Comprehensive guarantee method for on-orbit life of replenishable manned spacecraft

Abstract

The invention discloses a method for comprehensively guaranteeing the on-orbit life of a replenishable manned spacecraft. The method comprises the following steps: carrying out maintainable and replenishable design by taking long-term on-orbit stable operation as a center; establishing a space-ground integrated spare part and resource-consuming material guarantee system to form a material supply chain; the on-orbit service life evaluation is used for predicting the remaining service life of an on-orbit product and providing a basis for making a maintenance plan and determining an uplink material list; planning replenishment materials and launching upward, and matching with the launching task of the visiting aircraft; supplementary materials are managed in an on-orbit mode, management is carried out in the whole cycle of on-orbit storage, use, inspection, discarding and descending of the materials, and it is ensured that the materials are reliably stored in the on-orbit mode and easy to find. The problems of on-orbit material use consumption rule evaluation and product on-orbit life feature recognition are solved, an efficient material supply and on-orbit management system is established, and on the premise that safety and task reliability are met, platform resource utilization is excellent, long-term operation guarantee support dependence is small, and the capacity of gradually prolonging the service life is achieved.

Description

Technical Field

[0001] The present application relates to the technical field of overall spacecraft design, and in particular to a method for comprehensive assurance of the on-orbit life of a replenishable manned spacecraft. Background Art

[0002] my country's space station has fully entered the stage of long-term operation and development. With the mastery of manned space technology, breakthroughs in rendezvous and docking technology, and the application of multi-vehicle combined spacecraft system design and operation technology, safety, reliability, and maintainability technologies have also been innovatively practiced and continuously developed. The on-orbit flight life of manned spacecraft has been continuously extended, and support measures have gradually been systematically improved.

[0003] In the manned spacecraft stage and the space laboratory stage, the inherent reliability design and safety design were the main focus. Focusing on the goal of ensuring the safety of astronauts and the success of the rendezvous and docking mission, the design and analysis, verification and evaluation, and process control were fully carried out to achieve "one-fault work, two-fault safety". In the manned spacecraft stage, the identification and analysis of hazard sources, system-level reliability and safety design, and electronic product reliability design were fully carried out to improve the inherent reliability of spacecraft systems and products; on this basis, the identification and quantitative control of key important characteristics of products were carried out to further ensure the reliability of the product realization process, and a set of system reliability and safety assessment methods based on the Bayesian method were established to achieve quantitative evaluation of safety and reliability indicators. In the space laboratory stage, the flight event guarantee chain analysis work was innovatively carried out, and the static FMEA, FTA combined with dynamic timing analysis methods were used to comprehensively identify mission risks, and autonomous safety mode design was carried out to ensure the safety of the space laboratory during unmanned operation; in addition, in view of the characteristics of the space laboratory accepting manned ship docking and berthing, the management design of multi-aircraft assembly was carried out to achieve the integrated use of functions between cabins, and control can be taken over in emergency situations. At the same time, on-orbit maintenance was successfully implemented on some software and equipment, further improving safety.

[0004] The life of a long-life repairable manned spacecraft represented by the space station is generally not less than 15 years. Maintaining the long-term stable operation of repairable manned spacecraft in orbit and extending its operating life with support is a practical need to maximize the benefits of in-orbit operations. Since the assembly and construction of the International Space Station, NASA has organized three systematic life assessment demonstrations, and based on this, it has determined the list of uplink supplies and spare parts, and has gradually extended the service life of the International Space Station. It has been in orbit for more than 25 years. Based on the operating experience of the International Space Station, uplinking or storing repair spare parts and materials in orbit in response to life risks, giving full play to the initiative of astronauts in taking care of spacecraft in orbit, can effectively ensure the long-term safety of spacecraft in orbit and mission reliability and gradually extend its life.

[0005] On-orbit life assessment is a prerequisite for ensuring the service life of the system. Accurate prediction of the remaining service life of the product is helpful for formulating maintenance plans and determining the uplink material list. It can also identify the life risks of the spacecraft system in advance and take compensation measures in time. Although there are many life assessment models that meet specific statistical laws, the methods for evaluating the use and consumption laws of materials and identifying the characteristics of the on-orbit life of products in the actual on-orbit working environment and working conditions of manned space projects, as well as related working mechanisms, still need to be explored.

[0006] In addition, on-orbit maintenance and replacement operations are carried out under the premise that the spacecraft system still maintains orbital flight and ensures the safety of astronauts. The system allows limited maintenance time, is far away from the ground spare parts support system, and has large maintenance and support constraints. Whether spare parts for faulty or expired equipment can be obtained determines whether the system can recover quickly from the fault. However, the storage space for on-orbit spare parts and materials is extremely limited. In addition to spare parts to maintain the safe and reliable operation of the platform, a large amount of astronaut crew living supplies and materials for space application experiments (tests) need to be stored. Therefore, it is necessary to solve the problem of ensuring the safe operation of the platform and the successful implementation of various tasks without excessive storage of spare parts. Due to the limited on-orbit storage space, it is inevitable to adopt a space-ground integrated storage mode. The storage location (on-orbit or on the ground), storage product status (whole machine or component), and storage time (pre-storage according to plan or storage after a fault occurs) of spare parts and materials need to be combined with the system reliability and safety design of the spacecraft and the on-orbit maintenance strategy and maintenance level, and formulated after comprehensive analysis. Summary of the invention

[0007] The present application provides a comprehensive guarantee method for the on-orbit life of a replenishable manned spacecraft, which is based on a maintainable and replenishable design centered on ensuring long-term stable on-orbit operation, solves the problems of on-orbit material consumption evaluation and product on-orbit life characteristics identification, establishes an efficient material replenishment and on-orbit management system, and achieves optimal platform resource utilization while meeting safety and mission reliability, minimal reliance on long-term operational support, and the ability to gradually extend the service life.

[0008] In the first aspect, a method for comprehensive guarantee of the on-orbit life of a replenishable manned spacecraft is provided, comprising:

[0009] Design for maintainability and replenishability with a focus on long-term stable operation on orbit;

[0010] Establish a space-ground integrated spare parts and resource-consuming material support system to form a material supply chain;

[0011] On-orbit service life assessment is used to predict the remaining service life of on-orbit products and provide a basis for formulating maintenance plans and determining the uplink material list;

[0012] Plan resupply and launch uplink to match the launch mission of the visiting spacecraft;

[0013] The on-orbit management of supply materials includes management of the entire cycle of on-orbit storage, use, inspection, disposal and downlink, ensuring that the on-orbit storage of materials is reliable and easy to find.

[0014] In conjunction with the first aspect, in certain implementations of the first aspect, the repairable and replenishable design centered on long-term stable operation on orbit includes:

[0015] Focusing on the requirements of life, safety and reliability indicators, we analyze the mission requirements and environmental profiles of manned spacecraft. Based on the maturity, life and inherent reliability level of the product, the support mode and constraints in the on-orbit flight environment, we determine the life comprehensive support strategy and the integrated design principles of Ankewei to meet the following requirements:

[0016] Based on product life design, design is carried out for factors affecting life and weak links to extend the product's on-orbit service life;

[0017] On the basis of long-life design, comprehensive reliability design is carried out for system functions and hardware equipment. Through system-level function reconstruction, equipment-level redundancy design and margin design measures, the system mission reliability during long-life operation is improved;

[0018] For equipment that still cannot meet the 15-year life requirement after long-life research, or equipment and systems with high reliability design costs, additional maintenance measures should be used to achieve long-life requirements by regularly replacing equipment at the end of its service life, repairing random failures, and restoring and maintaining the system's mission reliability level.

[0019] In conjunction with the first aspect, in certain implementations of the first aspect, the repairable and replenishable design centered on long-term stable operation on orbit includes:

[0020] During reliability design, comprehensive analysis is performed to ensure that redundancy is appropriate. The mission functions are decomposed based on the combined spacecraft as a whole and redundant resources are allocated in a coordinated manner. During the autonomous flight of a single spacecraft, on-orbit maintenance is used as a supplement. Maintainability design is carried out for products with failure consequences of Class I and II and with FTA minimum cut sets of less than 3 orders.

[0021] Conduct maintenance safety analysis to analyze the impact of removing faulty equipment on the safety of manned spacecraft systems during maintenance, and clarify the maximum allowable maintenance time for the system to maintain safe operation as a constraint for the maintenance plan;

[0022] For non-repairable products, sufficient margins are reserved during the design and verification of their lifespans, and the lifespan characteristics can be detected on-orbit. The on-orbit detection means can integrate telemetry parameters, astronauts’ handheld equipment detection, and visual inspection.

[0023] During the on-orbit flight phase, based on the on-orbit service life assessment and life extension requirements, the life design and verification of alternative products for non-repairable products are carried out;

[0024] The propulsion system takes into account the rational use of the propellant and engines of the visiting spacecraft, and extends the service life of non-repairable products through the functional integration design between modules and the optimization of system usage patterns.

[0025] In conjunction with the first aspect, in certain implementations of the first aspect, the material support reserve strategy decision process of the space-ground integrated spare parts and resource-consumable material support system includes:

[0026] First, the principle of universal interchangeable design of similar products between aircraft is adopted during the development stage, so that spare parts can be used universally among aircraft and the efficiency of spare parts reserve is improved;

[0027] Secondly, for aircraft undergoing long-term autonomous flight missions, on-orbit storage of fault consequence severity of Class I and II, and on-orbit replaceable units (ORUs) with less redundancy than the double, can improve the reliability of single-flight missions and make up for the lack of redundancy in the single-flight stage;

[0028] Third, based on the functional integration design between the aircrafts of the combination, the mission requirements can be met even in the event of a second failure, making it feasible to carry out maintenance on the ground in terms of time. These spare parts are stored on the ground to reduce the pressure of on-orbit storage of spare parts.

[0029] Finally, the status of spare parts on the ground is determined based on the urgency of the fault and the spare parts production cycle. For maintenance spare parts that are not stored on orbit, if the component ordering cycle is long and the subassembly production cycle is long, a set of components and subassemblies are stored on the ground in advance. Once a fault occurs on orbit, the spare parts are quickly assembled, tested and verified on the ground, and on-orbit maintenance is carried out through the nearest transporter uplink.

[0030] In conjunction with the first aspect, in certain implementations of the first aspect, the on-orbit service life assessment includes:

[0031] Combined with the life design and verification work of manned spacecraft during the development phase, the differences between heaven and earth are analyzed, and on-orbit service life assessment is continuously carried out based on the actual working conditions and working modes on orbit.

[0032] In conjunction with the first aspect, in certain implementations of the first aspect, analyzing the difference between heaven and earth includes:

[0033] The impact of multiple environmental factors such as vacuum, radiation, and temperature changes on product performance on orbit;

[0034] The convection heat dissipation method in microgravity on orbit is different from that on the ground. The operating temperature of the equipment is higher than that on the ground, which affects the mission reliability of the equipment and aggravates the volatilization of organic matter, affecting the working performance of the product. The microgravity environment affects the wetting properties of materials. The surface of microgravity materials is less likely to be wetted by water, and the water film is easier to peel off, making it easier for bubbles to adhere to the surface of the material, affecting the liquid sealing performance of the active surface.

[0035] The alternating high and low temperatures on orbit cause the shaft and hole of the mechanism to contact, increase the friction resistance, accelerate the wear of the gears and reducers, and cause the output torque of the mechanism to gradually decrease;

[0036] In the actual electromagnetic environment on orbit, the anti-interference design robustness of electronic product circuits is insufficient, which affects the internal power supply quality of electromechanical products and the working performance of motor drive modules;

[0037] Humidity, condensed water, human sweat and growing microorganisms in the sealed cabin cause corrosion and affect product performance;

[0038] The actual load of the mechanism products on orbit is different from that verified on the ground; the long-term load on the wire rope and the lock hook in the outdoor environment will aggravate the creep on orbit.

[0039] In conjunction with the first aspect, in certain implementations of the first aspect, the on-orbit service life assessment includes:

[0040] Conduct on-orbit consumption characteristic analysis for consumable products. Based on the on-orbit usage mode and product on-orbit data, evaluate the usage consumption, continuously revise the on-orbit usage consumption model, complete the on-orbit service life evaluation of consumable products, and predict the remaining service life. Conduct on-orbit service life characteristic parameter re-analysis for other products, combine the difference analysis between on-orbit working conditions and ground verification, and revise the life characteristics identified in the development stage.

[0041] The manned spacecraft system conducts on-orbit consumption characteristic analysis, conducts life assessments regularly in combination with mission reliability assessments and maintainability assessments, and proposes comprehensive support requirements. When entering the late stage of the spacecraft system's life, the life assessment intervals are shortened, and support capability assessments for special missions are supplemented as appropriate. After the decision is made to enter the life extension period, a system life assessment is conducted once a year.

[0042] In conjunction with the first aspect, in certain implementations of the first aspect, the planning of replenishment materials and launch uplinks matches the launch mission of the visiting aircraft, including:

[0043] Based on the on-orbit consumption of resource-consuming materials, the on-orbit service life assessment results of planned maintenance products, the on-orbit inventory and endurance, and combined with the flight mission planning, the corresponding supply material plan is formulated, and the uplink product list is determined in accordance with the launch plan of the visiting spacecraft.

[0044] In conjunction with the first aspect, in certain implementations of the first aspect, the on-orbit management of the supply materials includes:

[0045] Platform consumables: Consumables are mainly stored on cargo ships and taken on demand. When replacing new consumables, the old materials replaced shall be disposed of in accordance with waste management requirements. Regular inventory of consumables shall be conducted on orbit, and the content and quantity of materials shall be counted and the cargo packages shall be sorted. Before the cargo transportation system is evacuated, routine inventory work shall be conducted, and cargo packages shall be integrated on the premise of reserving the amount used before evacuation to reduce the amount of cargo transferred and stored when the cargo ship is evacuated. In conjunction with routine inventory work, consumable material assessments shall be continuously carried out, and usage and consumption models shall be updated to support the identification of consumable material requirements and upstream planning for subsequent tasks. Sampling and downstream requirements shall be proposed based on the needs of on-orbit usage and consumption assessment of materials.

[0046] In conjunction with the first aspect, in certain implementations of the first aspect, the on-orbit management of the supply materials includes:

[0047] Maintenance spare parts: The reliability spare parts for the uplink transportation of the cargo transportation system are transferred to the designated storage area; in conjunction with the routine inspection of the manned spacecraft platform, the reliability spare parts are inspected on-orbit to check the material storage location, electrostatic protection and collision protection status. The reliability spare parts must not squeeze or interfere with the cables, pipes and connectors of the original installed equipment; the systems to which each reliability spare part belongs compare the inspection results with the safety benchmark requirements, adjust the storage status of the reliability spare parts, and eliminate deviations; after a random failure occurs on-orbit, the reliability spare parts are used for repair and replacement in accordance with the on-orbit fault handling plan; the replaced faulty parts are sent down to the ground for failure analysis, or the faulty parts that are not sent down are disposed of in accordance with the waste management requirements; after the reliability spare parts are used, they are replenished by the next cargo transportation system and the on-orbit reserve status is restored in accordance with the safety benchmark material storage requirements.

[0048] Compared with the prior art, the solution provided by this application includes at least the following beneficial technical effects:

[0049] 1) Solve the problem of on-orbit material consumption assessment and on-orbit life characteristics identification of products;

[0050] 2) Establish an efficient material supply and on-orbit management system;

[0051] 3) To achieve optimal utilization of platform resources while meeting life and reliability requirements, and to minimize reliance on long-term operational support;

[0052] 4) Enable spacecraft to have the ability to gradually extend their service life. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] Figure 1 It is a flow chart of the comprehensive guarantee of the on-orbit life of the replenishable spacecraft of the present invention.

[0054] Figure 2 It is a decision diagram of the spare parts and resource-consuming material reserve strategy of the present invention. DETAILED DESCRIPTION

[0055] The present application is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0056] like Figure 1 As shown, the present invention provides a method for comprehensive guarantee of the on-orbit life of a replenishable manned spacecraft, and the specific steps are as follows.

[0057] Step one: Design for maintainability and replenishability with a focus on long-term stable operation in orbit.

[0058] Focusing on the requirements of life, safety and reliability indicators, we analyze the mission requirements and environmental profiles of manned spacecraft. Based on the maturity, life and inherent reliability level of the product, the support mode and constraints in the on-orbit flight environment, and the characteristics of limited astronaut time, we determine the life comprehensive support strategy and the integrated design principles of safety and maintenance. The following factors should be considered:

[0059] 1) The design should be based on product life design, targeting factors affecting life and weak links to extend the product's on-orbit service life;

[0060] 2) Based on the long-life design, comprehensive reliability design is carried out for system functions and hardware equipment, and the system mission reliability during long-life operation is improved through measures such as system-level function reconstruction, equipment-level redundancy design and margin design;

[0061] 3) For equipment that still cannot meet the 15-year life requirement after long-life research, or equipment and systems with high reliability design costs (weight, power consumption, space), additional maintenance measures should be provided to achieve long-life requirements by regularly replacing equipment at the end of its service life, repairing random failures, and restoring and maintaining the system's reliability level.

[0062] During the reliability design, comprehensive analysis should be conducted to ensure that redundancy is appropriate. The mission function should be decomposed and redundant resources should be allocated in a coordinated manner based on the combined spacecraft as a whole. During the autonomous flight of a single spacecraft, on-orbit maintenance can be performed as a supplement. For products with failure consequences of Class I and II and FTA minimum cut sets of less than 3 orders, maintainability design should be carried out. In addition, maintenance safety analysis should be carried out to analyze the safety impact of the manned spacecraft system after the removal of the faulty equipment during the maintenance process, and the maximum allowable maintenance time for the system to maintain safe operation should be clarified as a constraint for the maintenance plan. For non-maintainable products, sufficient margin should be left in the design and verification of their own life, and the life characteristic quantity should be detectable on-orbit. The on-orbit detection means can integrate telemetry parameters, astronaut handheld device detection, visual inspection, etc. During the on-orbit flight phase, the life design and verification of alternative products for non-maintainable products should be carried out based on the on-orbit service life assessment and life extension requirements. The propulsion system should consider the rational use of products such as propellants and engines of visiting spacecraft, and extend the service life of non-maintainable products through the functional integration design between compartments and the optimization of system usage patterns. The system resources are optimized and the cost is minimized through the integrated design of safety and maintenance.

[0063] Through the comprehensive design of life span, safety, reliability, maintainability and supportability, the foundation is laid for optimizing the cost of support resources and conditions are provided for manned spacecraft to achieve a long life and further extend its life.

[0064] Step 2: Establish a space-ground integrated spare parts and resource-consuming material support system. The goal is to form a material supply chain that can ensure on-orbit safety while also being flexible and efficient.

[0065] Manned spacecraft are in orbit and can be repaired without shutting down the system. Whether spare parts for faulty equipment can be obtained determines whether the system can recover quickly from the fault. However, the storage space in the sealed cabin is limited, and there is a risk of insufficient storage of spare parts on orbit. The decision-making process of the space-ground integrated spare parts and material support reserve strategy is detailed in Figure 2 .

[0066] First, during the development phase, the principle of universal interchangeable design of similar products between spacecraft should be adopted to realize the commonality of spare parts between spacecraft and improve the efficiency of spare parts reserves. Secondly, for spacecraft undergoing long-term autonomous flight missions, spare parts with a severity of failure consequences of Class I and II and less than double redundancy should be stored on-orbit, especially the on-orbit replaceable units (ORUs) of the life support system that support astronauts’ stay. Spare parts should be stored on-orbit to improve the reliability of single-flight missions and make up for the lack of redundancy in the single-flight stage. Thirdly, the functional integration design between spacecraft based on the assembly can realize the support of astronauts’ stay and the implementation of various tasks in the event of a second-degree failure, making it feasible in terms of time for ground-based uplink maintenance materials. These spare parts can be stored on the ground to reduce the pressure of on-orbit storage of spare parts. Finally, the status of ground spare parts should be determined based on the trade-off between the urgency of the failure and the spare parts production cycle. For maintenance spare parts not stored on-orbit, if the ordering cycle of components is long and the production cycle of subassemblies is long (such as large and complex electromechanical products such as robotic arm joints), a set of components and subassemblies are stored on the ground in advance. Once a failure occurs on-orbit, the spare parts are quickly assembled, tested and verified on the ground, and the on-orbit maintenance is carried out through the nearest transporter uplink. Storing spare parts on the ground in the form of components and subassemblies can achieve multiple spare parts for the same type of components and subassemblies, further improving the efficiency and flexibility of spare parts reserves.

[0067] Step three, on-orbit service life assessment, is used to predict the remaining service life of on-orbit products and provide a basis for formulating maintenance plans and determining the uplink material list.

[0068] The life design and verification work of manned spacecraft during the development phase should be combined to analyze the differences between the earth and the sky, and continuously carry out on-orbit service life assessment based on the actual on-orbit working conditions and working modes. The differences between the earth and the sky mainly exist in the actual on-orbit environmental conditions, working modes, storage status and load conditions, including:

[0069] 1) The impact of multiple environmental factors such as on-orbit vacuum, radiation, and temperature changes on product performance.

[0070] 2) The convection heat dissipation method in microgravity on orbit is different from that on the ground. The operating temperature of the equipment is higher than that on the ground, which affects the mission reliability of the equipment and intensifies the volatilization of organic matter, affecting the working performance of the product. The microgravity environment affects the wetting properties of the material. The surface of the microgravity material is less likely to be wetted by water, and the water film is easier to peel off, making it easier for bubbles to adhere to the surface of the material, affecting the liquid sealing performance of the active surface.

[0071] 3) The alternating high and low temperatures on track cause the mechanism shafts and holes to contact, which increases the friction resistance and accelerates the wear of the gears and reducers, resulting in a gradual decrease in the mechanism output torque or even stuck.

[0072] 4) In the actual electromagnetic environment on orbit, the anti-interference design of electronic product circuits is not robust enough, which will affect the internal power supply quality of electromechanical products and the working performance of the motor drive module.

[0073] 5) Humidity, condensed water, human sweat and growing microorganisms in the sealed cabin may cause corrosion and affect product performance.

[0074] 6) The actual load of the mechanical product on orbit is different from that verified on the ground; the wire rope and lock hook are subjected to long-term load in the outdoor environment, and the creep on orbit is aggravated.

[0075] Consumable products should conduct on-orbit consumption characteristic analysis, evaluate the usage consumption according to the on-orbit usage mode and product on-orbit data, continuously revise the on-orbit usage consumption model, complete the on-orbit service life evaluation of consumable products, and predict the remaining service life. Other products should conduct on-orbit service life characteristic parameter re-analysis, and can combine the difference analysis of on-orbit working conditions and ground verification to revise the life characteristics identified in the development stage.

[0076] Manned spacecraft systems should conduct regular life assessments in combination with mission reliability assessments and maintainability assessments and propose comprehensive support requirements. When entering the late life of a spacecraft system, the life assessment interval should be shortened, and the support capability assessment of special tasks should be supplemented as appropriate. After entering the life extension period, a system life assessment should be conducted once a year. Based on the on-orbit service life assessment, life extension work should be carried out in terms of life assessment method research, life assessment method verification test planning and implementation, spare parts uplink, and replacement function expansion of non-repairable products, so as to gradually extend the life of manned spacecraft.

[0077] Step 4: Rationally plan the supply and launch uplink to match the launch mission of the visiting spacecraft.

[0078] Based on the on-orbit consumption of resource-consuming materials, the on-orbit service life assessment results of planned maintenance products, the on-orbit inventory and endurance, and combined with the flight mission planning, the corresponding supply material plan is formulated, and the uplink product list is determined in accordance with the launch plan of the visiting spacecraft.

[0079] Step 5: On-orbit management of supply materials, including management of the entire cycle of on-orbit storage, use, inspection, disposal and downlink, to ensure that the on-orbit storage of materials is reliable and easy to find.

[0080] In order to support the long-term stable operation of spacecraft, a large number of various materials need to be stored, used, managed and discarded in the limited activity space of manned spacecraft. Material planning, loading and uploading, on-orbit use, downlink and disposal, and use evaluation are management activity systems throughout the entire life cycle of materials. Improper management of any link may directly affect the balance of on-orbit use and consumption, causing excessive on-orbit inventory to occupy operating space or insufficient inventory, making it impossible to implement on-orbit missions as scheduled, and even threatening platform safety. Therefore, it is necessary to manage the on-orbit storage, use, inspection, disposal and downlink of replenishment materials.

[0081] Platform consumables: Consumables should be stored mainly on cargo ships and taken as needed. When replacing new consumables, the replaced old materials should be disposed of in accordance with waste management requirements. Regular inventory of consumables should be conducted on orbit, and the content and quantity of materials should be counted and the cargo packages should be sorted as appropriate. Before the cargo transportation system is evacuated, combined with routine inventory work, cargo packages should be integrated on the premise of reserving the amount used before evacuation to reduce the amount of cargo transferred and stored when the cargo ship is evacuated; combined with routine inventory work, consumable material assessments should be continuously carried out, and usage and consumption models should be updated to support the identification of consumable material requirements and upstream planning for subsequent tasks. Sampling and downstream requirements should be proposed based on the needs of on-orbit usage and consumption assessment of materials.

[0082] Maintenance spare parts: The reliability spare parts for the uplink transportation of the cargo transportation system must be transferred to the designated storage area as soon as possible. In conjunction with the routine inspection of the manned spacecraft platform, the reliability spare parts should be inspected on-orbit to check the material storage location, electrostatic protection and collision protection status. The reliability spare parts must not squeeze or interfere with the cables, pipes, connectors, etc. of the original installed equipment. The systems to which each reliability spare part belongs shall compare the inspection results with the safety benchmark requirements, adjust the storage status of the reliability spare parts as appropriate, and eliminate deviations. After a random failure occurs on-orbit, the reliability spare parts shall be used for repair and replacement in accordance with the on-orbit fault handling plan. After the replacement faulty parts, the failure analysis shall be carried out on the ground as appropriate. Faulty parts that do not descend shall be disposed of in accordance with waste management requirements. After the reliability spare parts are used, they should be replenished by the next cargo transportation system as much as possible, and the on-orbit reserve status shall be restored in accordance with the safety benchmark material storage requirements.

[0083] Although the present invention is disclosed as above in the form of a preferred embodiment, it is not intended to limit the present invention. Any person skilled in the art may make possible changes and modifications without departing from the spirit and scope of the present invention. Therefore, the scope of protection of the present invention shall be based on the scope defined by the claims of the present invention.

Claims

1. A method for comprehensive guarantee of the on-orbit life of a manned spacecraft capable of replenishment, characterized in that: include: Design for maintainability and replenishability with a focus on long-term stable operation on orbit; Establish a space-ground integrated spare parts and resource-consuming material support system to form a material supply chain; On-orbit service life assessment is used to predict the remaining service life of on-orbit products and provide a basis for formulating maintenance plans and determining the uplink material list; Plan resupply and launch uplink to match the launch mission of the visiting spacecraft; The on-orbit management of supply materials includes management of the entire cycle of on-orbit storage, use, inspection, disposal and downlink, ensuring that the on-orbit storage of materials is reliable and easy to find.

2. The method according to claim 1, characterized in that: The above-mentioned maintainable and replenishable design centered on long-term stable operation on orbit includes: Focusing on the requirements of life, safety and reliability indicators, we analyze the mission requirements and environmental profiles of manned spacecraft. Based on the maturity, life and inherent reliability level of the product, the support mode and constraints in the on-orbit flight environment, we determine the life comprehensive support strategy and the integrated design principles of Ankewei to meet the following requirements: Based on product life design, design is carried out for factors affecting life and weak links to extend the product's on-orbit service life; On the basis of long-life design, comprehensive reliability design is carried out for system functions and hardware equipment. Through system-level function reconstruction, equipment-level redundancy design and margin design measures, the system mission reliability during long-life operation is improved; For equipment that still cannot meet the 15-year life requirement after long-life research, or equipment or systems with a high reliability design cost, additional maintenance measures should be used to achieve long-life requirements by regularly replacing equipment at the end of its service life, repairing random failures, and restoring and maintaining the system's mission reliability level.

3. The method according to claim 1, characterized in that The above-mentioned maintainable and replenishable design centered on long-term stable operation on orbit includes: During reliability design, comprehensive analysis is performed to ensure appropriate redundancy. The mission functions are decomposed based on the combined spacecraft as a whole and redundant resources are allocated in a coordinated manner. On-orbit maintenance is used as a supplement during the autonomous flight of a single spacecraft. Maintainability design is carried out for products with failure consequences of Class I and II and with FTA minimum cut sets of less than 3 orders. Conduct maintenance safety analysis to analyze the impact of removing faulty equipment on the safety of manned spacecraft systems during maintenance, and clarify the maximum allowable maintenance time for the system to maintain safe operation as a constraint for the maintenance plan; For non-repairable products, sufficient margins are reserved during the design and verification of their lifespans, and the lifespan characteristics can be detected on-orbit. The on-orbit detection means can integrate telemetry parameters, astronauts’ handheld equipment detection, and visual inspection. During the on-orbit flight phase, based on the on-orbit service life assessment and life extension requirements, the life design and verification of alternative products for non-repairable products are carried out; The propulsion system takes into account the rational use of the propellant and engines of the visiting spacecraft, and extends the service life of non-repairable products through the functional integration design between modules and the optimization of system usage patterns.

4. The method according to claim 1, characterized in that: The material support reserve strategy decision-making process of the space-ground integrated spare parts and resource-consuming material support system includes: First, the principle of universal interchangeable design of similar products between aircraft is adopted during the development stage, so that spare parts can be used universally among aircraft and the efficiency of spare parts reserve is improved; Secondly, for aircraft undergoing long-term autonomous flight missions, on-orbit storage of fault consequence severity of Class I and II, and on-orbit replaceable units (ORUs) with less redundancy than the double, can improve the reliability of single-flight missions and make up for the lack of redundancy in the single-flight stage; Third, based on the functional integration design between the spacecraft of the combination, the mission requirements can be met even in the event of a second failure, making it feasible to carry out maintenance on the ground in terms of time. These spare parts are stored on the ground to reduce the pressure of on-orbit storage of spare parts. Finally, the status of spare parts on the ground is determined based on the urgency of the fault and the spare parts production cycle. For maintenance spare parts that are not stored on orbit, if the component ordering cycle is long and the subassembly production cycle is long, a set of components and subassemblies are stored on the ground in advance. Once a fault occurs on orbit, the spare parts are quickly assembled, tested and verified on the ground, and on-orbit maintenance is carried out through the nearest transporter uplink.

5. The method according to claim 1, characterized in that The on-orbit service life assessment includes: Combined with the life design and verification work of manned spacecraft during the development phase, the differences between heaven and earth are analyzed, and on-orbit service life assessment is continuously carried out based on the actual working conditions and working modes on orbit.

6. The method according to claim 5, characterized in that The analysis of the differences between heaven and earth includes: The impact of multiple environmental factors such as vacuum, radiation, and temperature changes on product performance on orbit; The convection heat dissipation method in microgravity on orbit is different from that on the ground. The operating temperature of the equipment is higher than that on the ground, which affects the mission reliability of the equipment and aggravates the volatilization of organic matter, affecting the working performance of the product. The microgravity environment affects the wetting properties of materials. The surface of microgravity materials is less likely to be wetted by water, and the water film is easier to peel off, making it easier for bubbles to adhere to the surface of the material, affecting the liquid sealing performance of the active surface. The alternating high and low temperatures on orbit cause the shaft and hole of the mechanism to contact, increase the friction resistance, accelerate the wear of the gears and reducers, and cause the output torque of the mechanism to gradually decrease; In the actual electromagnetic environment on orbit, the anti-interference design of electronic product circuits is not robust enough, which affects the internal power supply quality of electromechanical products and the working performance of motor drive modules; Humidity, condensed water, human sweat and growing microorganisms in the sealed cabin cause corrosion and affect product performance; The actual load of the mechanism products on orbit is different from that verified on the ground; the long-term load on the wire rope and the lock hook in the outdoor environment will aggravate the creep on orbit.

7. The method according to claim 5, characterized in that The on-orbit service life assessment includes: Conduct on-orbit consumption characteristic analysis for consumable products. Based on the on-orbit usage mode and product on-orbit data, evaluate the usage and consumption rules, continuously revise the on-orbit usage and consumption model, complete the on-orbit service life evaluation of consumable products, and predict the remaining service life. Conduct on-orbit service life characteristic parameter re-analysis for other products, combine the difference analysis between on-orbit working conditions and ground verification, and revise the life characteristics identified in the development stage. The manned spacecraft system conducts on-orbit consumption characteristic analysis, conducts life assessments regularly in combination with mission reliability assessments and maintainability assessments, and proposes comprehensive support requirements. When entering the late stage of the spacecraft system's life, the life assessment intervals are shortened, and support capability assessments for special missions are supplemented as appropriate. After the decision is made to enter the life extension period, a system life assessment is conducted once a year.

8. The method according to claim 1, characterized in that The planned replenishment and launch uplink are matched with the launch mission of the visiting spacecraft, including: Based on the on-orbit consumption of resource-consuming materials, the on-orbit service life assessment results of planned maintenance products, the on-orbit inventory and endurance, and combined with the flight mission planning, the corresponding supply material plan is formulated, and the uplink product list is determined in accordance with the launch plan of the visiting spacecraft.

9. The method according to claim 1, characterized in that: The on-orbit management of the supply materials includes: Platform consumables: Consumables are mainly stored on cargo ships and taken on demand. When replacing new consumables, the old materials replaced shall be disposed of in accordance with waste management requirements. Regular inventory of consumables shall be conducted on orbit, and the content and quantity of materials shall be counted and the cargo packages shall be sorted. Before the cargo transportation system is evacuated, routine inventory work shall be conducted, and cargo packages shall be integrated on the premise of reserving the amount used before evacuation to reduce the amount of cargo transferred and stored when the cargo ship is evacuated. In conjunction with routine inventory work, consumable material assessments shall be continuously carried out, and usage and consumption models shall be updated to support the identification of consumable material requirements and upstream planning for subsequent tasks. Sampling and downstream requirements shall be proposed based on the needs of on-orbit usage and consumption assessment of materials.

10. The method according to claim 1, characterized in that The on-orbit management of the supply materials includes: Maintenance spare parts: The reliability spare parts for the uplink transportation of the cargo transportation system are transferred to the designated storage area; in conjunction with the routine inspection of the manned spacecraft platform, the reliability spare parts are inspected on-orbit to check the material storage location, electrostatic protection and collision protection status. The reliability spare parts must not squeeze or interfere with the cables, pipes and connectors of the original installed equipment; the systems to which each reliability spare part belongs compare the inspection results with the safety benchmark requirements, adjust the storage status of the reliability spare parts, and eliminate deviations; after a random failure occurs on-orbit, the reliability spare parts are used for repair and replacement in accordance with the on-orbit fault handling plan; the replaced faulty parts are sent down to the ground for failure analysis, or the faulty parts that are not sent down are disposed of in accordance with the waste management requirements; after the reliability spare parts are used, they are replenished by the next cargo transportation system and the on-orbit reserve status is restored in accordance with the safety benchmark material storage requirements.

Images