Additive manufacturing lightweight modular single-component propulsion system based on SLM forming

Abstract

The invention relates to the technical field of single-component propulsion systems of satellite constellations and internet satellites, and provides an additive manufacturing lightweight modular single-component propulsion system based on SLM forming, which comprises a piston storage tank, a gas adding and discharging valve, a liquid adding and discharging valve, a pressure sensor, a filter, a first electromagnetic valve, a second electromagnetic valve, a single-component thrust chamber and a plug, the gas charging and discharging valve, the liquid charging and discharging valve, the pressure sensor, the filter, the first electromagnetic valve, the second electromagnetic valve, the single-component thrust chamber and the plug are respectively connected to the bottom of the piston storage tank; the piston storage box comprises a storage box shell, a storage box piston and a shell end socket, the storage box shell is of a follow-up fine flow channel thin-wall bearing structure, the storage box piston is arranged in an inner cavity of the storage box shell and is in dynamic seal with the storage box shell through a double-O-shaped ring, and the end of the storage box shell is fixedly connected with the shell end socket. The conventional assembly and conduit connection mode of the propulsion system is simplified, a distributed configuration is avoided, conduits and supports are reduced, and assembly welding of the conduits is canceled.

Description

Technical Field

[0001] The present invention relates to the technical field of monopropellant propulsion systems for satellite constellations and Internet satellites, and in particular to an additively manufactured lightweight modular monopropellant propulsion system based on SLM forming. Background Art

[0002] At present, domestic satellite constellations and Internet satellites are developing rapidly, but the low production capacity and high cost of mass production of satellites in my country are bottlenecks restricting the development of satellite constellations and Internet satellites. According to the weight and size of small satellites, the propulsion system adopts a relatively high-performance anhydrous hydrazine monocomponent propulsion system to achieve satellite attitude control, orbit control and formation control. Based on conventional propulsion system manufacturing technology, the propulsion system is a distributed configuration, and the single machines in the system are connected by ducts. As a result, there are problems such as complex structure, heavy weight, low development efficiency and high manufacturing cost. It is urgent to carry out lightweight and modular design based on additive manufacturing technology to improve rapid response manufacturing capabilities.

[0003] A green monopropellant propulsion system is disclosed in a Chinese patent document with the publication number CN117446214A, which connects a surface tension tank with a solenoid valve and a monopropellant thrust chamber through a conduit. An additively manufactured conformal fine flow channel thin-walled load-bearing lightweight piston tank structure that does not involve SLM forming.

[0004] A Chinese patent document with the publication number CN117446216A discloses a modular green monopropellant propulsion system suitable for a cubic satellite, which connects a non-metallic diaphragm tank with a solenoid valve and a monopropellant thrust chamber through a conduit. It does not involve an additively manufactured conformal fine flow channel thin-walled load-bearing lightweight piston tank structure formed by SLM.

[0005] A Chinese patent document with the publication number CN212313906U discloses a modular monopropellant propulsion system suitable for spacecraft, in which a tank, a filter, a self-locking valve, a pressure sensor, an engine, and a charging and discharging valve are connected and installed on a frame through a conduit. Additive manufacturing of a conformal fine flow channel thin-walled load-bearing lightweight piston tank structure that does not involve SLM forming.

[0006] In the Chinese patent document with the announcement number CN107891999A, a monocomponent micro-propulsion module device and a pressurization method based on additive manufacturing technology are disclosed, and the mounting interfaces of various components of the device are realized by additive manufacturing. An additive manufacturing conformal fine flow channel thin-wall load-bearing lightweight piston tank structure that does not involve SLM forming is disclosed. Summary of the invention

[0007] In view of the defects in the prior art, the object of the present invention is to provide an additively manufactured lightweight modular monocomponent propulsion system based on SLM forming.

[0008] According to the present invention, an additive manufacturing lightweight modular monopropellant propulsion system based on SLM forming is provided, comprising: a piston tank, an air addition and exhaust valve, a liquid addition and exhaust valve, a pressure sensor, a filter, a first solenoid valve, a second solenoid valve, a monopropellant thrust chamber and a plug, wherein the air addition and exhaust valve, the liquid addition and exhaust valve, the pressure sensor, the filter, the first solenoid valve, the second solenoid valve, the monopropellant thrust chamber and the plug are respectively connected to the bottom of the piston tank;

[0009] The piston tank includes a tank shell, a tank piston and a shell head. The tank shell is a thin-walled load-bearing structure with a conformal fine flow channel. A tank piston is arranged in the inner cavity of the tank shell. The tank piston is dynamically sealed with the tank shell through a double O-ring, and the shell head is fixedly connected to the end of the tank shell.

[0010] Preferably, a conformal fine flow channel is provided on the tank shell, the conformal fine flow channel is used to transport the propellant, and the diameter of the conformal fine flow channel is ≤1mm, and the cross-section of the conformal fine flow channel is rhombus-shaped.

[0011] Preferably, a plurality of interfaces are provided on the conformal fine flow channel, including a first interface, a second interface, a third interface, a fourth interface, a fifth interface, a sixth interface, a seventh interface and an eighth interface. The first interface is connected to the gas adding and discharging valve, the second interface is connected to the plug, the third interface is connected to the pressure sensor, the fourth interface is connected to the liquid adding and discharging valve, the fifth interface is connected to the filter, the sixth interface is connected to the first solenoid valve, the seventh interface is connected to the second solenoid valve, and the eighth interface is connected to the single-component thrust chamber.

[0012] Preferably, the tank housing and the fifth interface are integrally formed by additive manufacturing, and the fifth interface is a filter housing.

[0013] Preferably, the tank shell, the tank piston and the shell head are all manufactured by additive manufacturing using TC4 titanium alloy.

[0014] Preferably, the piston storage box is spherical, the wall thickness of the piston storage box is ≤2mm, and the pressure resistance of the piston storage box is ≥3.6MPa.

[0015] Preferably, the inner cavity of the tank shell is divided into an air cavity and a liquid cavity by a tank piston, the air cavity is filled with liquid ammonia through an air adding and discharging valve, and the liquid cavity is filled with anhydrous hydrazine through a liquid adding and discharging valve, and the single component thrust chamber is switched between constant thrust output and variable thrust output by piston tank temperature control.

[0016] Preferably, the filter comprises a filter housing, a filter screen assembly and a filter head, the filter head is connected to the top of the filter housing, and the filter screen assembly is installed inside the filter housing;

[0017] The filter housing is the fifth interface. The filter housing and the tank housing are integrally formed by additive manufacturing, and the filter head is connected to the filter housing by spot welding.

[0018] Preferably, the gas adding and discharging valve, the liquid adding and discharging valve, the pressure sensor, the filter, the first solenoid valve, the second solenoid valve, the single component thrust chamber and the plug are respectively inserted into the bottom of the tank shell by screws, and the shell head is connected to the tank shell by welding.

[0019] Preferably, the piston storage box has 6 interface ears for external installation, and the interface ears are through holes with a diameter of 5.5 mm.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] The present invention is based on the TC4 titanium alloy additive manufacturing technology formed by SLM, realizes the thin-walled load-bearing tank structure with fine flow channels, integrates and modularizes the installation structure of the gas addition and exhaust valve, the liquid addition and exhaust valve, the pressure sensor, the filter, the first solenoid valve, the second solenoid valve and the single-component thrust chamber, simplifies the conventional components of the propulsion system and the connection mode of the conduit, reduces the conduits and brackets, and cancels the assembly welding of the conduits. Therefore, the design requirements of lightweight, modular and integrated propulsion systems are met. It can be applied to mass-produced propulsion systems with limited weight and size for satellite constellations and Internet satellites. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Other features, objects and advantages of the present invention will become more apparent from the detailed description of non-limiting embodiments made with reference to the following drawings:

[0023] Figure 1 It is a schematic diagram of a lightweight modular monopropellant propulsion system of additive manufacturing based on SLM forming of the present invention;

[0024] Figure 2 It is a schematic diagram of the structure of the thin-walled load-bearing tank with fine flow channels manufactured by additive manufacturing based on SLM forming of the present invention;

[0025] Figure 3 It is a schematic cross-sectional view of the structure of a thin-walled load-bearing tank with a conformal fine flow channel manufactured by additive manufacturing based on SLM forming of the present invention.

[0026] The figure shows: 1-piston tank; 2-gas adding and discharging valve; 3-liquid adding and discharging valve; 4-pressure sensor; 5-filter; 6-first solenoid valve; 7-second solenoid valve; 8-single component thrust chamber; 9-plug; 10-first interface; 11-second interface; 12-third interface; 13-fourth interface; 14-fifth interface; 15-sixth interface; 16-seventh interface; 17-eighth interface; 18-tank shell; 19-tank piston; 20-shell head; 21-double O-ring. DETAILED DESCRIPTION

[0027] The present invention is described in detail below in conjunction with specific embodiments. The following embodiments will help those skilled in the art to further understand the present invention, but are not intended to limit the present invention in any form. It should be noted that, for those of ordinary skill in the art, several changes and improvements can also be made without departing from the concept of the present invention. These all belong to the protection scope of the present invention.

[0028] Example 1

[0029] According to the present invention, a lightweight modular monopropellant propulsion system based on SLM forming is provided. Figure 1-3 As shown, the size is ≤220mm×200mm×160mm, and the total impact is ≥2000N·s. It includes: a piston tank 1, a gas adding and discharging valve 2, a liquid adding and discharging valve 3, a pressure sensor 4, a filter 5, a first solenoid valve 6, a second solenoid valve 7, a single component thrust chamber 8 and a plug 9. The gas adding and discharging valve 2, the liquid adding and discharging valve 3, the pressure sensor 4, the filter 5, the first solenoid valve 6, the second solenoid valve 7, the single component thrust chamber 8 and the plug 9 are all integrated and installed at the bottom of the piston tank 1. The piston tank 1 is spherical, the wall thickness of the piston tank 1 is ≤2mm, and the pressure resistance of the piston tank 1 is ≥3.6MPa. There are 6 interface ears installed with the outside on the piston tank 1, and the interface ears are through holes with a diameter of 5.5mm. Preferably, the gas adding and discharging valve 2, the liquid adding and discharging valve 3, the pressure sensor 4 and the plug 9 are connected to the tank housing 18 by threads, and preferably, the first solenoid valve 6, the second solenoid valve 7 and the monopropellant thrust chamber 8 are connected to the tank housing 18 by screws. The first solenoid valve and the second solenoid valve ensure secondary insurance during filling, that is, reduce the risk of propellant entering the monopropellant thrust chamber when the solenoid valve has internal leakage.

[0030] like Figure 2 As shown, the conformal fine flow channel on the piston tank 1 is provided with eight interfaces, including the first interface 10, the second interface 11, the third interface 12, the fourth interface 13, the fifth interface 14, the sixth interface 15, the seventh interface 16 and the eighth interface 17. The second interface 11 is a test port, which is used to pass the protective gas when the shell head 20 is welded with the tank shell 18. Among them, the first interface 10 is connected to the gas adding and discharging valve 2, the second interface 11 is connected to the plug 9, the third interface 12 is connected to the pressure sensor 4, the fourth interface 13 is connected to the liquid adding and discharging valve 3, the fifth interface 14 is connected to the filter 5, the sixth interface 15 is connected to the first solenoid valve 6, the seventh interface 16 is connected to the second solenoid valve 7, and the eighth interface 17 is connected to the single component thrust chamber 8. Preferably, the fifth interface 14 is a filter housing, which is integrally formed with the tank shell 18 by additive manufacturing. Preferably, the conformal fine flow channel is attached to the tank shell 18 and is additively manufactured together with the tank shell 18.

[0031] like Figure 3As shown, the piston tank 1 includes a tank shell 18, a tank piston 19 and a shell head 20, all of which are made of TC4 titanium alloy additive manufacturing. The tank shell 18 is a thin-walled bearing structure with a conformal fine flow channel. The flow channels for conveying propellants are all conformally additively manufactured on the tank shell 18. The diameter of the conformal fine flow channel is ≤1mm, and the cross-section of the conformal fine flow channel is a diamond shape. The tank piston 19 is dynamically sealed with the tank shell 18 through a double O-ring 21, and the shell head 20 is connected to the tank shell 18 by welding.

[0032] The filter 5 includes a filter housing, a filter screen assembly and a filter head. The filter head is connected to the top of the filter housing, and the filter screen assembly is installed inside the filter housing. The filter housing is the fifth interface 14. The filter housing and the tank housing 18 are integrally formed by additive manufacturing, and the filter head is connected to the filter housing by spot welding.

[0033] Example 2

[0034] This embodiment 2 is completed on the basis of embodiment 1 and is a preferred embodiment. Specifically:

[0035] Ammonia is selected as the pressurized gas, and anhydrous hydrazine is selected as the propellant. The tank piston 19 in the piston tank 1 divides the tank into an air chamber and a liquid chamber. The air chamber is filled with liquid ammonia through the gas filling and exhaust valve 2, and the liquid chamber is filled with anhydrous hydrazine through the liquid filling and exhaust valve 3. The saturated vapor pressure of liquid ammonia is controlled by controlling the temperature of the piston tank 1, and the inlet pressure of the monopropellant thrust chamber 8 is controlled, thereby controlling the output thrust of the monopropellant thrust chamber 8. The heat capacity of the additively manufactured lightweight modular monopropellant propulsion system provides liquid ammonia vaporization heat, and the thrust output of the monopropellant thrust chamber 8 remains basically unchanged within a few minutes. If the temperature of the piston tank 1 is different, the thrust output of the monopropellant thrust chamber 8 will also change. According to the temperature range of the piston tank 1 of 5°C to 53.1°C, the saturated vapor pressure of liquid ammonia corresponds to 0.51MPa-2.2MPa, and the thrust variable range of the monopropellant thrust chamber 8 is 0.37N-1.5N.

[0036] The additively manufactured lightweight modular monopropellant propulsion system controls the temperature of the piston tank 1, so that the monopropellant thrust chamber 8 can output either constant thrust or variable thrust.

[0037] Example 3

[0038] This embodiment 3 is completed on the basis of embodiment 1 and is a preferred embodiment. Specifically:

[0039] Helium is selected as the boost gas, anhydrous hydrazine is selected as the propellant, and the additively manufactured lightweight modular monopropellant propulsion system is in the drop pressure working mode, with a drop pressure ratio of 2.3:1, and the initial boost pressure range of the piston tank 1 can be 2.2MPa-1.0MPa. When the initial boost pressure is 2.2MPa, the drop pressure working pressure range is 2.2MPa-0.95MPa, and the output thrust range of the monopropellant thrust chamber 8 is 1.5N-0.67N; when the initial boost pressure is 1.0MPa, the drop pressure working pressure range is 1.0MPa-0.43MPa, and the output thrust range of the monopropellant thrust chamber 8 is 0.7N-0.31N.

[0040] In the description of the present application, it should be understood that the terms "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present application.

[0041] The above describes the specific embodiments of the present invention. It should be understood that the present invention is not limited to the above specific embodiments, and those skilled in the art can make various changes or modifications within the scope of the claims, which does not affect the essence of the present invention. In the absence of conflict, the embodiments of the present application and the features in the embodiments can be combined with each other arbitrarily.

Claims

1. A lightweight modular monopropellant propulsion system based on SLM forming, characterized in that: include: A piston tank (1), an air addition and discharge valve (2), a liquid addition and discharge valve (3), a pressure sensor (4), a filter (5), a first solenoid valve (6), a second solenoid valve (7), a single component thrust chamber (8) and a plug (9), wherein the air addition and discharge valve (2), the liquid addition and discharge valve (3), the pressure sensor (4), the filter (5), the first solenoid valve (6), the second solenoid valve (7), the single component thrust chamber (8) and the plug (9) are respectively connected to the bottom of the piston tank (1); The piston tank (1) comprises a tank shell (18), a tank piston (19) and a shell head (20); the tank shell (18) is a thin-walled load-bearing structure with a conformal fine flow channel; the tank piston (19) is arranged in the inner cavity of the tank shell (18); the tank piston (19) is dynamically sealed with the tank shell (18) via a double O-ring (21); and the shell head (20) is fixedly connected to the end of the tank shell (18).

2. The SLM-based additive manufacturing lightweight modular monopropellant propulsion system according to claim 1, characterized in that: The tank shell (18) is provided with a conformal fine flow channel, the conformal fine flow channel is used to transport propellant, the diameter of the conformal fine flow channel is ≤1 mm, and the cross section of the conformal fine flow channel is rhombus-shaped.

3. The SLM-based additive manufacturing lightweight modular monopropellant propulsion system according to claim 2, characterized in that: The conformal fine flow channel is provided with a plurality of interfaces, the interfaces comprising a first interface (10), a second interface (11), a third interface (12), a fourth interface (13), a fifth interface (14), a sixth interface (15), a seventh interface (16) and an eighth interface (17), the first interface (10) being connected to the gas adding and discharging valve (2), the second interface (11) being connected to the plug (9), the third interface (12) being connected to the pressure sensor (4), the fourth interface (13) being connected to the liquid adding and discharging valve (3), the fifth interface (14) being connected to the filter (5), the sixth interface (15) being connected to the first solenoid valve (6), the seventh interface (16) being connected to the second solenoid valve (7), and the eighth interface (17) being connected to the single component thrust chamber (8).

4. The SLM-based additive manufacturing lightweight modular monopropellant propulsion system according to claim 3 is characterized in that: The tank shell (18) and the fifth interface (14) are integrally formed by additive manufacturing, and the fifth interface (14) is a filter shell.

5. The SLM-based additive manufacturing lightweight modular monopropellant propulsion system according to claim 1, characterized in that: The tank shell (18), the tank piston (19) and the shell head (20) are all manufactured by additive manufacturing using TC4 titanium alloy.

6. The SLM-based additive manufacturing lightweight modular monopropellant propulsion system according to claim 1, characterized in that: The piston storage box (1) is in a spherical column shape, the wall thickness of the piston storage box (1) is ≤2 mm, and the pressure resistance of the piston storage box (1) is ≥3.6 MPa.

7. The SLM-based additive manufacturing lightweight modular monopropellant propulsion system according to claim 1, characterized in that: The inner cavity of the tank shell (18) is divided into an air cavity and a liquid cavity by the tank piston (19); the air cavity is filled with liquid ammonia through the gas filling and discharge valve (2); and the liquid cavity is filled with anhydrous hydrazine through the liquid filling and discharge valve (3); and the monocomponent thrust chamber (8) is switched between constant thrust output and variable thrust output by temperature control of the piston tank (1).

8. The SLM-based additive manufacturing lightweight modular monopropellant propulsion system according to claim 3, characterized in that: The filter (5) comprises a filter housing, a filter screen assembly and a filter head, the filter head is connected to the top of the filter housing, and the filter screen assembly is installed inside the filter housing; The filter housing is the fifth interface (14), the filter housing and the tank housing (18) are integrally formed by additive manufacturing, and the filter head is connected to the filter housing by spot welding.

9. The SLM-based additive manufacturing lightweight modular monopropellant propulsion system according to claim 1, characterized in that: The gas addition and discharge valve (2), the liquid addition and discharge valve (3), the pressure sensor (4), the filter (5), the first solenoid valve (6), the second solenoid valve (7), the single component thrust chamber (8) and the plug (9) are respectively inserted into the bottom of the tank shell (18) by screws, and the shell head (20) is connected to the tank shell (18) by welding.

10. The SLM-based additive manufacturing lightweight modular monopropellant propulsion system according to claim 1, characterized in that: The piston storage box (1) is provided with 6 interface ears for external installation, and the interface ears are through holes with a diameter of 5.5 mm.

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