Method for protecting and fixing line-following resistor of spacecraft

Abstract

The invention provides a method for protecting and fixing a spacecraft line-following resistor. The spacecraft line-following resistor comprises a wire, a resistor and a resistor packaging box, s1, welding a wire and a resistor; s2, the wires and the resistors are placed in a resistor packaging box, and the two ends of the multiple wires are bent and crossed; s3, the resistor packaging box is subjected to potting, the resistor and the welding spots are coated with a potting adhesive, and the potting resistor packaging box is obtained; and S4, winding the encapsulated resistor packaging box by using an adhesive tape. According to the resistor packaging box provided by the invention, the lead connected with the upper resistor penetrates through the lower groove, the lead connected with the lower resistor penetrates through the upper groove, and the interior of the packaging box is encapsulated and insulated by silicon rubber and is integrated with the packaging box. When the outer side of the wire is pulled, the whole packaging box is stressed, and the welding spot is effectively protected.

Description

Technical Field

[0001] The present invention belongs to the technical field of satellite AIT, and in particular, relates to a method for protecting and fixing a spacecraft inline resistor. Background Art

[0002] Satellite AIT is the core link in the satellite manufacturing process, which covers the three stages of satellite assembly, integration and testing. This technical field focuses on assembling the various subsystems, components and assemblies of the satellite according to precise design requirements to form a complete satellite structure. During the integration stage, AIT technology ensures seamless connection and collaborative work between electrical, mechanical, thermal control and other systems to maximize satellite functions. Subsequently, a series of tests, including thermal tests, mechanical tests, electromagnetic compatibility tests, etc., are carried out to verify the performance, stability and reliability of the satellite to ensure its normal operation in the space environment.

[0003] Satellite AIT is directly related to the success and performance of satellites. Through this process, potential problems in the manufacturing process can be discovered and solved in a timely manner, reducing launch risks and improving the reliability and service life of satellites. At the same time, with the continuous advancement of aerospace technology, the field of satellite AIT is also developing in the direction of intelligence and modularization, introducing automated equipment and intelligent testing systems to improve production efficiency and test accuracy, and reduce manufacturing costs.

[0004] The satellite AIT field is an important process in satellite development. The quality of the cable network, which is the lifeline of the satellite, directly affects the success of satellite launch and in-orbit service. The protection and fixation of cables and in-line resistors are key links to ensure the overall quality of the cables. The cables mainly refer to low-frequency cable conductors without shielding layers. In general, in-line resistors are arranged close to the surface of the satellite structure and fixed by nylon tie straps on the brackets installed on the satellite.

[0005] According to the current method of protecting resistors by wrapping multiple layers of soft tape after welding, the resistor soldering points are easily damaged by external stresses such as pulling, bending, and squeezing during the laying and testing process, affecting the circuit connection. When the cable routing direction changes, the position of the resistor needs to be re-fixed, which is time-consuming, labor-intensive, and has a complicated process and high operational risks, posing a certain threat to the quality of satellite AIT and mission progress.

[0006] Patent document CN113346300A discloses a space cable assembly protection device and a preparation method thereof, the device comprising a printed circuit board, a protective shell, and a protective sleeve; the printed circuit board is a surface mount pad printed circuit board, comprising N pairs of interconnected surface mount pads, the wires in the first cable and the second cable to be interconnected are soldered on the corresponding printed circuit board surface mount pads to achieve electrical performance connection between the wires; N is greater than or equal to the maximum number of wires in the interconnected first cable and the second cable; the printed circuit board with the wires welded is encapsulated in a protective shell, the first cable and the second cable extend from the outlet of the protective shell, and the protective shell fixes and protects the printed circuit board and the connecting wires; the protective sleeve is coated on the outside of the protective shell, and is used to coat and protect the printed circuit board and the protective shell; this solution cannot solve the problem that the resistance welding points are easily directly damaged by external stresses such as pulling, bending, and extrusion during the laying and testing process, thereby affecting the circuit connection.

[0007] This problem needs to be solved urgently. Summary of the invention

[0008] In view of the defects in the prior art, the purpose of the present invention is to provide a method for protecting and fixing a spacecraft inline resistor.

[0009] The protection and fixing method of the spacecraft inline resistor provided by the present invention comprises: a wire, a resistor and a resistor packaging box;

[0010] Step S1: welding the wire and the resistor;

[0011] Step S2: placing the wires and the resistors in a resistor packaging box, and bending and crossing two ends of a plurality of the wires;

[0012] Step S3: potting the resistor packaging box, and allowing the potting glue to cover the resistor and the welding point to obtain a potted resistor packaging box;

[0013] Step S4: wrapping the potted resistor packaging box with tape.

[0014] Preferably, in the step S1, the core wire of the conductor is tinned to obtain a tinned core wire; the pins of the resistor are trimmed, and the tinned core wire and the pins of the resistor are overlap-welded.

[0015] Preferably, in step S1, the length of the core wire is 2.5 mm to 3 mm; the core wire is tinned 0.5 mm from the root of the core wire.

[0016] Preferably, the sides of the resistor packaging box are respectively provided with through slots having the same number as the number of resistors;

[0017] A partition is arranged in the resistor packaging box to separate the resistors.

[0018] Preferably, in step S2, the wire includes a first wire and a second wire; the head ends of the first wire and the second wire are crossed to form a first intersection, and the tail ends of the first wire and the second wire are crossed to form a second intersection; the distance between the first intersection and the second intersection is greater than or equal to 3 mm; the first intersection and the second intersection are located in the resistor packaging box.

[0019] Preferably, in step S2, the bending radius of the wire is greater than or equal to a single diameter of the wire.

[0020] Preferably, in step S3, the potting glue covers the resistor and the solder joints; and the potting glue does not overflow from the resistor packaging box.

[0021] Preferably, in step S3, the lap welding length is 2.5 mm to 3 mm.

[0022] Preferably, in step S4, 3M polyimide tape is used to axially wrap the resistor packaging box.

[0023] Preferably, the resistor packaging box is made of nylon; and the resistor is a plug-in packaged resistor.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] 1. The resistor packaging box provided by the present invention adopts nylon 1010 material, which has the advantages of high mechanical strength, good impact toughness and wear resistance, and easy molding and processing, thereby ensuring the reliability of the protection and fixing method, realizing the protection and fixation of the in-line resistor inside the spacecraft, and solving the problem that the resistor welding point is easily damaged and the resistor is difficult to fix.

[0026] 2. The resistor packaging box provided by the present invention only needs to modify the size of the resistor packaging box for resistors of different models and specifications, and the method is universal.

[0027] 3. The wires connected to the upper resistors in the resistor packaging box provided by the present invention pass through the grooves at the bottom, and the wires connected to the lower resistors pass through the grooves at the top, and the inside is encapsulated and integrally formed. When the outer side of the wire is pulled, the packaging box as a whole is stressed, effectively protecting the solder joints. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] 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:

[0029] Figure 1 A schematic diagram of a double-cavity resistor packaging box provided by the present invention;

[0030] Figure 2A schematic diagram of installing a resistor with a cable provided by the present invention in a resistor packaging box;

[0031] Figure 3 This is a schematic diagram of the resistor packaging box provided by the present invention in a state where no resistor is installed. DETAILED DESCRIPTION

[0032] 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.

[0033] Embodiment 1, the present invention provides a method for protecting and fixing a spacecraft inline resistor, comprising: a cable, a resistor and a resistor packaging box;

[0034] Specifically, the cable is connected to the resistor by welding, the resistor is connected to the resistor packaging box by potting glue, and the cable is a non-shielded wire;

[0035] Specifically, the resistors are two plug-in packaged resistors, and the size is adapted to the resistor packaging box; the middle baffle in the resistor packaging box cavity is used to separate the two resistors, the gap in the cavity is used for cable forming, and the grooves on the sides are used for the passage and fixation of the wires.

[0036] The protection and fixing method of spacecraft in-line resistors provided by the present invention solves the problems of low strength of welding points of wire series resistors and great hidden dangers in assembly, ensures electrical insulation between different internal resistors, and effectively protects resistors and welding points from external stress. It has the advantages of simple structure, small size, and light weight. After application, it can effectively realize the coating and protection of satellite wire series resistors, which plays an important role in ensuring the satellite lifeline and the normal operation of the entire satellite in orbit.

[0037] In other words, a method for protecting and fixing a spacecraft inline resistor provided by the present invention includes: a wire, a resistor and a resistor packaging box; the wire and the resistor are connected by welding, and the resistor and the resistor packaging box are connected by potting glue.

[0038] Specifically, the conductor is a single wire of a cable.

[0039] Specifically, the wire is a wire without a shielding layer. In other words, the wire has no shielding layer.

[0040] Specifically, the resistor is a plug-in package resistor.

[0041] The resistor packaging box, such as Figure 2 shown.

[0042] In view of the existing technical defects, the present invention provides a nylon resistor packaging box for protecting and fixing an in-line resistor, thereby realizing the protection and positioning functions of the resistor and the pin solder joints.

[0043] Specifically, the steps for protecting and fixing the spacecraft inline resistor are as follows:

[0044] Step 1: Strip the wire 2.5mm to 3mm, and tin the core wire with tin-lead solder; do not tin the part 0.5mm from the root of the core wire;

[0045] Step 2: Cut the resistor pins 4mm away from the root;

[0046] Step 3: Lap-weld the wire core and the resistor pin, with a welding length of 2.5mm to 3mm;

[0047] Step 4: Place the soldered wires and resistors in the resistor packaging box. Cross the wires in the resistor box to prevent the direct-connected wires from being pulled directly by external forces during use, which may reduce the mechanical strength of the solder joints. Figure 1 As shown in the figure, the distance between the two bending points of the two wires, that is, the two crossing points, is greater than or equal to 3mm, and the bending radius is guaranteed to be no less than the single diameter of the wire. Figure 1 shown.

[0048] Specifically, the wire includes a first wire and a second wire; the head ends of the first wire and the second wire are crossed to form a first intersection, and the tail ends of the first wire and the second wire are crossed to form a second intersection; the distance between the first intersection and the second intersection is greater than or equal to 3 mm; the first intersection and the second intersection are located in the resistor packaging box.

[0049] In the embodiment, the lateral distance of the wire cross-forming is 3 mm, that is, the distance between the intersection points of the wires is 3 mm, and the bending radius is not less than a single diameter of the wire;

[0050] Specifically, the cross-molding of the wires can avoid direct pulling on the solder joints, and the bending radius related to the solder joints is determined in accordance with the requirements of the welding standards.

[0051] Step 5: Slowly inject silicone rubber into the resistor packaging box, allowing the silicone rubber to fill the inside of the packaging box until the silicone rubber completely covers the resistor and solder joints and the potting height does not exceed the packaging box. After completion, place it in the air to cure for 24 hours;

[0052] Specifically, preferably, the potting glue, that is, silicone rubber, covers the resistor and the welding point; and the potting glue does not overflow from the resistor packaging box.

[0053] Specifically, the crossed wires can avoid directly pulling the solder joints, and the bending radius related to the solder joints is determined according to the requirements of the welding standard. The purpose of slowly injecting the silicone rubber is to avoid bubbles in the silicone rubber and insufficient filling.

[0054] Step 6: Use 3M polyimide tape to axially wrap the potted resistor packaging box and completely cover it.

[0055] A resistor packaging box for spacecraft inline resistors, made of nylon, with a shape like Figure 1 shown.

[0056] The invention has a simple principle, a practical structure and a clear process, which not only reflects the maturity of the technology application but also demonstrates its innovation.

[0057] Example 2: A spacecraft uses a resistor packaging box to protect and fix the strip resistor. The two resistors used are RJ57-1W-20Ω-F±100ppm. The configuration and size of the resistor packaging box are as follows: Figure 1 For resistors of different models and specifications, the size of the resistor packaging box can be determined according to the resistor size and fixed process parameters.

[0058] The external dimensions of the resistor packaging box in this example are 50.5×13.5×6.5mm. The resistor with the cable is placed in the resistor packaging box, and the cable is placed in the groove on the side of the packaging box. Figure 2 After installation is completed, inject silicone rubber into the resistor packaging box until the silicone rubber completely covers the resistor and solder joints, and place it in the air to cool until the silicone rubber is completely solidified.

[0059] 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.

[0060] 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 method for protecting and fixing a spacecraft inline resistor, characterized in that: include: Wires, resistors and resistor packaging boxes; Step S1: welding the wire and the resistor; Step S2: placing the wires and the resistors in a resistor packaging box, and bending and crossing two ends of a plurality of the wires; Step S3: potting the resistor packaging box, and allowing the potting glue to cover the resistor and the welding point to obtain a potted resistor packaging box; Step S4: wrapping the potted resistor packaging box with tape.

2. The method for protecting and fixing a spacecraft inline resistor according to claim 1, characterized in that: In the step S1, the core wire of the conductor is tinned to obtain a tinned core wire; the pins of the resistor are trimmed, and the tinned core wire and the pins of the resistor are overlap-welded.

3. The method for protecting and fixing a spacecraft inline resistor according to claim 2, characterized in that: In the step S1, the length of the core wire is 2.5 mm to 3 mm; the core wire is tinned 0.5 mm from the root of the core wire.

4. The method for protecting and fixing a spacecraft inline resistor according to claim 1, characterized in that: The sides of the resistor packaging box are respectively provided with through slots having the same number as the number of resistors; A partition is arranged in the resistor packaging box to separate the resistors.

5. The method for protecting and fixing a spacecraft inline resistor according to claim 1, characterized in that: In step S2, the wire includes a first wire and a second wire; the head ends of the first wire and the second wire are crossed to form a first intersection, and the tail ends of the first wire and the second wire are crossed to form a second intersection; the distance between the first intersection and the second intersection is greater than or equal to 3 mm; the first intersection and the second intersection are located in the resistor packaging box.

6. The method for protecting and fixing a spacecraft inline resistor according to claim 5, characterized in that: In the step S2, the bending radius of the wire is greater than or equal to a single diameter of the wire.

7. The method for protecting and fixing a spacecraft inline resistor according to claim 1, characterized in that: In the step S3, the potting glue covers the resistor and the solder joints; the potting glue does not overflow from the resistor packaging box.

8. The method for protecting and fixing a spacecraft inline resistor according to claim 1, characterized in that: In step S3, the lap welding length is 2.5 mm to 3 mm.

9. The method for protecting and fixing a spacecraft inline resistor according to claim 1, characterized in that: In the step S4, the resistor packaging box is axially wound with 3M polyimide tape.

10. The method for protecting and fixing a spacecraft inline resistor according to claim 1, characterized in that: The resistor packaging box is made of nylon; the resistor is a plug-in package resistor.

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