specifically:

[0021] The star-rocket separation spring actuates;

[0022] Before the test, the V-shaped clips did not match the end frame;

[0023] The explosive bolts were detonated via a single-sided, single-head abnormal detonation.

[0024] The connecting bolts of the V-shaped locking block at the preset location are installed incorrectly;

[0025] Take the upper limit of the strap pretension force;

[0026] The continuous and uninterrupted loading of the wrapping tape causes uneven stress distribution.

[0027] The axial dimension of the satellite end frame is not the dimension specified in the "Satellite and Launch Vehicle Docking Dimensions".

[0028] Under operating condition two, a satellite-rocket separation and unlocking margin test was conducted, with the satellite support tilting and falling.

[0029] Furthermore, the unlocking and separation test conditions include condition three: based on the settings of condition two, the star-rocket separation spring does not move, the V-shaped locking block and end frame are matched before the test, and the settings of other star-rocket separation elements are the same as those of condition two.

[0030] Under operating condition three, a satellite-rocket separation and unlocking margin test was conducted, and the satellite support descended normally.

[0031] Furthermore, the unlocking and separation test conditions include condition four: based on the settings of condition three, the star-rocket separation spring is activated, and the settings of other star-rocket separation elements remain the same as in condition three;

[0032] Under operating condition four, a satellite-rocket separation and unlocking margin test was conducted, during which the satellite support tilted and fell.

[0033] Furthermore, the unlocking and separation test conditions include condition five: based on the settings of condition four, all connecting bolts of the V-shaped locking block are installed normally, and the settings of other star-rocket separation elements are the same as those of condition four.

[0034] Under operating condition 5, a satellite-rocket separation and unlocking margin test was conducted, and the satellite support descended normally.

[0035] Furthermore, the historical failure tests for satellite-rocket docking and separation include Historical Failure Test 1 and Historical Failure Test 2. In Historical Failure Test 1, four satellite-rocket separation factors—the action of the separation spring, the matching of the V-shaped locking block and the end frame, the detonation method of the explosive bolts, and the axial dimensions of the satellite end frame—are in a state unfavorable to normal separation. Specifically:

[0036] The star-rocket separation spring actuates;

[0037] Before the test, the V-shaped clips did not match the end frame;

[0038] The explosive bolts were detonated via a single-sided, single-head abnormal detonation.

[0039] All connecting bolts of the V-shaped clamp were installed correctly.

[0040] The preload of the strap should be within the preset range;

[0041] The preload of the strapping is applied uniformly.

[0042] The axial dimension of the satellite end frame is not the dimension specified in the "Satellite and Launch Vehicle Docking Dimensions".

[0043] In the second historical fault test, four factors related to satellite-rocket separation—the action of the separation spring, the matching of the V-shaped locking block and the end frame, the installation status of the connecting bolts of the V-shaped locking block, and the axial dimension of the satellite end frame—were deemed unfavorable for normal separation. Specifically:

[0044] The star-rocket separation spring actuates;

[0045] Before the test, the V-shaped clips did not match the end frame;

[0046] The explosive bolts are detonated via a double-sided, double-headed normal initiation method.

[0047] The connecting bolts of the V-shaped locking block at the preset location are installed incorrectly;

[0048] The preload of the strap should be within the preset range;

[0049] The preload of the strapping is applied uniformly.

[0050] The axial dimension of the satellite end frame is not specified in the "Satellite and Launch Vehicle Docking Dimensions".

[0051] Furthermore, the comparison and judgment of the influence weight of each star-rocket separation element on the separation result is specifically as follows:

[0052] A comparative analysis was conducted on the star-rocket separation elements and test results of historical fault test 1, historical fault test 2, and unlocking and separation tests under five working conditions. When any three of the four star-rocket separation elements—the action of the star-rocket separation spring, the matching of the V-shaped locking block and the end frame, the detonation mode of the explosive bolt, and the installation status of the connecting bolts of the V-shaped locking block—are in a state unfavorable to normal separation, the probability of abnormal test results is high. It was determined that the action of the star-rocket separation spring, the matching of the V-shaped locking block and the end frame, the detonation mode of the explosive bolt, and the installation status of the connecting bolts of the V-shaped locking block are the main influencing factors that cause abnormal test phenomena.

[0053] A comparative analysis was conducted on the satellite-rocket separation elements and test results in unlocking and separation test conditions two and four. When the satellite was not matched, the V-shaped block around the abnormal installation position of the V-shaped block connecting bolt tilted and fell. After the matching, the satellite was tilted and fell around the V-shaped block near the detonation point of the single-sided single-head explosive bolt. The time for the V-shaped block to detach from the end frame at the abnormal installation position of the V-shaped block connecting bolt was significantly reduced. It was determined that the influence weight of "V-shaped block matching with end frame" was greater than the influence weight of "V-shaped block connecting bolt installation status".

[0054] A comparative analysis was conducted on the satellite-rocket separation elements and test results in historical fault test 1 and unlocking and separation test condition 5. Compared with historical fault test 1, in unlocking and separation test condition 5, under the condition that "the V-shaped locking block and the end frame were matched before the test", even if the "size of the pretension force of the strap" and "the loading method of the pretension force of the strap" were unfavorable, the satellite support not only did not tilt and fall, but fell normally. It was determined that the influence weight of "the matching of the V-shaped locking block and the end frame" was greater than the influence weight of "the detonation method of the explosive bolts", and "the size of the pretension force of the strap" and "the loading method of the pretension force of the strap" were secondary influencing factors that caused the abnormal phenomena in the test.

[0055] The axial dimensions of the satellite end frame are classified as a less significant factor in causing experimental anomalies.

[0056] Based on the degree of influence of each satellite-launch separation element, the comprehensive influence function of each satellite-launch separation element on the experimental result anomalies is established as follows:

[0057] P θ =K(λ1Δ1+λ2Δ2+λ3Δ3+λ4Δ4+λ5Δ5+λ6Δ6+λ7Δ7)

[0058] Among them, P θ Let P be the probability that the experimental result is abnormal, 0 ≤ P θ ≤1; K corresponds to the action of the star-rocket separation spring, which is an amplification factor; Δ1 corresponds to the matching of the V-shaped locking block and the end frame; Δ2 corresponds to the detonation mode of the explosive bolt; Δ3 corresponds to the installation status of the V-shaped locking block connecting bolt; Δ4 corresponds to the magnitude of the preload of the wrapping tape; Δ5 corresponds to the loading method of the preload of the wrapping tape; Δ6 corresponds to the axial dimension of the satellite end frame; Δ7 corresponds to the remaining unverifiable and uncontrollable factors.

[0059] When the star-rocket separation elements corresponding to Δ1 to Δ7 are in a state unfavorable to normal separation, set them to 1; otherwise, set them to 0.

[0060] When the star-arrow separation spring is activated, K is set to 1; when the star-arrow separation spring is not activated, K is set to 0.5.

[0061] λ1 to λ7 are the influence coefficients of the corresponding star-rocket separation elements, and λ1 to λ7 satisfy the following quantitative relationship:

[0062] λ1>λ2, λ3>λ4, λ5>λ6, λ7.

[0063] Furthermore, the influence coefficients of the star-rocket separation factors are as follows: λ1 = 0.4, λ2 = 0.3, λ3 = 0.15, λ4 = 0.05, λ5 = 0.05, λ6 = 0.025, λ7 = 0.025.

[0064] Furthermore, the optimization of the spacecraft-rocket docking and separation test is specifically as follows:

[0065] For the satellite-rocket docking separation test that conforms to the "Satellite and Launch Vehicle Docking Dimension Specification GJB / Z 200-2001" standard, the satellite-rocket separation spring is set to remain stationary and K is set to 0.5. At the same time, a process of matching the V-shaped locking block with the end frame is added to the test and Δ1 is set to 0. Other parameters in the comprehensive influence function are set in a direction that is conducive to normal separation.

[0066] For satellite-rocket docking separation tests where the satellite-rocket mechanical interface does not conform to the "Satellite and Launch Vehicle Docking Dimensions Specification GJB / Z200-2001" standard, the satellite-rocket separation spring is set to actuate in the test, with K set to 1. At the same time, a process of matching the V-shaped locking block with the end frame is added to the test, with Δ1 set to 0. Other parameters in the comprehensive influence function are set in a direction that is conducive to normal separation.

[0067] The advantages of this invention compared to the prior art are:

[0068] (1) This invention proposes a high-reliability star-rocket docking and separation test method based on star-rocket separation elements. Taking the star-rocket docking and separation test of a high-density launch vehicle as an example, the separation unlocking margin test under different working conditions is carried out by comprehensively sorting out the various star-rocket separation elements. After identifying the influence weight of each element on the test based on the test results, the test method is optimized to effectively improve the test reliability and reduce the probability of test anomalies.

[0069] (2) The five working conditions designed in this invention and the selected historical tests can realize the weight comparison of various star-rocket separation elements, and the five working conditions designed can be completed by a set of star-rocket docking and separation test devices, saving test costs.

[0070] (3) Compared with traditional test methods, this invention solves the long-standing problem that designers do not have a comprehensive and in-depth understanding of the influencing factors of the star-rocket docking and separation test. It greatly reduces the probability of abnormal phenomena in the test, has extremely high technical feasibility and application value, and effectively improves the reliability of the test. It has been successfully applied in multiple star-rocket docking and separation tests. Attached Figure Description

[0071] Figure 1 The flowchart shows a high-reliability spacecraft docking and separation test method based on spacecraft-rocket separation elements.

[0072] Figure 2 The star-rocket separation elements proposed in the embodiments of the present invention;

[0073] Figure 3 This is a schematic diagram of the test state for the separation and unlocking margin of the satellite and rocket in an embodiment of the present invention. Detailed Implementation

[0074] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0075] Example 1

[0076] like Figure 1 As shown, the high-reliability spacecraft docking and separation test method based on spacecraft-rocket separation elements of the present invention includes the following steps:

[0077] S1. Based on the structural characteristics of the strap-type connection unlocking device and the reasons for the quality problems caused by the historical failure tests of star-rocket docking and separation, extract the key elements of star-rocket separation.

[0078] After reviewing a series of quality issues and phenomena observed in satellite-rocket separation tests, and based on existing experience and knowledge, the factors affecting the success or failure of satellite-rocket separation tests are summarized into eight items: the action of the satellite-rocket separation spring, the compatibility of the V-shaped clamp and the end frame, the detonation method of the explosive bolts, the installation status of the connecting bolts of the V-shaped clamp, the magnitude of the preload of the strapping tape, the method of applying the preload of the strapping tape, the axial dimensions of the satellite end frame, and other factors that are not verifiable or controllable, such as... Figure 2 As shown.

[0079] The eight key separation factors for the satellite and launch vehicle have been determined. However, the magnitude of each factor's impact on the satellite support's descent attitude is still unclear from a design perspective, and no related experiments have been conducted to investigate this. Therefore, the probability of abnormal descent attitude of the satellite support is tentatively expressed as a function of the combined influence of each separation factor, as follows:

[0080] P θ =f(K, Δ1, Δ2, Δ3, Δ4, Δ5, Δ6, Δ7)

[0081] In the formula:

[0082] P θ —The probability of an abnormal phenomenon occurring in the experiment, 0≤P θ ≤1;

[0083] K – Function of the star-arrow separation spring;

[0084] Δ1 — Matching of the V-shaped card block with the end frame;

[0085] Δ2 — Explosive bolt detonation mode;

[0086] Δ3 — Installation status of the connecting bolts of the V-shaped clamp;

[0087] Δ4 — Magnitude of the preload of the strap;

[0088] Δ5 — Packing method for preload of the strapping;

[0089] Δ6 — Axial dimension of the satellite end frame;

[0090] Δ7 – The remaining unverifiable and uncontrollable factors.

[0091] S2. Design various unlocking and separation test conditions according to different combinations of star-rocket separation elements, so that the star-rocket separation elements are pulled to the limit in a direction that is not conducive to normal separation, and complete the star-rocket separation unlocking margin test.

[0092] All separation elements Δ1 to Δ5 were subjected to extreme deviations in directions unfavorable to normal separation. The extent to which these extreme deviations would cause abnormal phenomena was assessed, and the margin limits were determined. The factors considered in the separation unlock margin test are shown in Table 1. Based on the extreme deviation conditions, the influence weight of each separation element was identified step-by-step using a method of controlling variables individually.

[0093] Table 1. Factors to Consider in the Star-Rocket Separation and Unlocking Margin Test

[0094]

[0095] Taking into account historical fault tests and unlocking margin tests, the occurrence of various separation elements and test anomalies is summarized, as shown in Table 2.

[0096] Table 2. Relationship between Separation Elements and Abnormal Experimental Phenomena

[0097] Experimental Project Separation elements Abnormal phenomena in the experiment Historical Fault Test 1 <![CDATA[K,Δ1,Δ2,Δ6]]> Satellite support tilts and falls Historical Fault Test 2 <![CDATA[K,Δ1,Δ3,Δ6]]> Satellite support tilts and falls Unlock margin test condition 1 <![CDATA[K,Δ4,Δ6]]> Satellite support descended normally Unlock Margin Test Condition 2 <![CDATA[K,Δ1,Δ2,Δ3,Δ4,Δ5,Δ6]]> Satellite support tilts and falls Unlock margin test condition three <![CDATA[Δ2,Δ3,Δ4,Δ5,Δ6]]> Satellite support descended normally Unlock margin test condition four <![CDATA[K,Δ2,Δ3,Δ4,Δ5,Δ6]]> Satellite support tilts and falls Unlock margin test condition five <![CDATA[K,Δ2,Δ4,Δ5,Δ6]]> Satellite support descended normally

[0098] Based on Tables 1 and 2, the status of each separation element in the five design conditions and two historical failure tests of satellite-rocket docking separation is described in detail:

[0099] Unlock margin test condition 1:

[0100] The star-arrow separation spring actuates (K);

[0101] The preload of the strapping tape is pulled to the lower limit, so that the preload of the strapping tape is in a half-load state (Δ4);

[0102] The axial dimension of the satellite end frame is not the dimension specified in the "Sat and Launch Vehicle Docking Dimensions Specification (GJB / Z 200-2001)" (Δ6);

[0103] The V-shaped clips were matched with the end frame before the test;

[0104] The explosive bolts are detonated via a double-sided, double-headed normal initiation method.

[0105] All connecting bolts of the V-shaped clamp were installed correctly.

[0106] The preload of the strapping is applied uniformly.

[0107] Unlock margin test condition two:

[0108] The star-arrow separation spring actuates (K);

[0109] Before the test, the V-shaped card block did not match the end frame (Δ1);

[0110] The explosive bolts were detonated in a single-sided, single-head abnormal manner (Δ2).

[0111] The connecting bolts of the V-shaped locking block at the preset location are installed abnormally (Δ3);

[0112] The preload of the strap is set to the upper limit (Δ4);

[0113] The continuous and uninterrupted loading of the wrapping tape caused uneven stress distribution (Δ5);

[0114] The axial dimension of the satellite end frame is not the dimension specified in the "Satellite and Launch Vehicle Docking Dimensions" (Δ6).

[0115] Unlock margin test condition three:

[0116] The spring does not operate when the star-rocket separation mechanism separates.

[0117] The V-shaped clips and end frames were matched before the test;

[0118] The explosive bolts were detonated in a single-sided, single-head abnormal manner (Δ2).

[0119] The connecting bolts of the V-shaped locking block at the preset location are installed abnormally (Δ3);

[0120] The preload of the strap is set to the upper limit (Δ4);

[0121] The continuous and uninterrupted loading of the wrapping tape caused uneven stress distribution (Δ5);

[0122] The axial dimension of the satellite end frame is not the dimension specified in the "Satellite and Launch Vehicle Docking Dimensions Specification" (Δ6). Unlocking margin test condition four:

[0123] The star-arrow separation spring actuates (K);

[0124] The V-shaped clips and end frames were matched before the test;

[0125] The explosive bolts were detonated in a single-sided, single-head abnormal manner (Δ2).

[0126] The connecting bolts of the V-shaped locking block at the preset location are installed abnormally (Δ3);

[0127] The preload of the strap is set to the upper limit (Δ4);

[0128] The continuous and uninterrupted loading of the wrapping tape caused uneven stress distribution (Δ5);

[0129] The axial dimension of the satellite end frame is not the dimension specified in the "Satellite and Launch Vehicle Docking Dimensions Specification" (Δ6). Unlocking margin test condition five:

[0130] The star-arrow separation spring actuates (K);

[0131] The V-shaped clips and end frames were matched before the test;

[0132] The explosive bolts were detonated in a single-sided, single-head abnormal manner (Δ2).

[0133] All connecting bolts of the V-shaped clamp were installed correctly.

[0134] The preload of the strap is set to the upper limit (Δ4);

[0135] The continuous and uninterrupted loading of the wrapping tape caused uneven stress distribution (Δ5);

[0136] The axial dimension of the satellite end frame is not the dimension specified in the "Satellite and Launch Vehicle Docking Dimensions Specification" (Δ6). Historical Failure Test 1:

[0137] The star-arrow separation spring actuates (K);

[0138] Before the test, the V-shaped card block did not match the end frame (Δ1);

[0139] The explosive bolts were detonated in a single-sided, single-head abnormal manner (Δ2).

[0140] All connecting bolts of the V-shaped clamp were installed correctly.

[0141] The preload of the strap should be within the preset range;

[0142] The preload of the strapping is applied uniformly.

[0143] The axial dimension of the satellite end frame is not the dimension specified in the "Satellite and Launch Vehicle Docking Dimensions" (Δ6).

[0144] Historical Fault Test 2:

[0145] The star-arrow separation spring actuates (K);

[0146] Before the test, the V-shaped card block did not match the end frame (Δ1);

[0147] The explosive bolts are detonated via a double-sided, double-headed normal initiation method.

[0148] The connecting bolts of the V-shaped locking block at the preset location are installed abnormally (Δ3);

[0149] The preload of the strap should be within the preset range;

[0150] The preload of the strapping is applied uniformly.

[0151] The axial dimension of the satellite end frame is not the dimension specified in the "Satellite and Launch Vehicle Docking Dimensions" (Δ6).

[0152] The schematic diagram of the star-rocket separation and unlocking margin test state in this embodiment is as follows: Figure 3 As shown.

[0153] S3. Based on the status of the separation elements and the corresponding test results in the historical fault test of the satellite-rocket docking and separation, and the status of the separation elements and the corresponding test results in the satellite-rocket separation unlocking margin test under different working conditions, compare and judge the weight of each satellite-rocket separation element on the separation result.

[0154] S3 specifically includes:

[0155] A comparative analysis of the star-rocket separation elements and test results for historical fault tests I, II, and unlocking / separation test conditions I, II, III, IV, and V revealed that when any three of the four star-rocket separation elements—the action of the star-rocket separation spring, the matching of the V-shaped locking block and the end frame, the detonation method of the explosive bolts, and the installation status of the connecting bolts of the V-shaped locking block—are unfavorable for normal separation, the probability of abnormal test results is relatively high. Therefore, it was determined that the action of the star-rocket separation spring, the matching of the V-shaped locking block and the end frame, the detonation method of the explosive bolts, and the installation status of the connecting bolts of the V-shaped locking block are the main influencing factors causing abnormal test phenomena.

[0156] A comparative analysis was conducted on the satellite-rocket separation elements and test results in unlocking and separation test conditions two and four. When mismatched, the satellite support tilted and fell around the V-shaped locking block at the abnormal installation position of the V-shaped locking bolt. After matching, the satellite support tilted and fell around the V-shaped locking block near the single-sided detonation point of the explosive bolt. However, the time it took for the V-shaped locking block at the abnormal installation position of the V-shaped locking bolt to detach from the end frame was significantly reduced. This indicates that when the radial movement of the strap is transmitted along the circumferential direction, it no longer stagnates at the abnormal installation position of the V-shaped locking bolt, but rather passes relatively smoothly through the V-shaped locking block and continues to transmit in the direction of movement. This causes the satellite support to eventually tilt and fall around the V-shaped locking block near the single-sided detonation point of the explosive bolt. The different locking points during the tilting and falling of the satellite support indicate that the matching of the V-shaped locking block with the end frame significantly changed the tilting and falling attitude of the satellite support. It was determined that the influence weight of "the matching of the V-shaped locking block with the end frame" is greater than the influence weight of "the installation state of the connecting bolt of the V-shaped locking block."

[0157] A comparative analysis was conducted on the satellite-rocket separation elements and test results in Historical Fault Test 1 and Unlocking and Separation Test Condition 5. Compared with Historical Fault Test 1, in Unlocking and Separation Test Condition 5, under the condition that "the V-shaped locking block and the end frame were matched before the test", even if the "magnitude of the strap pretension force" and "the method of applying the strap pretension force" were unfavorable, the satellite support not only did not tilt and fall, but fell normally. It was determined that the influence weight of "the matching of the V-shaped locking block and the end frame" was greater than the influence weight of "the detonation method of the explosive bolts", and "the magnitude of the strap pretension force" and "the method of applying the strap pretension force" were secondary influencing factors that caused the abnormal phenomena in the test.

[0158] The axial dimensions of the satellite end frame are classified as a less significant factor in causing experimental anomalies.

[0159] In summary, based on the results of the assessment of the influence of each star-rocket separation factor, the probability of the occurrence of experimental anomalies is specified by the following expression.

[0160] P θ =K(λ1Δ1+λ2Δ2+λ3Δ3+λ4Δ4+λ5Δ5+λ6Δ6+λ7Δ7)

[0161] Here, K, as the amplification factor, will increase P when other Δ values ​​are present. θ The numerical values; the influence weights λ1 related to the matching of the V-shaped locking block and the end frame, λ2 related to the detonation mode of the pyrotechnic device, and λ3 related to the installation status of the connecting bolts of the V-shaped locking block are the main influences P. θ The numerical influence coefficients; the influence weights λ4 and λ5 related to the magnitude of the strap preload and the strap preload loading method are for P. θ The influence coefficients with minimal numerical impact; the influence weight λ6 related to the axial dimensions of the satellite end frame cannot be determined; the influence weight λ7 related to other unverifiable control factors also cannot be determined, but qualitatively, the importance of λ6 and λ7 can be ranked after λ4 and λ5, which is consistent with objective experimental phenomena. The influence weights of λ1 to λ7 can be expressed by the following formula:

[0162] λ1>λ2, λ3>λ4, λ5>λ6, λ7.

[0163] Based on the test conditions in Table 2, the amplification factor, separation element and its influence weight under each condition are substituted into the above expression to make the calculated probability of the test anomaly consistent with the actual test phenomenon. Based on design experience and knowledge, by making the probability of the test anomaly in historical fault test 2 and unlocking margin test condition 4 the same, the amplification factor and the influence weight of each separation element can be quantified.

[0164] In this embodiment, λ1 is 0.4, λ2 is 0.3, λ3 is 0.15, λ4 and λ5 are both 0.05, λ6 is 0.025, and λ7 is 0.025. When the star-rocket separation elements corresponding to Δ1 to Δ7 are in a state unfavorable to normal separation, they are set to 1; otherwise, they are set to 0. When the star-rocket separation spring is actuated and not actuated, K is set to 1 and 0.5 respectively, and 0 ≤ P. θ ≤1. In this embodiment, for Δ1 to Δ7, the case of setting it to 1 corresponds to the state of operating condition 2.

[0165] S4. Based on the influence weight of each star-rocket separation element on the separation result, optimize the star-rocket docking and separation test, and set the star-rocket separation elements with influence weights higher than the preset threshold to a state that is conducive to normal separation.

[0166] This method comprehensively identifies several factors affecting separation, including the function of the satellite-rocket separation spring, the compatibility of the V-shaped locking block with the satellite-rocket end frame, the pyrotechnic detonation method, the installation status of the connecting bolts of the V-shaped locking block, the magnitude of the wrapping tape preload, the wrapping tape preload application method, and the axial dimensions of the satellite end frame. After identifying the order of influence as follows: compatibility of the V-shaped locking block with the end frame > pyrotechnic detonation method, installation status of the connecting bolts of the V-shaped locking block > magnitude of the wrapping tape preload, and wrapping tape preload application method, modifications were made to the satellite-rocket docking and separation test method.

[0167] Specifically as follows:

[0168] For the satellite-launch vehicle docking and separation test conforming to the "Satellite and Launch Vehicle Docking Dimensions Specification (GJB / Z200-2001)" standard, based on the high adaptability of the satellite-launch vehicle mechanical interface and the high reliability of the satellite-launch vehicle separation spring, the separation spring was set to remain stationary in the test, i.e., K was set to 0.5. Simultaneously, a process of matching the V-shaped locking block with the end frame was added to the test, i.e., Δ1 was set to 0. Other parameters in the comprehensive influence function were set in a direction favorable to normal separation. Then P... θ The value is at most 0.0125, which greatly reduces the probability of abnormal test results.

[0169] For satellite-launcher docking and separation tests where the satellite-launcher mechanical interface does not conform to the "Satellite and Launch Vehicle Docking Dimensions Specification (GJB / Z200-2001)" standard, given that the compatibility of the satellite-launcher mechanical interface has not been fully verified, the test must include a satellite-launcher separation spring actuation (K set to 1). Simultaneously, a V-shaped locking block matching process with the end frame should be added to the test (Δ1 set to 0). Other parameters in the comprehensive influence function should be set in a direction conducive to normal separation. Then P... θ The value is at most 0.025, which greatly reduces the probability of abnormal test results.

[0170] This method greatly reduces the probability of abnormal phenomena in the experiment, effectively improves the reliability of the experiment, and has extremely high technical feasibility and good application prospects and value.

[0171] Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make possible changes and modifications to the technical solutions of the present invention by utilizing the methods and techniques disclosed above without departing from the spirit and scope of the present invention. Therefore, any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solutions of the present invention shall fall within the protection scope of the technical solutions of the present invention.

Claims

1. A high-reliability satellite-rocket docking and separation test method based on satellite-rocket separation elements, applicable to satellite-rocket docking and separation tests using a strap-type connection and unlocking device, characterized in that... Includes the following steps: Based on the structural characteristics of the strap-type connection unlocking device and the reasons for quality problems arising from historical failure tests of satellite-rocket docking and separation, the satellite-rocket separation elements are extracted. These elements include the action of the satellite-rocket separation spring, the matching of the V-shaped locking block and the end frame, the detonation form of the explosive bolts, the installation status of the connecting bolts of the V-shaped locking block, the magnitude of the strap preload, the loading method of the strap preload, and the axial dimension of the satellite end frame. Based on different combinations of star-rocket separation elements, various unlocking and separation test conditions are designed to make the star-rocket separation elements be pulled to the extreme in a direction that is not conducive to normal separation, so as to complete the star-rocket separation unlocking margin test. Based on the status of the separation elements and the corresponding test results in the historical failure test of the separation of the satellite and rocket, and the status of the separation elements and the corresponding test results in the separation unlocking margin test of the satellite and rocket under different working conditions, the influence weight of each separation element on the separation result is compared and judged. Based on the influence weight of each star-rocket separation element on the separation result, the star-rocket docking and separation test is optimized, and star-rocket separation elements with influence weights higher than the preset threshold are set to a state that is conducive to normal separation.

2. The high-reliability spacecraft docking and separation test method based on spacecraft-rocket separation elements according to claim 1, characterized in that, The unlocking and separation test conditions include Condition 1: The three star-rocket separation factors—the action of the separation spring, the magnitude of the strap preload, and the axial dimension of the satellite end frame—are subjected to extreme pulling in a direction unfavorable to normal separation. Specifically: The star-rocket separation spring actuates; The preload of the strapping tape is pulled to the lower limit, so that the preload of the strapping tape is in a half-load state; The axial dimension of the satellite end frame is not the dimension specified in the "Satellite and Launch Vehicle Docking Dimensions". The V-shaped clips were matched with the end frame before the test; The explosive bolts are detonated via a double-sided, double-headed normal initiation method. All connecting bolts of the V-shaped clamp were installed correctly. The preload of the strapping is applied uniformly. Under operating condition one, a satellite-rocket separation and unlocking margin test was conducted, and the satellite support descended normally.

3. The high-reliability spacecraft docking and separation test method based on spacecraft-rocket separation elements according to claim 2, characterized in that, The unlocking and separation test conditions include condition two: all star-rocket separation elements are pulled to their limits in a direction unfavorable to normal separation, specifically: The star-rocket separation spring actuates; Before the test, the V-shaped clips did not match the end frame; The explosive bolts were detonated via a single-sided, single-head abnormal detonation. The connecting bolts of the V-shaped locking block at the preset location are installed incorrectly; Take the upper limit of the strap pretension force; The continuous and uninterrupted loading of the wrapping tape causes uneven stress distribution. The axial dimension of the satellite end frame is not the dimension specified in the "Satellite and Launch Vehicle Docking Dimensions". Under operating condition two, a satellite-rocket separation and unlocking margin test was conducted, with the satellite support tilting and falling.

4. The high-reliability spacecraft docking and separation test method based on spacecraft-rocket separation elements according to claim 3, characterized in that, The unlocking and separation test conditions include Condition 3: Based on the settings of Condition 2, the star-rocket separation spring does not move, the V-shaped locking block and end frame are matched before the test, and the settings of other star-rocket separation elements are the same as those of Condition 2. Under operating condition three, a satellite-rocket separation and unlocking margin test was conducted, and the satellite support descended normally.

5. The high-reliability spacecraft docking and separation test method based on spacecraft-rocket separation elements according to claim 4, characterized in that, The unlocking and separation test conditions include condition four: based on the settings of condition three, the star-rocket separation spring is activated, and the settings of other star-rocket separation elements remain the same as in condition three; Under operating condition four, a satellite-rocket separation and unlocking margin test was conducted, during which the satellite support tilted and fell.

6. The high-reliability spacecraft docking and separation test method based on spacecraft-rocket separation elements according to claim 5, characterized in that, The unlocking and separation test conditions include condition five: based on the settings of condition four, all connecting bolts of the V-shaped locking block are installed normally, and the settings of other star-rocket separation elements are the same as those of condition four. Under operating condition 5, a satellite-rocket separation and unlocking margin test was conducted, and the satellite support descended normally.

7. The high-reliability spacecraft docking and separation test method based on spacecraft-rocket separation elements according to claim 6, characterized in that, The historical failure tests for satellite-rocket docking and separation include Historical Failure Test 1 and Historical Failure Test 2. In Historical Failure Test 1, four satellite-rocket separation factors—the action of the separation spring, the matching of the V-shaped locking block and the end frame, the detonation method of the explosive bolts, and the axial dimension of the satellite end frame—were set to conditions unfavorable for normal separation. Specifically: The star-rocket separation spring actuates; Before the test, the V-shaped clips did not match the end frame; The explosive bolts were detonated via a single-sided, single-head abnormal detonation. All connecting bolts of the V-shaped clamp were installed correctly. The preload of the strap should be within the preset range; The preload of the strapping is applied uniformly. The axial dimension of the satellite end frame is not the dimension specified in the "Satellite and Launch Vehicle Docking Dimensions". In the second historical fault test, four factors related to satellite-rocket separation—the action of the separation spring, the matching of the V-shaped locking block and the end frame, the installation status of the connecting bolts of the V-shaped locking block, and the axial dimension of the satellite end frame—were deemed unfavorable for normal separation. Specifically: The star-rocket separation spring actuates; Before the test, the V-shaped clips did not match the end frame; The explosive bolts are detonated via a double-sided, double-headed normal initiation method. The connecting bolts of the V-shaped locking block at the preset location are installed incorrectly; The preload of the strap should be within the preset range; The preload of the strapping is applied uniformly. The axial dimension of the satellite end frame is not specified in the "Sat and Launch Vehicle Docking Dimensions".

8. The high-reliability spacecraft docking and separation test method based on spacecraft-rocket separation elements according to claim 7, characterized in that, The comparison and judgment of the influence weight of each star-rocket separation element on the separation result is as follows: A comparative analysis was conducted on the star-rocket separation elements and test results of historical fault test 1, historical fault test 2, and unlocking and separation tests under five working conditions. When any three of the four star-rocket separation elements—the action of the star-rocket separation spring, the matching of the V-shaped locking block and the end frame, the detonation mode of the explosive bolt, and the installation status of the connecting bolts of the V-shaped locking block—are in a state unfavorable to normal separation, the probability of abnormal test results is high. It was determined that the action of the star-rocket separation spring, the matching of the V-shaped locking block and the end frame, the detonation mode of the explosive bolt, and the installation status of the connecting bolts of the V-shaped locking block are the main influencing factors that cause abnormal test phenomena. A comparative analysis was conducted on the satellite-rocket separation elements and test results in unlocking and separation test conditions two and four. When the satellite was not matched, the V-shaped block around the abnormal installation position of the V-shaped block connecting bolt tilted and fell. After the matching, the satellite was tilted and fell around the V-shaped block near the single-sided single-head detonation point of the explosive bolt. The time for the V-shaped block to detach from the end frame at the abnormal installation position of the V-shaped block connecting bolt was significantly reduced. It was determined that the influence weight of "V-shaped block matching with end frame" was greater than the influence weight of "V-shaped block connecting bolt installation status". A comparative analysis was conducted on the satellite-rocket separation elements and test results in historical fault test 1 and unlocking and separation test condition 5. Compared with historical fault test 1, in unlocking and separation test condition 5, under the condition that "the V-shaped locking block and the end frame were matched before the test", even if the "size of the pretension force of the strap" and "the loading method of the pretension force of the strap" were unfavorable, the satellite support not only did not tilt and fall, but fell normally. It was determined that the influence weight of "the matching of the V-shaped locking block and the end frame" was greater than the influence weight of "the detonation method of the explosive bolt", and "the size of the pretension force of the strap" and "the loading method of the pretension force of the strap" were secondary influencing factors that caused the abnormal phenomena in the test. The axial dimensions of the satellite end frame are classified as a less significant factor in causing experimental anomalies. Based on the degree of influence of each satellite-launch separation element, the comprehensive influence function of each satellite-launch separation element on the experimental result anomalies is established as follows: P θ =K(λ1Δ1+λ2Δ2+λ3Δ3+λ4Δ4+λ5Δ5+λ6Δ6+λ7Δ7) Among them, P θ Let P be the probability that the experimental result is abnormal, 0 ≤ P θ ≤1; K corresponds to the action of the star-rocket separation spring, which is an amplification factor; Δ1 corresponds to the matching of the V-shaped locking block and the end frame; Δ2 corresponds to the detonation mode of the explosive bolt; Δ3 corresponds to the installation status of the V-shaped locking block connecting bolt; Δ4 corresponds to the magnitude of the preload of the wrapping tape; Δ5 corresponds to the loading method of the preload of the wrapping tape; Δ6 corresponds to the axial dimension of the satellite end frame; Δ7 corresponds to the remaining unverifiable and uncontrollable factors. When the star-rocket separation elements corresponding to Δ1 to Δ7 are in a state unfavorable to normal separation, set them to 1; otherwise, set them to 0. When the star-arrow separation spring is activated, K is set to 1; when the star-arrow separation spring is not activated, K is set to 0.

5. λ1 to λ7 are the influence coefficients of the corresponding star-rocket separation elements, and λ1 to λ7 satisfy the following quantitative relationship: λ1>λ2, λ3>λ4, λ5>λ6, λ7.

9. The high-reliability spacecraft docking and separation test method based on spacecraft-rocket separation elements according to claim 8, characterized in that, The specific influence coefficients of the star-rocket separation factors are: λ1 = 0.4, λ2 = 0.3, λ3 = 0.15, λ4 = 0.05, λ5 = 0.05, λ6 = 0.025, and λ7 = 0.

025.

10. The high-reliability spacecraft docking and separation test method based on spacecraft-rocket separation elements according to claim 9, characterized in that, The optimization of the spacecraft-rocket docking and separation test is as follows: For the satellite-rocket docking separation test that conforms to the "GJB / Z 200-2001" standard for satellite-launcher docking dimensions, the satellite-rocket separation spring is set to remain stationary and K is set to 0.

5. At the same time, a process of matching the V-shaped locking block with the end frame is added to the test, and Δ1 is set to 0. Other parameters in the comprehensive influence function are set in a direction that is conducive to normal separation. For satellite-launcher docking and separation tests where the satellite-launcher mechanical interface does not conform to the "Satellite and Launch Vehicle Docking Dimensions Specification GJB / Z200-2001" standard, the satellite-launcher separation spring is set to actuate in the test, with K set to 1. At the same time, a process of matching the V-shaped locking block with the end frame is added to the test, with Δ1 set to 0. Other parameters in the comprehensive influence function are set in a direction that is conducive to normal separation.

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