Electric thruster cooling system and method for electric propulsion ignition test

Abstract

The invention provides an electric thruster cooling system and method for an electric propulsion ignition test, and belongs to the technical field of cooling systems. Through the structural arrangement that the two cooling plates make close contact with the PPU module and the EPCU module respectively, the two cooling plates conduct independent refrigeration on the PPU module and the EPCU module through the upper control computer, and it is guaranteed that the temperature of the PPU module and the temperature of the EPCU module meet the requirement in the ignition test. The system comprises two cooling plates, a cooling pipeline and a cooling unit, one side of one cooling plate is tightly connected with a PPU module, one side of the other cooling plate is tightly connected with a PEPCU module, and temperature sensors are installed on the two cooling plates; a notch is milled in the back face of the cooling plate, the cooling plate is provided with a cooling pipeline through the notch, the portion, outside the vacuum cabin, of the cooling pipeline is connected with a cooling unit through a cabin penetrating flange, and the cooling unit comprises a heat exchanger and a medium pipeline and is connected with a control system.

Description

Technical Field

[0001] This invention relates to a cooling system and method for an electric thruster during an electric propulsion ignition test, specifically belonging to the technical field of cooling systems. Background Technology

[0002] The detector is equipped with an electric propulsion subsystem, and a whole-device-level electric propulsion ignition test needs to be carried out on the structural thermal controller. The whole device needs to verify the ability of the electric propulsion system to work normally under the support of the primary power supply subsystem and the GNC subsystem in a vacuum environment, as well as the impact of the electric propulsion subsystem on other related subsystem products of the whole device during operation. Publication number "CN115949562A" describes a self-cooling air-breathing radio frequency plasma electric thruster, comprising an air inlet, an ionization chamber, and a nozzle. The air inlet is divided into a main air inlet and a secondary air inlet. The main air inlet is connected to the ionization chamber, and a cooling channel is arranged around the periphery of the ionization chamber. The secondary air inlet is connected to a guide air channel, which is connected to the cooling channel through a cooling channel inlet. The cooling channel is connected to the ionization chamber through a cooling channel outlet. Gas drawn in through the main air inlet directly enters the ionization chamber for ionization. The gas taken in by the secondary air intake is guided to the inlet of the cooling channel through the air guide channel. After entering the cooling channel through the cooling channel inlet to cool the ionization chamber, it enters the ionization chamber through the cooling channel outlet for ionization. The two streams of gas entering the ionization chamber are ionized and accelerated through the nozzle, thereby generating thrust in the thruster. The device takes in gas from the surrounding thin atmosphere as working fluid through a special air intake device. Part of the gas directly enters the ionization chamber for acceleration, while the other part passes through the cooling channel to cool the thruster. However, the airflow cooling method is not very efficient. In the vacuum state electric propulsion ignition test of the detector, in order to verify the ability of the electric propulsion system to work normally with the support of the primary power supply subsystem and the GNC subsystem, as well as the impact of the electric propulsion subsystem on other related subsystem products of the whole device during operation, since the PPU and EPCU products will generate a large amount of heat consumption, it is necessary to implement separate cooling for them to ensure that the temperature of the related products meets the requirements during operation. Summary of the Invention

[0003] The purpose of this invention is to provide a cooling system and method for electric thrusters during electric propulsion ignition testing, so as to ensure that the temperature of the relevant products meets the requirements during operation.

[0004] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: The invention includes two cooling plates, cooling pipes, and a cooling unit. One cooling plate is tightly connected to a PPU module on one side, and the other cooling plate is tightly connected to an EPCU module on one side. Temperature sensors are installed on both cooling plates and connected to a control system. The cooling plates, PPU modules, and EPCU modules are all fixedly mounted on a process plate and are arranged inside the vacuum chamber through the process plate. The back of the cooling plate is milled with grooves, and cooling pipes are installed on the cooling plates through the grooves. The portion of the cooling pipes outside the vacuum chamber is connected to the cooling unit through a through-chamber flange. The cooling unit includes a heat exchanger and a medium pipeline, and the cooling unit is connected to a control system.

[0005] Furthermore, the control system automatically controls the normal operation of the bath oil unit, and the control functions are implemented through dedicated software. The software has functions such as displaying, storing, and alarming real-time data on bath oil temperature and pressure, and can also adjust and control the temperature based on feedback from the cooling plate. The cooling plate is made of copper plate. A heat-conducting medium is applied between the cooling plate and the PPU module, and between the cooling plate and the EPCU module. The cooling pipes are made of copper and are insulated from the vacuum chamber.

[0006] Furthermore, the cooling plate achieves temperature control for both the PPU and EPCU through close contact, and the application of a thermally conductive medium further enhances temperature control. The copper cooling pipes are soldered to the copper-based cooling plate, ensuring a sufficiently large contact area. The cooling pipes transfer heat to the cooling plate via an internal medium to achieve temperature control. The front of the cooling plate features mounting holes for both the PPU and EPCU modules; the hole spacing and center circle dimensions are determined based on the product. The coolant in the cooling pipes is bath oil medium, and the cooling unit is grounded. The cooling unit has four independent medium pipes, with two medium pipes corresponding to two cooling plates, and the other two medium pipes are spares.

[0007] Furthermore, the oil bath unit is used to provide refrigerant for cooling, realizing the cooling and heating of the refrigerant; the cooling pipeline is used to transport the refrigerant, and through the heat exchanger of the oil bath unit, it exchanges heat with the refrigerant and heating system of the temperature control unit to realize the high and low temperature control of the cooling plate; Furthermore, five temperature measuring points are installed on the cooling plate, and the cooling pipes integrated on the back of the cooling plate adopt a continuous S-shaped zigzag flow channel layout.

[0008] Furthermore, the electric thruster cooling system cools the PPU module and EPCU module, including the following steps: Step 1: Detect and provide feedback on the temperature of the two cooling plates using temperature sensors; Step 2: The control system regulates and controls the temperature of the heat transfer medium through the cooling unit; Step 3: The cooling pipes regulate the temperature of the two cooling plates through the heat transfer medium, and then regulate the temperature of the PPU module and EPCU module through the two cooling plates.

[0009] The structure, which features two cooling plates in close contact with the PPU and EPCU modules respectively, allows the two cooling plates to individually cool the PPU and EPCU modules via a host control computer. This improves the overall intelligence of the device and ensures that the PPU and EPCU modules meet the temperature requirements during ignition testing, which is beneficial for the smooth conduct of electric propulsion ignition tests. As a result, the device is characterized by its simple structure and efficient cooling effect. Attached Figure Description

[0010] Figure 1 This is a schematic diagram of the back structure of the cooling plate of the present invention; Figure 2 This is a schematic diagram of the front structure of the cooling plate of the present invention; Figure 3 This is a schematic diagram showing the contact positions of the two cooling plates of the present invention with the PPU module and the EPCU module; Figure 4 This is a schematic diagram of the installation position of the process plate of the present invention; Figure 5 This is a schematic diagram of the cooling system flow of the present invention.

[0011] 1. Cooling system; 2. Cooling unit; 3. Control system; 4. Cooling piping; 5. Cooling plate; 6. PPU module; 7. EPCU module; 8. Process plate; 9. Through-chamber flange. Detailed Implementation

[0012] The following will be combined with the appendix Figure 1-5 The technical solutions in the embodiments are described clearly and completely.

[0013] Specific implementation method one: as follows Figure 1-4 As shown, the cooling system 1 includes two cooling plates 5, cooling pipes 4, and a cooling unit 2. One cooling plate 5 is tightly connected to a PPU module 6 on one side, and the other cooling plate 5 is tightly connected to an EPCU module 7 on one side. Temperature sensors are installed on both cooling plates 5, and the temperature sensors are connected to a control system 3. The cooling plates 5, PPU module 6, and EPCU module are all fixedly installed on a process plate 8. The cooling plates 5, PPU module 6, and EPCU module 7 are set inside the vacuum chamber through the process plate 8. The PPU module 6 and EPCU module 7 are individually cooled by a host control computer. The two cooling plates 5 maintain close contact with the PPU module 6 and EPCU module 7, and a heat-conducting medium can be applied between them. The dimensions and interfaces of the cooling plates 5 must meet the product and installation requirements. A Pt100 temperature sensor is used on the cooling plates 5 for temperature measurement, and the temperature sensor is connected to the control system 3. Leakage testing should be performed on the cooling plates 5 before installation. Specifically, such as Figure 1 and Figure 2 As shown, the back of the cooling plate 5 is milled with a groove, and the cooling plate 5 is installed with a cooling pipe 4 through the groove. The part of the cooling pipe 4 located outside the vacuum chamber is connected to the cooling unit 2 through the through-chamber flange 9. The cooling unit 2 includes a heat exchanger and a medium pipeline, and the cooling unit 2 is connected to the control system 3. Cooling plate 5 is made of copper plate with a thickness of 18mm. The back of cooling plate 5 is milled with flow channels for installing copper pipes. It has a pressure resistance of 1MPa. Cooling pipe 4, along with the system, should be leak-tested before being put into use. After passing the leak test, temperature-controlled wrapping is applied on-site. The copper pipes and copper plate are soldered together with silver solder to ensure a sufficiently large contact surface. The pressure loss of the pipe + cooling plate design should not exceed 0.1MPa, while the outlet pressure of the oil bath unit is 0.35MPa, meeting the coolant pressure difference range of 0.2-0.4MPa required in the specifications. The copper pipes transfer heat to the copper plate through the temperature control of the medium inside the pipes to achieve temperature control. Corresponding product mounting holes are arranged on the front of cooling plate 5. The hole spacing and center circle dimensions are determined according to the product. Detailed calculations and designs will be performed later based on the interface requirements of PPU module 6 and EPCU module 7. At least five PT100 temperature measurement points will be installed on cooling plate 5. The coolant in cooling pipe 4 is bath oil medium, and cooling unit 2 is grounded; the medium pipeline in cooling unit 2 is independently set with four lines, two of which are set to correspond to two cooling plates 5, and the other two medium pipelines are set as spares. The oil bath unit uses heat transfer oil as the heat transfer medium to achieve a working environment of -30℃ to +120℃ inside the container. The oil bath unit mainly includes an oil bath-type temperature control unit and corresponding refrigerant piping, used in conjunction with the cooling plate 5 inside the vacuum chamber. The cooling plate 5 and the heat transfer piping of the temperature control unit are filled with the heat transfer medium, forming a variable-volume closed pipeline with the expansion tank. Heat exchange is achieved through a heat exchanger with the refrigerant and heating system of the temperature control unit, thus realizing high and low temperature control of the cooling plate 5. The unit integrates cooling and heating functions, enabling cycle switching between cooling and heating. After heating operation, the cooling system can be directly activated for temperature reduction. The oil bath refrigeration and heating system uses silicone oil as the heat transfer medium between itself and the heat sink. Different types and specifications of heat transfer oil are suitable for different heat transfer temperatures, with a minimum operating temperature of -80℃. The unit's medium temperature range is -80℃ to 160℃, with a temperature control accuracy of ±1℃. All components except the piping are housed within the heat transfer oil temperature control unit. Because only the heat transfer medium within the expansion chamber comes into contact with oxygen in the air (and the expansion chamber temperature ranges from room temperature to 60°C), the risk of oxidation and absorption of moisture from the air by the heat transfer medium is reduced. At high temperatures, no heat transfer medium evaporates, eliminating the need for replacement, and continuous temperature control can be achieved without pressurization.

[0014] The system employs a fully enclosed pipeline design and a high-efficiency plate heat exchanger, reducing the demand for heat transfer fluid while improving the system's heat utilization rate and achieving rapid temperature rise and fall. Within the closed system, the heat transfer medium is contained in an expansion tank. The heat transfer medium in the expansion tank does not participate in the circulation; regardless of high or low temperatures, the expansion tank temperature ranges from room temperature to 60 degrees Celsius, reducing the risk of moisture absorption and evaporation by the heat transfer medium during operation.

[0015] The temperature control unit employs PID control, which, by changing the control setpoint, can quickly respond to system lag during the process and minimize system overshoot. The control consists of two sets of PID control loops: a master loop and a slave loop. The control output of the master loop serves as the setpoint for the slave loop. The system includes a feedforward PV signal; the output of the PID controller in the master loop is combined with the feedforward PV signal to serve as the setpoint for the control loop. This gradient control of temperature changes ensures system accuracy.

[0016] A specially designed hysteresis predictor generates a dynamic signal that replaces the process variable as a feedback signal, enabling the controller to anticipate minimal hysteresis in its control action. This ensures the controller always generates a suitable control signal, reducing the impact of hysteresis and maintaining system stability. The temperature control system monitors its operation through three-point sampling (material temperature, system outlet temperature, and system inlet temperature).

[0017] Specific implementation method two: such as Figure 5 As shown, the electric thruster cooling system cools the PPU module 6 and EPCU module 7, including the following steps: Step 1: Detect and provide feedback on the temperature of the two cooling plates 5 using temperature sensors; Step 2: Control system 3 regulates and controls the temperature of the heat transfer medium through cooling unit 2; Step 3: The cooling pipe 4 adjusts the temperature of the two cooling plates 5 through the heat transfer medium, and then adjusts the temperature of the PPU module 6 and EPCU module 7 through the two cooling plates 5 respectively.

[0018] The entire control and monitoring system consists of a control computer, a PLC control system, secondary instruments, communication modules, sensors, buttons, and indicator lights. Control and monitoring system structure; Through the cooperation of the host computer software (3D Force Control) and the slave computer software (Siemens PLC control module), the operation control and status monitoring of the entire equipment are realized. The control system is divided into a field control layer and a local control layer at the control level, and into automatic mode and manual mode at the functional level, as detailed below: Field control layer: This mainly includes the actuators, sensors, control cabinets, and tablet PCs within the system. The control mode is selected by switching between local and remote modes using the local / remote mode switch button on the field control cabinet. The field control adopts a modular design, allowing the system to independently complete manual and automatic temperature cycling. In local control mode, manual operation is performed via a local touchscreen tablet PC to control the equipment. In this mode, the host computer is only used to monitor all parameters and equipment operating status. If the remote control from the host computer malfunctions, the system can switch back to local control mode at any time, allowing direct control of the equipment through the control cabinet.

[0019] Remote control layer: In remote control mode, control of the equipment is achieved by clicking buttons on the host computer configuration screen. Buttons on the field control cabinet are disabled. The host computer configuration screen must not only monitor all process parameters and equipment operating status, but also display and store the required test specimen temperature data.

[0020] Automatic control mode: Customers operate and configure the equipment by sending operating commands and parameters to various subsystems through the monitoring screen of the control computer. The PLC controller collects various parameters and statuses during equipment operation through various IO modules, and exchanges status information and control commands with the vacuum pump unit through the communication module.

[0021] Manual control mode: Customers can operate the equipment via the touchscreen, secondary instruments, buttons, and local operation panels or buttons on devices such as vacuum pump units within the control cabinet. The control computer obtains all operating statuses and parameters of the equipment through the PLC controller and I / O modules.

[0022] The local oil bath chiller unit is equipped with a Siemens Smart 700 touchscreen, featuring outlet temperature display, inlet temperature display, and alarm displays for power failure and phase loss. The unit has comprehensive alarm functions, including but not limited to: phase sequence / phase loss protection switch, temperature over-limit, heater over-temperature, compressor suction and discharge pressure, system closed circuit, sensor open circuit, etc. When necessary, the PLC can provide power-off protection for the unit or part of the system. Additionally, the equipment is equipped with audible and visual alarms, allowing for rapid on-site access to equipment fault information.

[0023] The on-site operation panel (HMI touchscreen) is installed on the door of the electrical cabinet. It enables monitoring of all temperatures, including manual operation, programmed operation, operation curves, and alarm information display. It can operate independently of a PLC (local control) or work in parallel with a host computer (remote control). HMI operation can be disabled on the touchscreen or via the host computer, retaining only the remote control function. To allow for flexible user configuration, the system features both manual and automatic operation modes. It accurately displays parameters such as temperature and runtime at multiple test points, and incorporates two-level hardware bidirectional protection to prevent unit malfunction and potential damage to the tested product.

[0024] The PLC in the heating and cooling system has a reserved RS485 interface for communication with the host computer. The PLC can receive commands (start / stop, temperature setpoint, alarm reset, etc.) from the host computer and report the heat transfer oil temperature, unit operating status and alarm information to the host computer in real time. The unit supports multiple communication protocols such as PPI slave, MPI slave and free port. Workflow: Two cooling plates 5 are designed according to requirements. After the PPU module 6 and EPCU module 7 are fixed to the cooling plates 5, they are installed on the process plate 8. Through the cooperation of the host computer software (3D Force Control) and the slave computer software (Siemens PLC control module), the two cooling plates 5 can individually cool the PPU module 6 and EPCU module 7, thereby realizing the operation control and status monitoring of the entire equipment, and ensuring that the temperature of the PPU module 6 and EPCU module 7 meets the requirements in the ignition test.

[0025] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent substitutions, and improvements made to the above embodiments without departing from the scope of the present invention, based on the technical essence of the present invention and within the spirit and principles of the present invention, shall still fall within the protection scope of the present invention.

Claims

1. A cooling system for an electric thruster during an electric propulsion ignition test, characterized in that, It includes two cooling plates (5), cooling pipes (4) and a cooling unit (2). One cooling plate (5) is tightly connected to a PPU module (6) on one side, and the other cooling plate (5) is tightly connected to an EPCU module (7) on one side. Temperature sensors are installed on both cooling plates (5), and the temperature sensors are connected to a control system (3). The cooling plates (5), PPU module (6) and EPCU module (7) are all fixedly installed on a process plate (8). The cooling plates (5), PPU module (6) and EPCU module (7) are set in the vacuum chamber through the process plate (8). The cooling plate (5) has a slot milled on the back. The cooling plate (5) is fitted with a cooling pipe (4) through the slot. The part of the cooling pipe (4) located outside the vacuum chamber is connected to a cooling unit (2) through a through-chamber flange (9). The cooling unit (2) includes a heat exchanger and a medium pipeline, and the cooling unit (2) is connected to a control system (3).

2. The electric thruster cooling system for an electric propulsion ignition test according to claim 1, characterized in that, The cooling plate (5) is made of copper plate. The cooling plate (5) and the PPU module (6) and the cooling plate (5) and the EPCU module (7) are coated with heat-conducting medium. The cooling pipe (4) is made of copper and is insulated from the vacuum chamber.

3. The electric thruster cooling system for an electric propulsion ignition test according to claim 2, characterized in that, The coolant in the cooling pipe (4) is bath oil medium, and the cooling unit (2) is grounded.

4. The electric thruster cooling system for an electric propulsion ignition test according to claim 1, characterized in that, The cooling unit (2) has four independent medium pipelines, two of which are set for the two cooling plates (5), and the other two are spare medium pipelines.

5. The electric thruster cooling system for an electric propulsion ignition test according to claim 1, characterized in that, Five temperature measuring points are installed on the cooling plate (5), and the cooling pipe (4) integrated on the back of the cooling plate (5) adopts a continuous S-shaped zigzag flow channel layout.

6. The electric thruster cooling method for an electric propulsion ignition test according to claim 1, characterized in that, The cooling system according to claim 1 performs cooling treatment on the PPU module (6) and EPCU module (7), comprising the following steps: Step 1: Detect and provide feedback on the temperature of the two cooling plates (5) using temperature sensors; Step 2: The control system (3) regulates and controls the temperature of the heat transfer medium through the cooling unit (2); Step 3: The cooling pipe (4) adjusts the temperature of the two cooling plates (5) through the heat transfer medium, and then adjusts the temperature of the PPU module (6) and EPCU module (7) through the two cooling plates (5).

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