A satellite unlocking device path equivalent device with continuously adjustable composite power resistance

Abstract

The present application belongs to the field of satellite communication technology and discloses a composite satellite unlocking device path equivalent device with continuously adjustable power resistance, comprising a CPLD chip, a programmable power resistor card, and a fixed resistor. The CPLD chip is connected to the programmable power resistor card and the fixed resistor respectively via an optocoupler isolation circuit. The programmable power resistor card is connected to the positive electrode of the unlocking voltage signal, and the optocoupler isolation circuit is connected to the negative electrode of the unlocking voltage signal. The programmable power resistor card and the fixed resistor are respectively connected to different resistance test holes. The CPLD chip is also connected to a dial switch panel and an indicator module. The present invention uses the adjustable power resistance of the programmable power resistor card to adapt to the changes in loop resistance caused by different factors such as different satellites and different deployment mechanisms, and verifies the correctness, rationality, and reliability of the unlocking path design with the closest-to-real loop state, meeting diverse testing needs.

Description

Technical Field

[0001] The present application relates to the field of satellite communication technology, and more specifically, to a satellite unlocking device path equivalent device with a composite power resistor that is continuously adjustable, and in particular, an equivalent device that is used in satellites and uses a power resistor with continuously adjustable resistance, supports synchronous testing of various types of unlocking mechanisms such as pyrotechnics / hot knives / memory alloys, and supports continuous detonation and synchronous verification of a composite unlocking electrical path. Background Art

[0002] As my country has included satellite internet in the communications network information infrastructure of its "new infrastructure" from a policy perspective, the rapid construction of large satellite constellations such as StarNet and Qianfan has steadily advanced, and the application of unlocking mechanisms has gradually increased. During satellite launch missions, key actions such as traditional rocket-to-spacecraft separation, solar array deployment, antenna mechanism deployment, and turntable unlocking often use electrically detonated pyrotechnic devices. As satellites decrease in size, the use of onboard deployment mechanisms has gradually increased, especially in impact-sensitive areas of spacecraft. The use of hot knife devices or memory alloy devices, which have the advantages of low cost, simple structure, low impact, light weight, and high reusability, as onboard unlocking devices has gradually increased, and the use of multiple unlocking devices such as hot knives and pyrotechnics onboard has gradually increased.

[0003] As the device for unlocking critical onboard equipment, its proper unlocking directly determines mission success. Therefore, the importance of validating the unlocking device's control and power supply circuits is self-evident. Due to numerous factors, including process technology and the processing environment, component selection, variations in hot knife / memory alloy, and varying circuit resistances due to varying connecting cable lengths, the unlocking path resistance can vary between satellites of the same design batch. To effectively verify the quality and reliability of satellite product batches, it is crucial to enhance the comprehensive evaluation capabilities of electrical test system results to ensure that satellites leave the factory healthy and are launched without damage. However, deploying a live unlocking device carries significant risks, high testing costs, and significant damage. It is a consumable component and cannot be effectively verified before delivery. Therefore, a hybrid circuit verification equivalent with continuously adjustable resistance, supporting both pyrotechnics and hot knife, was designed to address these requirements. This simulates the characteristics of different unlocking device circuits, enabling various tests and verifications without the use of actual products, ensuring the reliability and safety of the system in real-world applications. This reduces the need for frequent testing on actual products, thereby lowering development costs and minimizing testing risks.

[0004] Existing similar solutions mainly include the following categories:

[0005] A. Design and Implementation of an FPGA-Based Intelligent Pyrotechnic Device Equivalent: This system utilizes the EP3C16F256C8 and its peripheral circuits to measure the resistance of pyrotechnic device squibs during pyrotechnic device circuit testing (low-voltage state) and to detect the issuance of timing instructions during high- and low-voltage timing tests. The equivalent device's circuit resistance is tested, and low-voltage current timing and high-voltage voltage timing are experimentally verified on an experimental test platform. This system primarily tests pulse width and timing. Similar designs include a new pyrotechnic device comprehensive equivalent device and pyrotechnic device equivalent testing method, and the design and implementation of a distributed pyrotechnic device equivalent device, all utilizing different test systems to detect pyrotechnic device timing, circuit voltage / current, and other aspects.

[0006] B. Traditional pyrotechnic equivalent devices used to verify pyrotechnic device circuits primarily connect Ω or kΩ resistors in series in the pyrotechnic device circuit. When voltage is applied to the positive and negative ends of the pyrotechnic device circuit, the correctness of the pyrotechnic device circuit is verified by lighting a light-emitting diode. The resistor used in this design has an adjustable range of 0-5Ω and is not a power resistor, so it cannot be used for hot knife / memory alloy testing.

[0007] C. Onboard Adjustable Resistance Hot Knife Device: The required resistance of the resistor wire is calculated based on the power subsystem's energy allocation, the maximum current allowed by the onboard power supply, and the duration of the power supply. This allows for adjustments to the length of the resistor wire and its routing within the wiring board. The wired wiring board is then sandwiched between two ends with polyimide insulating pressure plates. The resulting assembly is then placed within the hot knife's housing. Wires are soldered to the outlet terminals, and the hot knife structure is sealed with sealant.

[0008] In summary, most current satellites use pyrotechnic equivalents or equivalent systems to fully verify the timing, voltage / current, and correctness of pyrotechnic paths of pyrotechnic devices. However, the simultaneous testing of multiple types of unlocking devices, such as hot knife / memory alloy unlocking devices, cannot meet the increasing demand for an increased number of unlocking paths and realistic simulation of different unlocking path resistance values. The following problems still exist:

[0009] (1) The design of the pyrotechnic equivalent system is complex and requires system configuration such as a lower computer and boards. It is large in size and weight, not easy to move, and cannot meet the growing demand for convenient use on production lines.

[0010] (2) The adjustable resistance range of existing equipment is only 0~5Ω, or fixed to 1Ω, 300Ω, 2kΩ, etc., and the resistance adjustment is a stepless knob design, which takes a long time to adjust multiple channels. The supported measurement voltage range is 22~29V, which cannot meet the verification requirements of different hot knife / memory alloy products with large differences, and cannot meet the testing requirements of different bus voltages of 12V / 28V / 30V / 42V / 64V / 100V;

[0011] (3) Traditional equivalent devices only consider the verification of pyrotechnics and are only applicable to the instantaneous pulse detonation of conventional pyrotechnics at the millisecond level. The series resistors are ordinary resistors rather than power resistors. When conducting the minute-level continuous high current test required for hot knife / memory alloy unlocking, the components will be damaged due to heat accumulation.

[0012] (4) The existing adjustable resistance hot knife device is an onboard product and cannot be used for path verification of products such as hot knives / memory alloys. The entire power supply path cannot be verified before delivery, which poses a risk of recurrence due to potential problems. The complexity of onboard products will increase risks and reduce the reliability of satellites on orbit.

[0013] (5) Traditional pyrotechnic equivalents can only be used for single pyrotechnic channel verification and cannot meet the requirements of mixed synchronous testing of pyrotechnics, hot knives / memory alloys. Summary of the Invention

[0014] In order to solve the above problems, the present application provides a satellite unlocking device path equivalent device with a composite power resistor that is continuously adjustable.

[0015] The present application provides a composite power resistor continuously adjustable satellite unlocking device path equivalent device adopts the following technical solution:

[0016] A composite satellite unlocking device path equivalent device with continuously adjustable power resistance comprises a CPLD chip, a programmable power resistor card and a fixed resistor. The CPLD chip is respectively connected to the programmable power resistor card and the fixed resistor via an optocoupler isolation circuit. The programmable power resistor card is connected to the positive electrode of an unlocking voltage signal, and the optocoupler isolation circuit is connected to the negative electrode of the unlocking voltage signal. The programmable power resistor card and the fixed resistor are respectively connected to different resistance test holes. The CPLD chip is also connected to a dial switch panel and an indicator module, wherein the indicator module is a plurality of LED indicator lights. The CPLD chip is used for detecting an unlocking drive signal, selecting a load power resistor value, and outputting an indicator module for latching when pyrotechnic products are continuously detonated. The programmable power resistor card realizes resistance values of different gears by controlling different internal cascade resistor chains. The dial switch panel is provided with a plurality of dial buttons for selecting different test paths and the power load resistor values of the programmable power resistor card.

[0017] Furthermore, in order to meet the test requirements of long-term high-current power supply of hot knife / memory alloy, and to achieve adjustable 0-50Ω power resistance for different resistance / voltage test requirements, the resistance adjustment range of the programmable resistor card is 0-50Ω, with an adjustment step of 0.1Ω~1Ω, which can be set according to actual usage requirements, and the maximum allowable path current is 10A, which has certain requirements for the resistance power, so the resistor is selected as a 100W power resistor; the resistance value of the fixed resistor is 2kΩ.

[0018] The design of the power programmable resistor matrix can not only meet the test requirements of equivalent load of different resistance values in each path, but also can be applied to high-power testing of hot knife / memory alloy, and can also perform mixed testing of pyrotechnics / hot knife / memory alloy at the same time.

[0019] The power resistor matrix is adjusted via an external dip switch, which solves the problem of long adjustment time for multi-channel stepless knobs and avoids the problem of poor knob adjustment accuracy after the initial setup is completed;

[0020] To meet the testing requirements of lightweight, convenient, and miniaturized design, the CPLD chip is powered by a 9V lithium battery connected to a DC-DC converter. All single-channel pyrotechnics, hot knives, memory alloy programmable resistor cards, and optocoupler isolation circuits can be shared, saving volume and weight and reducing design complexity.

[0021] By choosing a field-programmable digital logic chip such as CPLD, you can build combinational logic or sequential logic functions that meet the requirements, implement test functions through hardware description language, and then compile and burn it into the CPLD to generate specific circuits that meet the corresponding needs. It has strong scalability.

[0022] In summary, this application includes at least one of the following beneficial technical effects:

[0023] The adjustable power resistor has a resistance range of 0~50Ω. Due to factors such as different cable lengths and the inherent resistance of the hot knife / memory alloy in different satellite deployment mechanisms, the loop resistance varies. Besides setting the resistance to KΩ to meet the requirements of pyrotechnic device path testing, the correctness, rationality, and reliability of the unlocking path design can be verified by adjusting the adjustable resistor value to the closest-to-real loop state.

[0024] The product adjusts the resistance matrix resistance value through the panel dial switch, with high adjustment accuracy and greatly improved multi-channel adjustment efficiency; it can meet the test requirements of different bus voltages by adjusting different loop resistance values;

[0025] The resistors used are all power resistors, which can not only meet the requirements of ms-level transient detonation path verification of explosive devices, but also the long-term power-on unlocking path verification of deployment mechanisms such as hot knives and memory alloys.

[0026] In addition to supporting a single pyrotechnic device access verification mode, it also supports mixed simultaneous verification testing of multiple unlocking device mechanisms such as pyrotechnic devices, hot knives, and memory alloys;

[0027] All pyrotechnics / memory alloy / hot knife verification paths share the same adjustable power resistor, which reduces the weight, volume and complexity of the designed product. It is suitable for mass production needs such as lightweight, miniaturization and convenience. The equivalent device has a simple design, without complex hardware and software systems, and is highly reliable, easy to operate and highly scalable. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 This is a schematic diagram of the circuit principle of this application;

[0029] Figure 2 Design a schematic diagram for a programmable power resistor card;

[0030] Figure 3 This is a schematic diagram of the design of the dip switch panel (diagram when the step is 0.5). DETAILED DESCRIPTION

[0031] The technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application; it is obvious that the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

[0032] In the description of this application, it should be noted that the terms "upper," "lower," "inner," "outer," "top / bottom," and the like, indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate the description of this application and simplify the description. They do not indicate or imply that the devices or components referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0033] In the description of this application, it should be noted that, unless otherwise expressly specified or limited, the terms "installed," "provided with," "mounted / connected," and "connected" should be understood in a broad sense. For example, "connected" can mean a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, or it can be internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in this application based on the specific circumstances.

[0034] The present application is further described in detail below with reference to the accompanying drawings.

[0035] An embodiment of the present application discloses a composite satellite unlocking device path equivalent device with continuously adjustable power resistance, comprising a CPLD chip, a programmable power resistor card and a fixed resistor. The CPLD chip is respectively connected to the programmable power resistor card and the fixed resistor through an optocoupler isolation circuit. The programmable power resistor card is connected to the positive electrode of the unlocking voltage signal, and the optocoupler isolation circuit is connected to the negative electrode of the unlocking voltage signal. The programmable power resistor card and the fixed resistor are respectively connected to different resistance test holes. The CPLD chip is also connected to a dial switch panel and an indicator module, and the indicator module is a plurality of LED indicator lights. The CPLD chip is used for detecting the unlocking drive signal, selecting the load power resistor value, and outputting the latch of the indicator module for continuous detonation of pyrotechnics. The programmable power resistor card realizes resistance values of different gears by controlling different internal cascade resistor chains. The dial switch panel is provided with a plurality of dial buttons to select different test paths and the power load resistor values of the programmable power resistor card.

[0036] Furthermore, in order to meet the test requirements of long-term high current power supply of hot knife / memory alloy, and to achieve the adjustable 0-50Ω power resistance for different resistance / voltage test requirements, refer to Figure 2 The resistance adjustment range of the programmable resistor card is 0-50Ω, and the adjustment step of 0.1Ω~1Ω can be set according to actual usage requirements. The maximum allowable path current is 10A, which has certain requirements for the resistor power, so the resistor is selected as a 100W power resistor; the resistance value of the fixed resistor is 2kΩ.

[0037] The design of the power programmable resistor matrix can not only meet the test requirements of equivalent load of different resistance values in each path, but also can be applied to high-power testing of hot knife / memory alloy, and can also perform mixed testing of pyrotechnics / hot knife / memory alloy at the same time.

[0038] The power resistor matrix is adjusted via an external dip switch, which solves the problem of long adjustment time for multi-channel stepless knobs and avoids the problem of poor knob adjustment accuracy after the initial setup is completed;

[0039] To meet the testing requirements of lightweight, convenient, and miniaturized design, the CPLD chip is powered by a 9V lithium battery connected to a DC-DC converter. All single-channel pyrotechnics, hot knives, memory alloy programmable resistor cards, and optocoupler isolation circuits can be shared, saving volume and weight and reducing design complexity.

[0040] By choosing a field-programmable digital logic chip such as CPLD, you can build combinational logic or sequential logic functions that meet the requirements, implement test functions through hardware description language, and then compile and burn it into the CPLD to generate specific circuits that meet the corresponding needs. It has strong scalability.

[0041] The implementation principle of the satellite unlocking device path equivalent device with continuously adjustable composite power resistance in the embodiment of the present application is as follows:

[0042] This design has two options for power load resistors. One is a programmable power resistor. Considering the need for long-term high-current power supply of hot knife / memory alloy, a 0-50Ω / 100W, 0.1Ω resistance resolution power resistor matrix is designed. The other is a fixed resistor (2kΩ, adjustable according to needs). The resistance value is set by the user through the panel resistor dial switch, and the CPLD is used to control the power resistor card to select the resistor channel or fixed resistor.

[0043] When you only need to test the correctness of the path connection, you only need to switch the dip switch to a fixed resistor (2kΩ, which can be adjusted according to needs). At this time, when there is an unlocking voltage signal input, the corresponding LED indicator lights up, indicating that the path is correct.

[0044] When it is necessary to simulate the actual situation of the entire pyrotechnic device circuit (such as instantaneous high-current pyrotechnic device testing, long-term high-current hot knife / memory alloy testing), switch the dip switch to the variable resistor state: After determining the required equivalent load resistance value, set the power load matching resistance. Switch the corresponding resistance value dip switch on the panel without slowly adjusting the knob. The CPLD I / O signal detects the dip switch state and controls the programmable power resistor matrix output to configure the corresponding power load resistance value. The set resistance value can be tested through the resistance test hole. At the same time, if the timing, voltage, current, pulse width, etc. of the pyrotechnic device / hot knife / memory alloy needs to be tested, in addition to testing the corresponding lead-out node of the on-board electrical connector, it can also be tested through the secondary test port to improve test redundancy and reduce the impact on the operational safety of on-board equipment.

[0045] Unlock drive voltage signal input: The unlock drive voltage signal is isolated by a programmable power resistor card or a fixed resistor and an optocoupler, and then outputs the corresponding signal into the CPLD;

[0046] LED Indicator: Depending on test requirements, the DIP switch can be set to flash or maintain. The CPLD implements a latched LED display for three tests of pyrotechnics, or a single LED display for hot knives / alloys. When only the unlocking voltage signal is required, the indicator lights up; when it is not, the DIP switch is set to flash. If the indicator remains on after the unlocking signal is input, the DIP switch is set to maintain.

[0047] Conventional pyrotechnic device test: The dial switch is set to hold. During the detonation process, the unlocking voltage signal will be sent three times in succession at an interval of 1s. As long as the detonation power signal is detected, the lock indicator light will be on, and the three LED lights will be lit in sequence according to the set three tests and locked and held. When the user presses the reset button, the LED indicator light will go out and return to the initial test state. Multiple repeated measurements can be performed.

[0048] Conventional memory alloy and hot knife path test: The dip switch is set to flashing, and an LED light is lit when there is a control signal in the path, and the LED light goes out when the control signal disappears.

[0049] Therefore, by configuring the flashing and holding panel buttons of the dip switch, you can switch or synchronize the pyrotechnic test or hot knife (alloy) test.

[0050] The device is powered by a 9V lithium battery during actual use, which is suitable for portable testing needs such as batch production testing or field testing.

[0051] The above are all preferred embodiments of the present application, and are not intended to limit the scope of protection of the present application. Therefore, any equivalent changes made based on the structure, shape, and principle of the present application should be included in the scope of protection of the present application.

Claims

1. A satellite unlocking device path equivalent device with continuously adjustable composite power resistance, characterized in that: The invention comprises a CPLD chip, a programmable power resistor card and a fixed resistor. The CPLD chip is respectively connected to the programmable power resistor card and the fixed resistor via an optocoupler isolation circuit. The programmable power resistor card is connected to the positive electrode of the unlocking voltage signal, and the optocoupler isolation circuit is connected to the negative electrode of the unlocking voltage signal. The programmable power resistor card and the fixed resistor are respectively connected to different resistance test holes. The CPLD chip is also connected to a dial switch panel and an indication module. The CPLD chip is used for detecting the unlocking drive signal, selecting the load power resistor value, and outputting the latch of the indication module for continuous detonation of the pyrotechnic product. The programmable power resistor card realizes resistance values of different gears by controlling different internal cascade resistor chains. The dial switch panel is provided with a plurality of dial control buttons for selecting different test paths and the power load resistor values of the programmable power resistor card. The programmable power resistor card is a 100W power resistor with a maximum allowable path current of 10A. Its resistance adjustment range is 0-50Ω with an adjustment step of 0.1Ω.

2. The satellite unlocking device path equivalent device with continuously adjustable composite power resistance according to claim 1, characterized in that: The resistance of the fixed resistor is 2 kΩ.

3. The satellite unlocking device path equivalent device with continuously adjustable composite power resistance according to claim 1, characterized in that: The indicator modules are a plurality of LED indicator lights.

4. The satellite unlocking device path equivalent device with continuously adjustable composite power resistance according to claim 1, characterized in that: The CPLD chip is powered by a 9V lithium battery connected to a DC-DC converter.

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