Semi-physical simulation test method and system for reusable rocket engine controller

Abstract

The invention discloses a reusable rocket engine controller semi-physical simulation test method and system, and relates to the technical field of control systems.The reusable rocket engine controller semi-physical simulation test method comprises the steps that in a rocket engine propulsion system, local coaxial capacitance between a PTFE lining and an outer metal shell is calculated; calculating a wiring side equivalent capacitance formed by a shielding cable relative to a cabinet grounding path in the controller side electrical connection link; calculating a data acquisition channel baseline of the independent data acquisition channel; an equivalent injection charge is calculated based on a data acquisition channel baseline and a reference capacitance of a controller acquisition module. According to the invention, the dynamic response of the electrical link in the actual operation process can be accurately reflected.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of control systems, and in particular to a reusable rocket engine controller semi-physical simulation test method and system. BACKGROUND

[0002] In modern aerospace engineering, the rocket engine controller is a key interface between the propulsion system and the upper control system, and its performance stability is directly related to the safe and reliable execution of key actions such as engine ignition, throttling and shutdown. In order to verify the logic function, signal response and electrical stability of the controller under ground conditions, it is usually necessary to carry out semi-physical simulation testing, and to generate equivalent signals and load conditions through a simulation system to simulate the control environment in actual flight. However, the propulsion system contains low-temperature fluid delivery pipelines, quick disconnect seats, shielded cables and multi-stage grounding structures, and there are complex distributed capacitances and transient charge transfer phenomena between the controller side and the propulsion system side, which can cause the reference potential at the input end of the controller to easily rise or drift during simulation testing. When the test conditions, wiring topology or grounding state change, this potential drift can significantly affect the stability of the sampling reference, and thus cause inconsistent and insufficient repeatability of the test results.

[0003] The existing semi-physical simulation test scheme mainly simulates the electrical characteristics of the propulsion system through software modeling or empirical parameter correction, usually ignoring the actual capacitance distribution and charge injection effects between the controller and the shielded cable, the quick disconnect seat and the metal shell, and cannot accurately reflect the dynamic response of the electrical link during actual operation. Due to the need for multiple disassembly and repeated connection during testing, different batches of tests often need to be re-parameterized, resulting in low test efficiency and poor reusability; at the same time, there is a lack of quantitative description of the energy storage distribution between the shielded path and the control link, which can easily cause error accumulation and affect the accurate evaluation of the stability of the controller. SUMMARY

[0004] The purpose of the present application is to solve the problem in the prior art that the dynamic response of the electrical link during actual operation cannot be accurately reflected, and a reusable rocket engine controller semi-physical simulation test method and system are proposed.

[0005] In order to solve the problems in the prior art, the present application adopts the following technical solutions: A reusable rocket engine controller semi-physical simulation test method, comprising: S1, calculating the local coaxial capacitance between the PTFE lining and the outer metal shell in the rocket engine propulsion system, and calculating the wiring side equivalent capacitance formed by the shielded cable relative to the cabinet grounding path in the controller side electrical connection link; S2, calculating the data acquisition channel baseline of the independent data acquisition channel; S3. Calculate the equivalent injected charge based on the baseline of the data acquisition channel and the reference capacitance of the controller acquisition module; S4. Determine the updated one-time lift amount based on the equivalent injected charge, reference capacitance, local coaxial capacitance and wiring-side equivalent capacitance, and calculate the lift amount error based on the updated one-time lift amount; S5. Generate a reusable configuration package for the hardware-in-the-loop simulation test process based on the lifting error and the preset error threshold. S6. Reuse the test parameters of the rocket engine controller according to the reuse configuration package.

[0006] Preferably, calculating the local coaxial capacitance between the PTFE liner and the outer metal shell includes: Obtain the effective axial length of the overlapping structure of the PTFE liner and outer metal shell of the cryogenic rapid disconnection seat in the rocket engine propulsion system; Measure the radius of the inner channel of the PTFE liner; Measure the outer radius of the contact point between the outer surface of the PTFE liner and the outer metal shell; The natural logarithm of the ratio between the inner channel radius and the outer radius is used to obtain the structural geometric proportionality coefficient. Based on the effective axial length of the structure and the geometric proportionality coefficient of the structure, the local coaxial capacitance between the PTFE liner and the outer metal shell is calculated. The formula for calculating the local coaxial capacitance between the PTFE liner and the outer metal shell is as follows: In the formula, It is the absolute dielectric constant of PTFE material. It is the effective axial length of the structure. It is the geometric scale factor on the structural side. It is a local coaxial capacitance between the PTFE inner liner and the outer metal shell.

[0007] Preferably, calculating the equivalent capacitance on the wiring side of the shielded cable relative to the cabinet grounding path in the controller-side electrical connection link includes: Obtain the effective axial length of the shielded cable on the wiring side in the electrical connection link on the controller side under approximately coaxial wiring conditions; Obtain the outer radius of the metal conductive coating layer inside the shielded cable; Obtain the average radial gap between the outer surface of the metal conductive coating inside the shielded cable and the external metal reference surface; The sum of the outer radius of the conductive metal coating and the average radial gap is divided by the outer radius of the conductive metal coating to obtain the radius ratio of the coaxial structure. The natural logarithm of the radius ratio of the coaxial structure is used to obtain the geometric scale coefficient on the wiring side. Obtain the absolute dielectric constant of the dielectric material between the conductive metal cladding layer and the external metal reference surface; Based on the absolute dielectric constant, the effective axial length of the cabling side, and the geometric scaling factor of the cabling side, the equivalent capacitance of the shielded cable relative to the cabinet grounding path in the controller-side electrical connection link is calculated. The formula for calculating the equivalent capacitance of the cabling side is as follows: In the formula, It is the absolute permittivity. It is the effective axial length of the k-th shielded cable under approximately coaxial cabling conditions. This is the geometric scaling factor on the cabling side, where k is the shielded cable number. It is the equivalent capacitance on the wiring side.

[0008] Preferably, calculating the baseline of the independent data acquisition channel includes: The controller acquisition module for locating the rocket engine controller; Four wires are simultaneously drawn from the reference potential node of the controller acquisition module; Determine the shielding path of the rocket engine propulsion system; Insert compliant shielded breakpoint jumpers at the reserved locations in the shielded path, and record the electrical connection status bits of the shielded breakpoint jumpers in the shielded path; Two of the four wires are connected to the analog-to-digital converter of the controller's acquisition module, while the other two wires are connected to an independent data acquisition channel through a high-impedance isolation network. The reference potential signal of the independent data acquisition channel is continuously sampled and recorded to obtain the real-time trajectory of the data acquisition channel; Acquire real-time trajectory data of the data acquisition channel before the start of the hardware-in-the-loop test exercise; The baseline of the data acquisition channel is obtained by averaging the sampled data over time.

[0009] Preferably, the equivalent injected charge is calculated based on the baseline of the data acquisition channel and the reference capacitance of the controller acquisition module, including: The opening, closing, and locking of the cryogenic rapid disconnector were practiced under conditions where no fluid was introduced into the rocket engine propulsion system. After the opening, closing and locking drills are completed, the potential offset is calculated based on the real-time trajectory and baseline of the data acquisition channel. The maximum value of all potential offsets is calculated to obtain the initial one-time rise. The reference capacitance of the controller acquisition module is added to the equivalent capacitance on the wiring side to obtain the total equivalent capacitance. The equivalent injected charge is obtained by multiplying the total equivalent capacitance by the initial one-time rise.

[0010] Preferably, the update one-time lift amount is determined based on the equivalent injected charge, reference capacitance, local coaxial capacitance, and wiring-side equivalent capacitance, including: The capacitance allocation coefficient is calculated based on the reference capacitance, local coaxial capacitance, and equivalent capacitance on the wiring side of the controller acquisition module. Divide the equivalent injected charge by the capacitance distribution factor to obtain the total injected charge; Switch the electrical connection status of the shielded breakpoint jumper and re-perform the opening, closing and locking drills of the low-temperature quick-disconnect socket to obtain the updated one-time lifting amount.

[0011] Preferably, the calculation of the lift error based on the updated one-time lift includes: The reconstructed wiring-side equivalent capacitance is determined based on the initial one-time lift, the updated one-time lift, the reference capacitance of the controller acquisition module, and the wiring-side equivalent capacitance. The reference capacitance, local coaxial capacitance, and reconstructed wiring-side equivalent capacitance of the controller acquisition module are added together to obtain the total equivalent capacitance after reconstruction. Divide the total injected charge by the reconstructed total equivalent capacitance to obtain the predicted one-time lift. Under the condition that no fluid was introduced into the rocket engine propulsion system, the opening, closing and locking of the cryogenic rapid disconnect seat was conducted for the third time to obtain the measured one-time lift. The difference between the measured one-time lift and the predicted one-time lift is calculated to obtain the lift error.

[0012] Preferably, based on the lift error and a preset error threshold, a reusable configuration package for the hardware-in-the-loop simulation test process is generated, including: The difference between the lifting error and the preset error threshold is calculated to obtain the error comparison result; When the error comparison results meet the tolerance requirements of the hardware-in-the-loop simulation test process, a reuse configuration package for the hardware-in-the-loop simulation test process is generated based on the sampling parameters of the controller acquisition module and the shielded connection status of the rocket engine propulsion system. When the error comparison result does not meet the tolerance requirements, a correction command for the equivalent capacitance on the wiring side is output. The opening, closing and locking drills of the low-temperature fast disconnector are repeated according to the correction command until the error comparison result meets the tolerance requirements of the hardware-in-the-loop simulation test process.

[0013] Preferably, the formula for calculating the capacitance distribution coefficient is as follows: In the formula, It is the reference capacitor for the controller's data acquisition module. It is a local coaxial capacitance. It is the equivalent capacitance on the wiring side.

[0014] To address the aforementioned problems, the present invention also provides a reusable rocket engine controller hardware-in-the-loop simulation testing system, the system comprising: The capacitance modeling module is used to calculate the local coaxial capacitance between the PTFE liner and the outer metal shell in a rocket engine propulsion system, and to calculate the equivalent capacitance of the wiring side formed by the shielded cable relative to the grounding path of the cabinet in the electrical connection link on the controller side. The baseline calculation module is used to calculate the baseline of the independent data acquisition channel; The injection quantity calculation module is used to calculate the equivalent injected charge based on the baseline of the data acquisition channel and the reference capacitance of the controller acquisition module; The error assessment module is used to determine the updated one-time lift amount based on the equivalent injected charge, reference capacitance, local coaxial capacitance and wiring-side equivalent capacitance, and to calculate the lift amount error based on the updated one-time lift amount; The reuse configuration generation module is used to generate a reuse configuration package for the semi-physical simulation test process based on the lifting error and the preset error threshold. The parameter reuse setting module is used to reuse and set the test parameters of the rocket engine controller according to the reuse configuration package.

[0015] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention achieves quantitative measurement of the potential drift and transient rise behavior of the controller input terminal by parametrically modeling the local coaxial capacitance of key parts of the propulsion system, the equivalent capacitance of the wiring on the controller side, and the reference capacitance of the controller acquisition module, and by combining the baseline calibration of the independent data acquisition channel. It can accurately reflect the dynamic response of the electrical link during actual operation and provide a repeatable and traceable electrical benchmark for semi-physical simulation testing.

[0016] 2. This invention, through multiple rounds of opening, closing and locking drills of the low-temperature rapid disconnector, combined with the switching of the electrical connection status of the shielding path, forms a complete error comparison and calibration process. It can automatically identify and correct differences in energy storage distribution caused by changes in wiring status, shielding breakpoints or grounding methods, thereby improving the reusability of the simulation test process and data consistency.

[0017] 3. By generating a reusable configuration package containing sampling parameters, wiring parameters, and error tolerance, this invention achieves the standardization and automatic reuse of test process parameters, reduces the workload of manual calibration and data acquisition for repeated tests, improves the engineering adaptability and efficient verification capability of the hardware-in-the-loop simulation platform, and ensures the accuracy and reliability of performance evaluation of rocket engine controllers under different test environments. Attached Figure Description

[0018] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate exemplary embodiments of the invention and, together with their description, serve to explain the invention and do not constitute an undue limitation thereof. In the drawings: Figure 1 This is a flowchart illustrating a hardware-in-the-loop simulation test method for a reusable rocket engine controller, provided in an embodiment of the present invention. Figure 2 This is a functional block diagram of a reusable rocket engine controller hardware-in-the-loop simulation test system provided in an embodiment of the present invention. Detailed Implementation

[0019] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0020] Example: This example provides a hardware-in-the-loop simulation test method for a reusable rocket engine controller. See [link to relevant documentation]. Figure 1 Specifically, including: S1. In the rocket engine propulsion system, calculate the local coaxial capacitance between the PTFE inner liner and the outer metal shell, and calculate the equivalent capacitance of the wiring side formed by the shielded cable relative to the grounding path of the cabinet in the electrical connection link on the controller side. In an embodiment of the present invention, calculating the local coaxial capacitance between the PTFE liner and the outer metal shell includes: Obtain the effective axial length of the overlapping structure of the PTFE liner and outer metal shell of the cryogenic rapid disconnection seat in the rocket engine propulsion system; Specifically, the rocket engine propulsion system refers to the power output system composed of propellant delivery, combustion, thrust control, and measurement and control components, which internally includes multiple high-pressure cryogenic fluid pipelines; the cryogenic quick disconnect seat is a mechanical connection device installed at the pipeline interface of the propulsion system for rapid separation and sealing restoration of the liquid medium; the PTFE liner is a polytetrafluoroethylene bushing installed inside the disconnect seat to isolate the cryogenic fluid from the metal shell and form an electrically insulating channel; the outer metal shell is a metal conductor layer covering the outside of the PTFE liner, used to withstand mechanical loads and form an external electric field shield; the effective axial length of the structure refers to the length of the continuous region where the PTFE liner and the outer metal shell overlap and maintain stable contact along the tube axis, and this length determines the capacitance distribution and energy storage characteristics of the local coaxial structure.

[0021] Specifically, the steps for obtaining the effective axial length of the overlapping structure between the PTFE liner and the outer metal shell of the cryogenic rapid disconnector in a rocket engine propulsion system include: first, disassembling the outer protective layer of the cryogenic rapid disconnector to expose the contact structure between the PTFE liner and the outer metal shell; then, using a high-precision vernier caliper or laser rangefinder, determining the contact starting point position between the initial end of the PTFE liner and the fully covered section of the outer metal shell along the axis of the disconnector; then, measuring step by step along the axis to the endpoint position where the PTFE liner and the outer metal shell separate; and by calculating the distance between the starting point and the endpoint, obtaining the continuous length of the PTFE liner and the outer metal shell that maintains mechanical contact and has a stable dielectric layer thickness in the axial direction; this length is the effective axial length of the structure, used to characterize the effective energy storage range formed by this local coaxial structure inside the disconnector.

[0022] Measure the radius of the inner channel of the PTFE liner; Measure the outer radius of the contact point between the outer surface of the PTFE liner and the outer metal shell; The natural logarithm of the ratio between the inner channel radius and the outer radius is used to obtain the structural geometric proportionality coefficient. Specifically, the inner channel radius refers to the radial distance from the inner wall of the PTFE inner liner's central channel to the geometric central axis, used to characterize the effective flow-guiding cross-sectional size of the cryogenic fluid channel; the outer radius refers to the radial distance at the contact point between the outer surface of the PTFE inner liner and the outer metal shell, used to reflect the thickness of the dielectric layer and the electrical constraint boundary of the external shielding layer; the ratio between the two represents the relative relationship between the radial thickness of the PTFE dielectric layer and the overall structural dimensions. The structural geometric proportionality coefficient obtained by performing a natural logarithmic operation on this ratio can characterize the nonlinearity of the electric field distribution in this local coaxial segment and serve as a geometric correction parameter for calculating the local equivalent capacitance.

[0023] Specifically, by accurately measuring the geometric dimensions of the PTFE liner inside the cryogenic quick-disconnect seat, the proportional parameters required for calculating the structural capacitance are established. First, the radial distance from the inner wall of the central channel of the PTFE liner to the axis is measured using an optical diameter gauge or laser rangefinder to obtain the inner channel radius, which reflects the guiding dimensions of the fluid channel. Then, the radius at the contact point between the outer surface of the PTFE liner and the outer metal shell is measured radially to obtain the outer radius, which characterizes the dielectric layer thickness and the shielding boundary of the outer shell. Finally, the natural logarithm of the ratio of the inner channel radius to the outer radius is taken to obtain the structural geometric proportionality coefficient. This coefficient describes the geometric relationship between the PTFE dielectric layer thickness and the coaxial structural dimensions, and provides correction parameters for subsequent local coaxial capacitance calculations, realizing the conversion of dielectric geometric characteristics into electrical equivalent parameters.

[0024] Based on the effective axial length of the structure and the geometric proportionality coefficient of the structure, the local coaxial capacitance between the PTFE liner and the outer metal shell is calculated. The formula for calculating the local coaxial capacitance between the PTFE liner and the outer metal shell is as follows: In the formula, It is the absolute dielectric constant of PTFE material. It is the effective axial length of the structure. It is the geometric scale factor on the structural side. It is a local coaxial capacitance between the PTFE inner liner and the outer metal shell.

[0025] Specifically, the polytetrafluoroethylene (PTFE) bushing inside the cryogenic rapid disconnector and the outer metal shell form a long, straight coaxial cylindrical structure. The bushing acts as a uniform dielectric layer, and the inner and outer surfaces of the metal shell serve as equipotential conductors. This structure is continuous in the axial direction with relatively small end effects, and the electrostatic field is mainly distributed radially, satisfying the field equations under steady-state electrostatic conditions. From the classical analytical conclusions of coaxial cylindrical capacitors, it is known that the capacitance is directly proportional to the dielectric constant of the dielectric, directly proportional to the axial overlap length, and inversely proportional to the logarithm of the ratio of the outer radius to the inner radius. In other words, the easier the dielectric is to polarize and the longer the overlap length, the more charge can be stored; the greater the difference between the two radii, the less charge can be stored per unit voltage. Approximating this coaxial line to this overlap section of the disconnector and neglecting edge effects, the resulting expression corresponds precisely to the local coaxial capacitance of this structure. Therefore, this method can be used to characterize the actual energy storage capacity between the bushing and the metal shell.

[0026] In embodiments of the present invention, calculating the equivalent capacitance on the cabling side of the shielded cable relative to the cabinet grounding path in the controller-side electrical connection link includes: Obtain the effective axial length of the shielded cable on the wiring side in the electrical connection link on the controller side under approximately coaxial wiring conditions; Specifically, the controller-side electrical connection link refers to a continuous transmission path consisting of a set of conductors and their shielding layers leading from the controller acquisition module to the external interface; the shielded cable is the cable segment in this path, with an outer metal braided layer or metal foil layer forming a conductive shielding shell, used to isolate the cable from the surrounding metal structure by electric field; the approximate coaxial wiring condition refers to the shielded cable being laid parallel to the adjacent metal conduit or cabinet metal surface along a certain length, maintaining basic concentricity or equidistance, so that it can be approximated as a coaxial cylindrical structure within this space; the effective axial length of the wiring side refers to the actual length along the cable axis of the segment that satisfies the above approximate coaxial relationship and maintains continuous shielding contact. This length determines the effective area between the shielding shell and the external metal reference surface that can participate in energy storage, used for subsequent calculation of the equivalent capacitance of the wiring side.

[0027] Specifically, the steps for obtaining the effective axial length of the cabling side include: determining the cabling path of the shielded cable from the controller acquisition module to the cabinet grounding terminal, and observing the relative positional relationship between the cable and adjacent metal housings, conduits, or cabinet walls along the path; then using a cabling diagram or a three-dimensional measuring device to determine the average radial distance between the cable and the external metal reference surface, and identifying the range of approximately coaxial segments that maintain equidistant distances and have no obvious bends; next, measuring the actual length of the shielded cable segment along the axial direction of the approximately coaxial segment using a flexible ranging tape or laser ranging tool; finally, recording the length of this continuously coaxially distributed segment as the effective axial length of the cabling side, which is used to characterize the effective range in which the shielded cable can form a stable electric field distribution and equivalent capacitance in the cabinet metal environment.

[0028] Obtain the outer radius of the metal conductive coating layer inside the shielded cable; Obtain the average radial gap between the outer surface of the metal conductive coating inside the shielded cable and the external metal reference surface; Specifically, the outer radius of the conductive metal sheath refers to the radial distance from the outer surface of the conductive metal sheath inside the shielded cable to the geometric center axis of the cable, which is used to characterize the thickness of the shielding layer and the conductive coverage area; the external metal reference surface refers to the external metal structural surface that is laid parallel to the shielded cable and forms a stable potential reference, such as the cabinet wall or grounding rail; the average radial clearance refers to the average distance between the outer surface of the conductive metal sheath of the shielded cable and the external metal reference surface over the entire wiring segment, which is used to characterize the spatial average distribution of the dielectric layer thickness between the two conductors. This parameter determines the electric field strength and equivalent capacitance between the cable and the external metal surface, and has a direct impact on the calculation of the equivalent capacitance on the wiring side.

[0029] Specifically, the steps for obtaining the outer radius of the metal conductive coating inside the shielded cable and the average radial gap between the outer surface of the coating and the external metal reference surface include: selecting a representative shielded cable segment in the electrical connection link on the controller side, performing partial stripping treatment on its ends to expose the inner metal conductive coating; then using a precision caliper or micro-diameter gauge to measure the radial distance from the geometric center of the cable to the outer surface of the metal conductive coating, and taking the average value of the multiple measurement results as the outer radius of the metal conductive coating; next, at the cable installation location, using a laser rangefinder or mechanical clearance gauge to measure the distance from the outer surface of the metal conductive coating to the external metal reference surface, taking multiple measurement points along the wiring direction and calculating the average value as the average radial gap between the two conductors.

[0030] The sum of the outer radius of the conductive metal coating and the average radial gap is divided by the outer radius of the conductive metal coating to obtain the radius ratio of the coaxial structure. The natural logarithm of the radius ratio of the coaxial structure is used to obtain the geometric scale coefficient on the wiring side. Obtain the absolute dielectric constant of the dielectric material between the conductive metal cladding layer and the external metal reference surface; Specifically, firstly, based on the previously obtained outer radius of the conductive metal cladding and the average radial clearance from the outer surface to the external metal reference surface, the ratio of the outer radius to the total radial distance is calculated point by point for the same wiring segment corresponding to the effective axial length, and the average within the segment is taken to obtain the coaxial structure radius ratio. Then, in the data processing terminal, the natural logarithm of this radius ratio is performed to generate the wiring-side geometric proportional coefficient, which is recorded in the parameter table with consistent length identifiers, and the measurement time and corresponding wiring segment number are marked to ensure traceability. Next, medium identification and value acquisition are carried out. First, the distance between the shielding layer and the external metal reference surface is confirmed according to the on-site wiring structure. The type of filling medium, including air, foam padding, or cable sheath residue, should be determined based on the bill of materials and manufacturer's datasheet. The absolute dielectric constant of the medium should be extracted and recorded. When mixed media are present on site or the datasheet is missing, a representative sample segment of the same length as the aforementioned cabling segment should be selected. A portable bridge should be used to calibrate and measure the capacitance formed by the shielding layer and the external metal reference surface of this segment. The absolute dielectric constant of the medium should be calculated by combining the recorded geometric proportionality coefficient and the effective axial length. The calculated value should be checked for consistency with the value in the datasheet. The value that passes the check should be used as the input of the absolute dielectric constant of the cabling segment.

[0031] Specifically, the coaxial structure radius ratio refers to the ratio of the sum of the outer radius of the internal conductive metal sheath of the shielded cable and the average radial gap between its outer surface and the external metal reference surface to the outer radius of the conductive metal sheath. It is used to characterize the geometric proportion of the cable segment in an approximately coaxial layout. The wiring side geometric proportion coefficient is a quantity obtained by taking the natural logarithm of the coaxial structure radius ratio. It is used to reflect the influence of the dielectric layer thickness between the shielded cable and the external metal reference surface on the electric field distribution and capacitance formation. The absolute dielectric constant of the dielectric material refers to the polarization capability of the dielectric filling medium between the conductive metal sheath and the external metal reference surface on the electric field. The higher the value, the more charge can be stored per unit voltage, which determines the size of the equivalent capacitance formed by the dielectric layer in the shielding path.

[0032] Specifically, the conductive metal sheath refers to the conductive layer, made of metal braided mesh or metal foil, that wraps around the signal conductor inside the shielded cable. Its function is to form an electromagnetic shielding channel and serve as the inner conductor boundary of the electric field. The external metal reference surface refers to the external metal structure that is laid parallel to the shielded cable and maintains a fixed potential, such as the cabinet wall, equipment housing, or grounding rail. It is used to provide a stable reference potential as the outer conductor boundary. Together, these two constitute the coaxial electric field system between the cable and the surrounding structure, which is an important geometric boundary condition that determines the equivalent capacitance on the wiring side.

[0033] Based on the absolute dielectric constant, the effective axial length of the cabling side, and the geometric scaling factor of the cabling side, the equivalent capacitance of the shielded cable relative to the cabinet grounding path in the controller-side electrical connection link is calculated. The formula for calculating the equivalent capacitance of the cabling side is as follows: In the formula, It is the absolute permittivity. It is the effective axial length of the k-th shielded cable under approximately coaxial cabling conditions. This is the geometric scaling factor on the cabling side, where k is the shielded cable number. It is the equivalent capacitance on the wiring side.

[0034] Specifically, the shielded cable and the external metal reference surface form a near-coaxial conductor system, with its dielectric layer composed of air or insulating material, continuously distributed along the axial direction. According to the relationship between capacitance and geometric parameters in an electrostatic field, the capacitance between conductors is proportional to the absolute permittivity of the dielectric, proportional to the conductor overlap length, and inversely proportional to the logarithm or geometric proportionality coefficient of the radial spacing between conductors. Since the shielded cable may have multiple near-coaxial regions with different directions and lengths during cabling, each segment needs to be calculated and summed according to its effective length to reflect the total energy storage capacity of the entire cabling channel. By introducing a geometric proportionality coefficient on the cabling side instead of the radius logarithmic ratio, the complex geometry can be normalized to a standard coaxial model, allowing the calculation results to accurately characterize the total equivalent capacitance of the shielded cable relative to the cabinet grounding path. This equivalent capacitance represents the total charge that the entire cabling channel can store under a given voltage, thus reflecting the coupling capability and energy response characteristics of the cabling side between electrical signals and the reference ground.

[0035] Specifically, before the hardware-in-the-loop simulation begins, capacitance quantification is performed on two key electrical structures to pre-characterize the energy sources that may cause a one-time rise in reference potential using calculable parameters: First, the PTFE bushing inside the cryogenic rapid disconnector and the outer metal shell form a long, straight coaxial section. The dielectric polarization and axial overlap length together determine the local energy that can be released instantaneously at this point. Therefore, the local coaxial capacitance needs to be calculated to assess the impact of the propulsion end on the reference node. Second, the shielded cable between the controller and the cabinet grounding path forms a distributed capacitance with the external metal reference surface under approximately coaxial wiring. Changes in length and gap will alter the energy distribution and rise amplitude of the reference loop. Therefore, the equivalent capacitance on the wiring side needs to be calculated to characterize the controller's absorption capacity on the reference node. By simultaneously obtaining the above two types of capacitance, a quantitative relationship between the source and the load can be established without the introduction of fluid, predicting and explaining the rise in reference potential, baseline drift, and changes in channel consistency. This provides a repeatable physical basis for subsequent exercise comparisons, error assessments, and reuse configuration generation.

[0036] S2. Calculate the baseline of the independent data acquisition channel; In an embodiment of the present invention, calculating the data acquisition channel baseline of an independent data acquisition channel includes: The controller acquisition module for locating the rocket engine controller; Specifically, the controller acquisition module of the rocket engine controller is the core unit that performs analog signal sampling and digital conversion. It contains an analog-to-digital converter, a reference potential node, and an isolation circuit, which is used to acquire voltage signals from various sensing channels of the propulsion system in real time and provide a stable reference.

[0037] Four wires are simultaneously drawn from the reference potential node of the controller acquisition module; Specifically, the reference potential node is an electrical equilibrium point in the acquisition module with a fixed potential and isolated from ground. Wires leading out from this node can synchronously monitor the dynamic changes of the module's reference. The four wires are designed to undertake data acquisition and reference monitoring tasks respectively. Two wires are connected to the analog-to-digital converter to form a reference input path, while the other two wires, after high-impedance isolation, enter an independent data acquisition channel to record minute fluctuations in the reference potential.

[0038] Specifically, firstly, within the control cabinet of the rocket engine control system, the installation location of the controller acquisition module is determined according to the electrical design drawings, and the positions of the module's power input terminal, signal sampling terminal, and reference potential node are confirmed. By removing the access port or pre-installed wiring terminals on the module casing, insulated shielded wires are used to make electrical connections to the reference potential node. To achieve high-precision synchronous sampling, four wires are simultaneously led out from the reference potential node. Two wires are connected to the reference input pin of the analog-to-digital converter to provide the measurement reference signal; the other two wires are connected to an independent data acquisition module through a high-impedance isolation network to record the fluctuation process of the reference potential in real time. All wires use shielded wire of the same specification, and reliable connections and consistent impedance are ensured through numbering and terminal crimping. After connection, insulation tests and continuity tests are conducted to verify the electrical connectivity and isolation between each wire and the reference node, ensuring stable and accurate signal transmission during subsequent sampling.

[0039] Determine the shielding path of the rocket engine propulsion system; Specifically, firstly, based on the electrical schematic and wiring design of the rocket engine propulsion system, the entire shielded cable path from the controller output to the actuator input is determined, and the locations of connectors, quick-disconnect sockets, and grounding terminals are identified. Then, according to the wiring harness routing within the cabinet and engine compartment, the continuity of the outer metal braided layer or aluminum foil covering of the shielded cable is checked to confirm whether a complete electrical closed path is formed between it and the cabinet grounding busbar. To ensure the accuracy of path identification, a conductivity tester or low-frequency signal generator is used to apply a micro-current to both ends of the shielding layer. The continuity status and path direction of the shielding layer are determined by resistance measurement and potential distribution changes. If there are branch shielding sections or intermediate connectors in the system, the electrical connection between their metal outer shells and the main ground plane is further confirmed. After completing the inspection, each shielding section is numbered and its start and end positions are marked, forming a complete topological description of the shielding path in the propulsion system.

[0040] Specifically, the shielding path of the rocket engine propulsion system is a conductive path continuously formed by shielded cables, connector metal shells, and cabinet grounding. It is used to suppress external electromagnetic interference during control signal transmission and to provide a unified grounding loop for the shielding layer, thereby maintaining the potential stability and signal integrity of the system measurement link.

[0041] Insert compliant shielded breakpoint jumpers at the reserved locations in the shielded path, and record the electrical connection status bits of the shielded breakpoint jumpers in the shielded path; Specifically, firstly, in the wiring path of the shielded cable of the propulsion system, according to the pre-reserved test node positions in the design, locate the shielded break point port for inserting the jumper, and confirm that the shielding layer at this location is reliably separated from the main shielding path. Connect both ends of the compliant shielded break point jumper to the metal braided mesh of the shielding layer on both sides of the break point, ensuring stable conductive contact and that the contact resistance meets design requirements through welding or thread crimping. After connection, use a continuity tester or digital multimeter to apply a weak test current to both ends of the break point to detect the continuity of the shielded break point jumper, and record its electrical connection status as either on or off. After connection, perform insulation testing and electromagnetic leakage checks on the outer surface of the shielding layer to confirm that the jumper connection does not affect the overall continuity and electrical integrity of the shielding layer. Finally, mark the shielding path number and the corresponding break point jumper status data in the test record table.

[0042] Two of the four wires are connected to the analog-to-digital converter of the controller's acquisition module, while the other two wires are connected to an independent data acquisition channel through a high-impedance isolation network. Specifically, four wires are first led out from the reference potential node of the controller acquisition module, and their numbers and functions are labeled. Two of these wires are used as the signal lines of the main acquisition path, connected to the input terminals of the analog-to-digital converter inside the controller acquisition module, to provide real-time monitoring of the reference potential signal. During the connection, the wires should be connected to the controller ground terminal via shielding terminals to reduce external electromagnetic interference. The remaining two wires are then used as auxiliary monitoring paths, connected to the independent data acquisition channel via a high-impedance isolation network. The high-impedance isolation network, composed of megohm-level resistors or opto-isolation modules, limits the signal current and isolates voltage coupling, ensuring electrical independence between the main acquisition circuit and the independent channel during sampling. After connection, the signal integrity of the main path and the isolation path is tested separately. A low-amplitude verification signal is applied to verify that the potential difference between the two paths is less than a predetermined deviation value, ensuring that the isolation path can synchronously record the transient potential changes of the reference node without affecting the sampling accuracy of the analog-to-digital converter.

[0043] Specifically, the reserved locations in the shielded path refer to the pre-designed disconnectable node positions in the control signal shielded cable wiring, used for connecting measuring equipment or jumpers during testing or calibration. Shielded breakpoint jumpers are short-circuit assemblies composed of conductive core wires, insulation layers, and an outer shielding layer, used to achieve electrically controllable connection or disconnection at the shielding layer breakpoint, thereby detecting the continuity and potential changes of the shielding layer. The electrical connection status bit is a digital identifier reflecting the conduction or open circuit status at both ends of the shielded breakpoint jumper, used to record the electrical continuity of the shielded path. The conductors are the conductors that transmit electrical signals. The configuration of four conductors is used to achieve synchronous monitoring between the reference node and the data acquisition system. Two conductors are directly connected to the analog-to-digital converter of the controller acquisition module to provide a stable reference input; the other two conductors are connected to an independent data acquisition channel via a high-impedance isolation network to prevent electrical disturbances in the sampling path from affecting the stability of the control loop. The high-impedance isolation network is an electrical isolation structure composed of high-resistance resistors or opto-isolation units, used to limit current flow and maintain channel potential isolation, thereby ensuring the sampling independence of the reference signal and the electrical safety of the system.

[0044] The reference potential signal of the independent data acquisition channel is continuously sampled and recorded to obtain the real-time trajectory of the data acquisition channel; Specifically, a high-input-impedance voltage sampling module is first installed at the input of the independent data acquisition channel to ensure that the signal measurement process does not cause load interference to the original circuit. Then, the input of this sampling module is connected to the lead wire of the reference potential node of the controller acquisition module, and power frequency interference and high-frequency noise are filtered out by an isolation filter circuit. Next, the sampling frequency and time step are set in the data acquisition system, and a continuous sampling program is started, causing the sampling module to periodically read the reference potential signal at fixed time intervals. Each sampled instantaneous voltage value is converted into a digital signal by an analog-to-digital converter and written to the buffer in real time. Simultaneously, the system records the sampling timestamp to form a time series. During the sampling process, the data acquisition program runs continuously until the preset sampling period ends, monitoring signal stability and data packet loss status to ensure the sampling process is continuous and complete. After sampling is completed, the potential change sequence of all sampling points over time is stored in chronological order as a continuous data trajectory, forming the real-time trajectory of the data acquisition channel, which is used for subsequent baseline extraction and potential offset analysis.

[0045] Specifically, an independent data acquisition channel refers to a voltage signal sampling branch configured independently of the controller's main acquisition module, used for synchronous monitoring of the reference potential without interfering with the control loop. The reference potential signal is the system ground potential or the instantaneous voltage of the grounding point relative to the independent measurement channel, used to characterize the electrical stability of the system's shielding layer and conductor structure. Continuous sampling refers to periodically reading the transient values ​​of the voltage signal within a set time interval and recording them with high time resolution to ensure complete capture of the potential change process. The real-time trajectory of the data acquisition channel refers to the sequence data of potential changes over time obtained by the independent channel throughout the entire sampling period, used to reflect the dynamic response process of the test node.

[0046] Acquire real-time trajectory data of the data acquisition channel before the start of the hardware-in-the-loop test exercise; Specifically, in the hardware-in-the-loop (HIL) simulation test system, the time series records of the real-time trajectory of the data acquisition channel are first read by the test control terminal to determine the time marker of the test exercise start command. Then, a pre-sampling time window is set before the exercise start time, preferably a range of five to ten seconds as the reference sampling segment. All recorded real-time trajectory data points within this interval are retrieved based on the timestamp, and the sampled data sequence within the corresponding time range is automatically extracted. After extraction, all voltage sample values ​​within this time period are rearranged in chronological order and stored in a separate buffer for subsequent time averaging calculations and baseline fitting. The resulting set of sampled data constitutes the static reference data collected before the start of the HIL simulation test exercise, accurately reflecting the reference potential level of the test node when it is not excited by a control signal.

[0047] The baseline of the data acquisition channel is obtained by averaging the sampled data over time.

[0048] Specifically, the sampled data extracted from the pre-sampling time period is first input into the data processing module in chronological order to check data integrity. Then, the processing module sets a time averaging method, dividing the entire sampling interval into continuous intervals of equal time steps. The arithmetic mean of the sampled voltage values ​​is calculated within each interval, resulting in the average voltage sequence for each interval. Subsequently, a weighted average is applied to the average voltage values ​​of all intervals to ensure that the result fully represents the overall static potential level within the sampling segment. The final output average voltage value serves as the baseline of the data acquisition channel, characterizing the static reference potential of the independent acquisition channel before the start of the hardware-in-the-loop simulation test.

[0049] Specifically, the sampled data is a set of multiple discrete voltage values ​​extracted from the real-time trajectory, used for subsequent data calculations or analysis. Time averaging involves calculating the arithmetic mean of all sampled data over a selected time period to eliminate errors caused by transient fluctuations, thereby obtaining a stable reference benchmark. The data acquisition channel baseline is a static potential reference value obtained through time averaging, used for subsequent judgment and calibration of potential offset and system noise levels.

[0050] Specifically, calculating the baseline of the independent data acquisition channels is to establish a stable potential reference point during the hardware-in-the-loop simulation test, used to distinguish the electrical changes between the normal static state and the dynamic response state. Because rocket engine control systems are affected by electromagnetic interference, temperature drift, and sampling circuit noise in the test environment, the acquired raw potential signals often contain random fluctuations and offset components. Directly using these for analysis would lead to distortion in the calculation of potential changes. By calculating the baseline of the data acquisition channels, the inherent average potential value of the system can be extracted during the static phase when no control signals are applied or actions are executed. This allows subsequent dynamic potential trajectories to be normalized and compared using this value as a zero point, thus accurately reflecting the true magnitude of changes after an electrical event is triggered. This baseline value can not only be used to calculate potential offset and reference rise, but also serve as a common reference for multi-channel signal synchronization alignment and noise compensation, improving the measurement consistency and data reproducibility of the entire simulation system.

[0051] S3. Calculate the equivalent injected charge based on the baseline of the data acquisition channel and the reference capacitance of the controller acquisition module; In an embodiment of the present invention, the equivalent injected charge is calculated based on the baseline of the data acquisition channel and the reference capacitance of the controller acquisition module, including: The opening, closing, and locking of the cryogenic rapid disconnector were practiced under conditions where no fluid was introduced into the rocket engine propulsion system. Specifically, firstly, with the rocket engine propulsion system in a static, sealed state and without any liquid or gaseous medium introduced, ensure all valves within the system are closed, and perform a sealing check on both ends of the cryogenic quick disconnector to confirm there are no leaks or residual pressure differentials. The control unit sends an opening / closing command to the disconnector's drive actuator, gradually releasing the internal mechanical locking mechanism, causing the plug and socket at the connection end to separate axially, completing one opening operation. After the opening operation is complete, the system maintains a stable monitoring phase, collecting the controller channel potential and signal changes to record the opening response characteristics. Next, a locking operation is performed, using the drive mechanism to reinsert the plug into the socket and reset the sealing structure until the mechanical locking device closes and sends a locking signal. Throughout the entire opening / closing and locking drill, the ambient temperature and power supply conditions must remain stable to ensure the disconnector's actions are triggered by control commands and are repeatable.

[0052] Specifically, a rocket engine propulsion system is an integrated structure composed of propellant delivery pipelines, combustion chambers, valves, quick-disconnect devices, and control units, used to complete the propellant supply and thrust output process of the engine. The condition of "no fluid introduction" means that no liquid or gaseous medium is introduced into the system under test conditions, keeping all fluid channels in a statically sealed state to eliminate interference from hydrodynamic factors on electrical signal measurements. The cryogenic quick-disconnect seat is a connection component with cryogenic sealing and rapid mechanical disengagement capabilities, used to achieve rapid separation and reconnection of fluid pipelines in the propulsion system. The opening, closing, and locking drill refers to performing a complete mechanical opening and closing cycle of the cryogenic quick-disconnect seat by controlling the drive mechanism to simulate its actions during a flight mission.

[0053] After the opening, closing and locking drills are completed, the potential offset is calculated based on the real-time trajectory and baseline of the data acquisition channel. Specifically, after completing the opening, closing, and locking drills of the low-temperature rapid disconnector, the real-time trajectory signal of the channel collected throughout the drill is extracted. This signal records the continuous change of the reference potential over time. Then, the baseline value of the data acquisition channel calculated in the previous stage is used as the zero potential reference to correct the static offset in the sampled signal. Next, the potential value at each time point in the real-time trajectory data is subtracted from the corresponding data acquisition channel baseline to obtain the instantaneous offset potential at each time point. To eliminate high-frequency noise interference, the instantaneous offset sequence is smoothed or averaged to extract the effective potential change trend generated by the disconnector during operation. Finally, the absolute peak value or statistical average amplitude is extracted from the processed offset curve, and this value is defined as the potential offset.

[0054] The maximum value of all potential offsets is calculated to obtain the initial one-time rise. The reference capacitance of the controller acquisition module is added to the equivalent capacitance on the wiring side to obtain the total equivalent capacitance. The equivalent injected charge is obtained by multiplying the total equivalent capacitance by the initial one-time rise.

[0055] Specifically, the potential offset refers to the instantaneous potential change measured in the data acquisition channel during the low-temperature rapid disconnector opening, closing, and locking drills, reflecting the fluctuation degree of the control system's ground potential response. The initial one-time rise is a parameter obtained by calculating the maximum value of all potential offsets, representing the highest potential rise caused by the disconnector in one complete mechanical action cycle, used to quantify the transient response strength of the control channel. The reference capacitance of the controller acquisition module refers to the equivalent electrical energy storage element inside the controller used for potential reference maintenance and analog-to-digital conversion; its capacity reflects the sensitivity of the acquisition module's input to voltage changes. The total equivalent capacitance is the sum of the reference capacitance and the equivalent capacitance on the wiring side, used to describe the total charge capacity that the entire control channel can store or release during operation. The equivalent injected charge is the value obtained by multiplying the total equivalent capacitance by the initial one-time rise, used to represent the total charge injected into the system due to the charging and discharging of the control channel capacitors during the drills, thus providing a basis for assessing the controller's electrical stability.

[0056] Specifically, the calculation of equivalent injected charge is based on the fundamental laws of capacitor charging and discharging. When a potential difference exists across a capacitor, the internal electric field stores a corresponding amount of charge, which is proportional to the capacitance value and the potential change. The reference capacitor in the control system and the equivalent capacitance on the wiring side together constitute an energy-storing electrical channel. During the potential change caused by the rapid opening and closing of the low-temperature disconnector, the total capacitance of the system will be charged simultaneously. Since the initial one-time rise reflects the transient potential increase caused by this action, multiplying the total equivalent capacitance by the initial one-time rise yields the total charge stored or released by the capacitor network during this process. This equivalent injected charge represents the amount of electrical energy transferred in a single exercise, reflecting the energy response capability of the controller input channel and the external shielded connection path under electrical transients, providing a quantitative basis for subsequent control accuracy calibration and electrical safety verification.

[0057] Specifically, in the hardware-in-the-loop simulation testing of a reusable rocket engine controller, the potential change at the input terminal of the controller's acquisition module is affected by the combined influence of the shielded cable wiring length, ground potential difference, and interface capacitance distribution. Relying solely on instantaneous sampled values ​​for judgment can easily lead to reference drift and misjudgments of electrical response. By calculating the equivalent injected charge based on the baseline of the data acquisition channel and the reference capacitance of the controller's acquisition module, the energy storage behavior formed by the parasitic capacitance of the wiring, interface coupling capacitance, and reference capacitance in the system can be quantified, reflecting the actual electrical energy transfer during controller operation. This equivalent injected charge characterizes the charge distribution pattern of the control channel under a single cryogenic disconnector operation, thereby correcting measurement deviations caused by electrical response hysteresis. This enables quantitative verification of the control module's input stability and energy consistency, ensuring the accurate and reliable electrical correspondence between each sampling channel and the actual operating state during the hardware-in-the-loop simulation testing.

[0058] Yes, the calculation method for the updated one-time rise is the same as that for the initial one-time rise. Both are based on the time series of the controller-side reference potential collected during the semi-physical simulation test. The peak rise of the potential relative to the baseline is obtained by calculating the maximum amplitude of the potential rise in the potential-time curve. The initial one-time rise is measured in the standard connected state before the shielded break jumper is switched, through the first low-temperature fast disconnector opening and closing and locking exercise. The updated one-time rise is obtained by repeating the same opening and closing and locking exercise after switching the electrical connection state of the shielded break jumper, using the same data sampling frequency, signal processing algorithm, and peak detection method. The only difference between the two is the electrical connection state of the shielded path; the calculation formula and processing logic remain consistent, thus ensuring the physical comparability and data processing consistency of the two measurement results.

[0059] S4. Determine the updated one-time lift amount based on the equivalent injected charge, reference capacitance, local coaxial capacitance and wiring-side equivalent capacitance, and calculate the lift amount error based on the updated one-time lift amount; In embodiments of the present invention, determining the updated one-time boost amount based on the equivalent injected charge, reference capacitance, local coaxial capacitance, and wiring-side equivalent capacitance includes: The capacitance allocation coefficient is calculated based on the reference capacitance, local coaxial capacitance, and equivalent capacitance on the wiring side of the controller acquisition module. In an embodiment of the present invention, the formula for calculating the capacitance allocation coefficient is as follows: In the formula, It is the reference capacitor for the controller's data acquisition module. It is a local coaxial capacitance. It is the equivalent capacitance on the wiring side.

[0060] Specifically, the capacitance distribution coefficient characterizes the proportion of a momentary injected charge distributed among multiple ground-to-ground capacitance branches. There are three parallel energy storage channels from the reference node to ground: the reference capacitor of the controller acquisition module, the equivalent capacitance on the wiring side, and the local coaxial capacitor located at the disconnect point. According to the principles of charge conservation and voltage consistency in electrostatics, the momentary injected charge produces the same potential rise in all three branches. The amount of charge distributed to each branch is proportional to its capacitance value; therefore, the total distribution capacity equals the sum of the three capacitances. The channels directly involved in observation on the reference node side are only the reference capacitor and the equivalent capacitance on the wiring side. The proportion of these two to the total distribution capacity is the distribution coefficient. Comparing the sum of these two to the sum of the three capacitances yields the proportion of the injected charge absorbed by the reference node side, thus forming the formula: the distribution coefficient is equal to the ratio of the reference capacitor plus the equivalent capacitance on the wiring side to the ratio of the reference capacitor plus the equivalent capacitance on the wiring side plus the local coaxial capacitor.

[0061] Divide the equivalent injected charge by the capacitance distribution factor to obtain the total injected charge; Switch the electrical connection status of the shielded breakpoint jumper and re-perform the opening, closing and locking drills of the low-temperature quick-disconnect socket to obtain the updated one-time lifting amount.

[0062] Specifically, the capacitance distribution factor is a parameter characterizing the charge distribution ratio among the capacitors in different parts of the control system. By comparing the relative sizes of the controller reference capacitor, local coaxial capacitor, and equivalent capacitance on the wiring side, it reflects the energy distribution law of charge on different branches during the charging and discharging process. Total injected charge refers to the total charge obtained by correcting the equivalent injected charge according to the overall capacitance relationship of the system after considering the capacitance distribution factor. It is used to describe the overall effect of energy storage and release of the control system under a single electrical excitation. Update one-time rise refers to the new potential rise measured when re-executing opening, closing, and locking operations after adjusting the shielding path or electrical connection status. This quantity is used to verify the consistency and stability of the system response after electrical structure reconfiguration and is a key indicator for evaluating the reliability of reusable controller simulation tests.

[0063] Specifically, before the switching operation begins, it is first confirmed that the rocket engine propulsion system is in a safe static condition without fluid flow. The main valve is closed and the high-pressure gas source is disconnected to prevent any mechanical impact or gas flow interference during the test. Then, a low-amplitude switching drive signal is applied to the jumper module in the shielded path via the control port, changing its electrical connection state from closed to open, or from open to closed, ensuring that the contact resistance change at the jumper end is within a detectable range. Immediately after the switching is completed, the status bit data of the jumper is read via the electrical monitoring port to confirm successful operation. After confirming that the shielded jumper is in the target state, the standardized opening, closing, and locking drill of the cryogenic rapid disconnector is repeated. The control system drives the disconnector mechanism to perform a complete mechanical separation and re-closing process, while keeping the controller acquisition module, data acquisition channel, and reference potential sampling channel operating simultaneously to ensure the synchronization of electrical response data. Throughout the drill, the time series of the reference potential signal on the controller side is continuously recorded, the peak segment is extracted, and the potential change amplitude is calculated to characterize the system's potential rise response under the current shielded connection state. After the exercise, the newly acquired potential rise amplitude is compared with the initial potential rise amplitude recorded in the previous exercise. If there is a difference between the two measured potential rise amplitudes, the updated one-time rise amount is calculated based on the change value. This rise amount represents the change in the system's response intensity to instantaneous charge injection after the change in the electrical connection mode of the shielding path. It can reflect the energy redistribution characteristics between the controller acquisition module and the propulsion system grounding network, providing a calibration basis for subsequent reuse test configuration.

[0064] In an embodiment of the present invention, calculating the lift error based on the updated one-time lift includes: The reconstructed wiring-side equivalent capacitance is determined based on the initial one-time lift, the updated one-time lift, the reference capacitance of the controller acquisition module, and the wiring-side equivalent capacitance. The formula for calculating the equivalent capacitance on the reconstructed wiring side is as follows: In the formula, It is an update of the one-time lift volume. This is the initial, one-time increase. It is the reference capacitor for the controller's data acquisition module. It is the equivalent capacitance on the wiring side. It is the equivalent capacitance on the reconstructed wiring side; Specifically, the reconstruction calculation of the equivalent capacitance on the wiring side is based on the principle of capacitive voltage division and the law of energy conservation in electrostatics. When the capacitor network between the controller reference node and the wiring side is subjected to the same injected charge, its potential rise is inversely proportional to the corresponding total capacitance. When the electrical connection state of the shielded breakpoint jumper changes, the equivalent capacitance on the wiring side changes due to the change in path conductivity, thus causing a change in the potential rise of the reference node under the same injected charge. By comparing the ratio of the potential rise before and after the switch, the proportional relationship of the change in wiring-side capacitance can be deduced. Since the reference capacitor and the wiring-side capacitor are connected in parallel, they share the charging role in the total energy storage of the system; therefore, the ratio of their capacitance values ​​directly affects the potential distribution ratio. By correlating the sum of the reference capacitor and the original wiring-side capacitor with the ratio of the updated rise to the initial rise, the reconstructed equivalent capacitance on the wiring side can be obtained using the capacitive voltage division formula, thereby quantitatively characterizing the impact of changes in the shielded path structure on the distribution of electrical energy storage in the system.

[0065] The reference capacitance, local coaxial capacitance, and reconstructed wiring-side equivalent capacitance of the controller acquisition module are added together to obtain the total equivalent capacitance after reconstruction. Divide the total injected charge by the reconstructed total equivalent capacitance to obtain the predicted one-time lift. Specifically, the reconstructed total equivalent capacitance refers to the overall energy storage parameter obtained by integrating the reference capacitance of the controller acquisition module, the local coaxial capacitance, and the reconstructed wiring-side equivalent capacitance in parallel after adjusting the electrical connection status of the shielded path. This parameter reflects the overall charge carrying capacity of the system under the new wiring topology. The predicted one-time rise is based on the capacitance distribution principle. The injected charge is applied to the reconstructed total equivalent capacitance, and the expected response value is obtained by calculating the theoretical potential rise of the system. This value is used to reflect the potential change trend of the control system under ideal conditions.

[0066] Under the condition that no fluid was introduced into the rocket engine propulsion system, the opening, closing and locking of the cryogenic rapid disconnect seat was conducted for the third time to obtain the measured one-time lift. Specifically, under the condition that no fluid is introduced into the rocket engine propulsion system, the structural components of the cryogenic rapid disconnector are first checked at room temperature to ensure their mechanical reset status, confirming that the internal sealing mechanism and metal contacts are in their initial positions. Then, an electrical command is triggered by the control unit to sequentially execute the opening and closing actions of the electromagnetic drive mechanism of the cryogenic rapid disconnector, recording the potential change signal from the controller's acquisition module in real time during each action. Immediately after the opening and closing actions are completed, a locking action is executed, and the mechanical locking sensor confirms the stable locking state while continuously collecting potential change data. Throughout the exercise, the data acquisition system records the potential signals synchronously over time, forming a complete potential change trajectory. After the exercise, the collected potential data is denoised and normalized, and the maximum rise of the potential curve is extracted to obtain the measured one-time rise corresponding to the opening, closing, and locking processes. This rise reflects the actual electrical response strength of the disconnector under the current wiring and grounding conditions.

[0067] Specifically, the measured one-time lift was obtained by recording the potential change curve and extracting the peak amplitude of the actual response value after performing the third opening and closing and locking drill on the cryogenic rapid disconnect seat under the condition of no fluid flow. This value was used to compare and verify the consistency between the prediction model and the actual electrical characteristics.

[0068] The difference between the measured one-time lift and the predicted one-time lift is calculated to obtain the lift error.

[0069] Specifically, the purpose of calculating the lift error based on the updated one-time lift is to evaluate the stability and consistency of the rocket engine controller's system response after electrical link reconfiguration. Changes in the shielding path, local coaxial capacitance, and equivalent capacitance on the wiring side can cause shifts in the charge distribution ratio, resulting in a difference between the potential rise of the reference node in the controller's acquisition module and the theoretically predicted value. By calculating the difference between the updated one-time lift as the measured value and the predicted one-time lift calculated based on the reconfigured capacitance model, the potential deviation of the system under actual test conditions can be obtained. This lift error reflects the integrity of electrical connections, the shielding grounding status, and the accuracy of the capacitance distribution model in the controller's acquisition loop. It provides a quantitative basis for parameter correction in subsequent reuse testing procedures and accuracy calibration of the hardware-in-the-loop simulation model, thereby ensuring the repeatability and engineering reliability of the simulation verification process.

[0070] S5. Generate a reusable configuration package for the hardware-in-the-loop simulation test process based on the lifting error and the preset error threshold. In an embodiment of the present invention, a reusable configuration package for a hardware-in-the-loop simulation test process is generated based on the lift error and a preset error threshold, including: The difference between the lifting error and the preset error threshold is calculated to obtain the error comparison result; When the error comparison results meet the tolerance requirements of the hardware-in-the-loop simulation test process, a reuse configuration package for the hardware-in-the-loop simulation test process is generated based on the sampling parameters of the controller acquisition module and the shielded connection status of the rocket engine propulsion system. Specifically, when the error comparison results meet the tolerance requirements of the hardware-in-the-loop simulation test process, the parameter acquisition unit is first activated. This unit establishes a communication connection with the controller acquisition module of the rocket engine controller. By reading the configuration data stored inside the controller acquisition module or by measuring the electrical parameters of the acquisition module with the help of dedicated testing equipment, the sampling parameters of the controller acquisition module are obtained. These sampling parameters include the reference capacitor of the controller acquisition module, the sampling frequency of the analog-to-digital converter, the impedance value of the high-impedance isolation network, the filtering threshold of the signal filtering circuit, and the gain coefficient of the data acquisition channel. Simultaneously, the shielding status detection unit is activated. This unit detects the shielding of the rocket engine propulsion system. The path is traversed and inspected. The shielded cable and related components are physically measured using tools such as laser rangefinders and vernier calipers, by reviewing the wiring records of the shielded path, to obtain the shielding connection status of the rocket engine propulsion system. This shielding connection status includes the current electrical connection status of the shielded breakpoint jumpers, the effective axial length of each segment of the shielded cable, the outer radius of the inner conductive metal sheath of the shielded cable, the average radial clearance from the outer surface of the conductive metal sheath to the outer metal reference surface, and the connection resistance value between the shielding layer and the cabinet grounding terminal. Subsequently, the data integration unit is activated, which retrieves all core data stored during the previous testing process, including the calculated P... The equivalent capacitance of the shielded cable in the electrical connection link between the TFE inner liner and the outer metal shell, the equivalent injected charge obtained based on the baseline and reference capacitance of the data acquisition channel, the total injected charge calculated by the capacitance distribution factor, the measured one-time lift, the predicted one-time lift, and the lift error are all included. These core data are then combined with the sampling parameters of the controller acquisition module and the shielded connection status of the rocket engine propulsion system. All data is categorized according to preset data classification rules. Electrical parameters such as the reference capacitance and sampling frequency are classified as acquisition module configuration data, and the shielded breakpoint jumper status and the effective axial length of the wiring side are also included. Data such as shielding path configuration, equivalent capacitance of local coaxial capacitor wiring, equivalent injected charge and total injected charge are classified as charge quantization data, and lift error is classified as error assessment data. Next, the configuration package generation unit is activated. This unit formats all the categorized data according to the standardized data format preset by the hardware-in-the-loop simulation test system, assigns a unique parameter identifier and data type description to each type of data, and adds a unique version identifier to the generated reusable configuration package. This version identifier includes the test date, test bench number, and batch information of the error comparison results, ensuring that the corresponding test scenario can be traced during subsequent calls.Finally, the configuration package generation unit integrates all formatted data and version identifiers into a reusable configuration package for a complete hardware-in-the-loop simulation test process. This reusable configuration package must clearly record the acquisition methods and valid ranges of various parameters. This allows for direct access to all core parameters in subsequent hardware-in-the-loop simulation tests of the same or similar rocket engine controllers simply by loading this reusable configuration package. This eliminates the need to repeatedly perform steps such as local coaxial capacitance calculation, data acquisition channel baseline establishment, equivalent injected charge quantization, and lift error verification, thus achieving rapid reuse of test parameters and standardized execution of the test process.

[0071] When the error comparison result does not meet the tolerance requirements, a correction command for the equivalent capacitance on the wiring side is output. The opening, closing and locking drills of the low-temperature fast disconnector are repeated according to the correction command until the error comparison result meets the tolerance requirements of the hardware-in-the-loop simulation test process.

[0072] Specifically, when the error comparison result does not meet the tolerance requirements, the error tracing unit is first activated. This unit retrieves data stored during previous testing, including the predicted lift error, the measured lift, the reconstructed equivalent capacitance of the wiring side, and the original equivalent capacitance of the wiring side. Through comparative analysis, it determines that the core reason for the error exceeding the standard is the mismatch between the equivalent capacitance of the wiring side and the actual electrical characteristics. Then, the correction instruction generation unit is activated. This unit, based on the error tracing result and the calculation logic of the equivalent capacitance of the wiring side, determines the key parameters that need to be corrected and generates a correction instruction for the equivalent capacitance of the wiring side. The correction instruction explicitly includes the screen that needs to be remeasured. The steps for recalculating the equivalent capacitance on the wiring side of the shielded cable, including the required accuracy range after correction, are as follows: The shielded cable parameters to be remeasured include the effective axial length on the wiring side of each segment of the shielded cable, the outer radius of the internal conductive metal sheath, and the average radial clearance from the outer surface of the conductive metal sheath to the external metal reference surface. Subsequently, the parameter remeasurement unit is activated. Following the correction instructions, this unit uses a laser rangefinder to measure the effective axial length on the wiring side of each segment of the shielded cable segment by segment, with each segment measured at least three times and the average value taken as the final measurement result. A precision vernier caliper is used to measure the internal... The outer radius of the conductive metal cladding is measured at multiple points, with at least four measurement points evenly distributed along the circumference of the cladding. The average value of the measurement results is taken as the final outer radius data. A mechanical gap gauge is used to measure the average radial clearance from the outer surface of the conductive metal cladding to the external metal reference surface multiple times, with at least five measurement intervals set along the cable axis. The average value of the measurement results is taken as the final radial clearance data. After the parameter retest is completed, the capacitance recalculation unit is activated. This unit, following the calculation steps specified in the correction instruction, substitutes the retested effective axial length of the wiring side, the average radial clearance of the conductive metal cladding's outer radius, into the equivalent wiring side data. The capacitance calculation formula first divides the sum of the outer radius of the conductive metal cladding layer and the average radial gap by the outer radius of the conductive metal cladding layer to obtain a new coaxial structure radius ratio. Then, the new coaxial structure radius ratio is logarithmically calculated to obtain a new wiring-side geometric ratio coefficient. Next, combined with the absolute dielectric constant of the dielectric material between the conductive metal cladding layer and the external metal reference surface, the equivalent capacitance of each segment of the shielded cable is calculated and summed. The corrected wiring-side equivalent capacitance is then recalculated, and it is verified whether the corrected capacitance value is within the accuracy range required by the correction command. If it is not, the measurement steps are re-executed in the parameter retest unit.After the corrected equivalent capacitance on the wiring side is confirmed to be acceptable, the repetitive exercise unit is activated. This unit controls the rocket engine propulsion system to remain in a state without fluid flow, closes all fluid valves in the propulsion system to ensure no residual pressure in the pipeline, and sends an opening / closing command to the drive mechanism of the cryogenic rapid disconnector according to the previously standardized operating procedure. The drive mechanism drives the disconnector to perform a separation action and maintains it for a preset time before sending a locking command to reset the disconnector and confirm that it is locked in place. During the exercise, an independent data acquisition channel is simultaneously activated to continuously sample the reference potential signal at a sampling frequency consistent with the previous test, obtaining a new real-time trajectory of the data acquisition channel. After the exercise, a new error calculation unit is activated. This unit retrieves the real-time trajectory of the data acquisition channel obtained in this exercise and calculates the new potential offset by combining it with the previously established baseline of the data acquisition channel. The maximum value of all new potential offsets is taken. The system obtains a new measured one-time rise, and simultaneously recalculates the new reconstructed total equivalent capacitance based on the corrected wiring-side equivalent capacitance. The total injected charge is divided by the new reconstructed total equivalent capacitance to obtain a new predicted one-time rise. The difference between the new measured one-time rise and the new predicted one-time rise is calculated to obtain a new rise error. This new rise error is then compared with a preset error threshold to obtain a new error comparison result. Finally, the result judgment unit is activated. If the new error comparison result meets the tolerance requirements of the hardware-in-the-loop simulation test process, the repetitive test process is stopped. If the new error comparison result still does not meet the tolerance requirements, the system returns to the error tracing unit to re-execute the above correction instructions, generate parameters, remeasure capacitance, recalculate the test, repeat the repetitive test, and calculate the new error until the generated error comparison result meets the tolerance requirements of the hardware-in-the-loop simulation test process.

[0073] Specifically, the lift error refers to the potential change deviation obtained by comparing the numerical difference between the predicted one-time lift and the updated one-time lift, used to characterize the consistency of the system's charge response after reconstructing the electrical path. The preset error threshold is a value determined based on the accuracy requirements of the rocket engine controller's hardware-in-the-loop simulation test, the controller's sensitivity to analog signals, and the allowable deviation range of safety trigger statistics, serving as a benchmark for judging whether the lift error meets the test tolerance requirements. The hardware-in-the-loop simulation test process refers to the comprehensive testing of the controller, electrical connection lines, and the shielding structure of the propulsion system through a simulation platform, used to verify the matching of control logic, signal response, and energy distribution. The reuse configuration package is a parameter set file automatically generated based on the current test results, containing the sampling parameters of the controller's acquisition module, shielding connection status, and data acquisition channel configuration, used to guide the rapid loading and reuse execution of subsequent multiple rounds of simulation tests.

[0074] Specifically, when generating the preset error threshold, the core accuracy requirements for the semi-physical simulation test of the rocket engine controller are first clarified. These requirements must be combined with the accuracy standards for measuring analog signals such as pressure and temperature in actual flight missions. Simultaneously, the sensitivity of the controller's acquisition module to analog signals must be obtained, i.e., the smallest signal change the acquisition module can distinguish. Then, the allowable deviation range of the rocket engine propulsion system's safety triggering mechanism is statistically analyzed, i.e., the maximum numerical range within which analog signal deviation will not lead to a false safety triggering action. Subsequently, relevant data from historical semi-physical simulation tests of similar rocket engine controllers are collected, including the actual distribution range of lift errors in past tests, the fluctuation amplitude of errors under different test scenarios, and the numerical range where the error meets the standard. Data is then filtered in conjunction with the hardware performance parameters of the current test bench, such as the sampling accuracy of the data acquisition channel and the error level of the measuring tools. Next, extreme scenarios are analyzed. Error influencing factors under test conditions include the maximum possible change in the shielded path connection status, the limit deviation of shielded cable wiring parameters, and the maximum possible charge on the PTFE liner. The theoretical maximum value of the lift error caused by these extreme factors is calculated. Then, the core accuracy requirements, identification sensitivity, safety trigger allowable deviation range, historical effective error data, and theoretical maximum value of extreme conditions are comprehensively weighted and analyzed. Among them, the core accuracy requirements have the highest weight, the safety trigger allowable deviation range is used as a constraint, and historical data and extreme condition data are used to correct the value. Finally, the rationality of the value is verified through multiple simulation calculations to ensure that the value can meet the accuracy requirements of the semi-physical simulation test data, while avoiding repeated corrections and low efficiency in the test process due to overly strict threshold settings, or the failure to effectively eliminate false signals due to overly lenient threshold settings. The final determined value is the preset error threshold.

[0075] S6. Reuse the test parameters of the rocket engine controller according to the reuse configuration package.

[0076] Specifically, when it is necessary to reuse the test parameters of the rocket engine controller according to the reuse configuration package, the configuration package loading unit is first started. This unit establishes a communication connection with the main control module of the hardware-in-the-loop simulation test system and imports the reuse configuration package completely into the storage unit of the main control module through a standardized data transmission protocol. During the import process, the integrity and format of the version identifier data of the configuration package are checked simultaneously. If the check finds that the version identifier does not match the current test bench or that the data is missing or damaged, a reloading command is triggered until the configuration package is imported completely and appropriately. Then, the parameter parsing unit is started. This unit disassembles the imported reuse configuration package and parses the data according to the pre-defined parameters in the configuration package. The established data classification rules extract controller acquisition module configuration data, shielding path configuration data, capacitance calculation data, charge quantization data, and error evaluation data. The controller acquisition module configuration data includes reference capacitance sampling frequency, high-impedance isolation network impedance filtering threshold, and channel gain coefficient. The shielding path configuration data includes shielding breakpoint jumper status, axial effective length of the wiring side, outer radius of the metal conductive cladding, average radial gap, and shielding grounding resistance. The capacitance calculation data includes local coaxial capacitance and equivalent capacitance on the wiring side. The charge quantization data includes equivalent injected charge and total injected charge. The error evaluation data includes lift error. Subsequently, the acquisition module parameter configuration is initiated. This unit connects to the rocket engine controller's acquisition module via a dedicated communication interface. It writes the parsed reference capacitance parameters into the acquisition module's reference circuit register, configures the sampling frequency parameters to the analog-to-digital converter's clock control unit, sends the configuration command corresponding to the high-impedance isolation network impedance parameters to the isolation circuit's control chip, loads the filter threshold parameters into the signal filtering circuit's adjustment module, and sets the channel gain coefficient to the data amplification unit. After each parameter configuration is completed, a feedback signal confirms whether the configuration is effective. If a parameter configuration is ineffective, the configuration command is repeatedly sent until confirmation of effectiveness. Simultaneously, the shielding path parameter configuration unit is activated. Based on the analyzed jumper status of the shielding breakpoints, the system adjusts the jumper connection status of the reserved breakpoints in the shielding path of the rocket engine propulsion system through mechanical control components to ensure that the jumper status is consistent with the records in the configuration package. Then, the effective axial length of the shielded cable wiring side, the outer radius of the metal conductive coating, and the average radial gap are checked using tools such as laser rangefinders and vernier calipers. If the check finds that the actual dimensions deviate from the data in the configuration package, the actual dimensions are matched to the configuration data by adjusting the cable wiring path or replacing the appropriate shielding components. Finally, the connection resistance between the shielding layer and the grounding terminal of the cabinet is measured using a resistance tester, and the connection resistance is made to meet the requirements in the configuration package by adjusting the tightness of the grounding terminal.Next, the core data pre-setting unit is activated. This unit extracts data such as the equivalent capacitance, equivalent injected charge, total injected charge, and rise error from the local coaxial capacitor wiring side and writes them into the corresponding data call interfaces in the hardware-in-the-loop simulation test system. Specifically, capacitance calculation data is written to the capacitance parameter call library, charge quantization data to the charge parameter call library, and error assessment data to the error benchmark library, ensuring that subsequent functional modules can directly access this pre-set data during testing. After completing all parameter configurations, the configuration verification unit is activated. This unit sends parameter reading commands to the controller acquisition module through the main control module to obtain parameters such as the actual reference capacitance sampling frequency of the current acquisition module and compares them with the reused configuration package. The data is compared with the corresponding data in the configuration package. Simultaneously, the grounding resistance and cable dimensions of the jumper wires in the shielding path are checked again to confirm that all actual parameters deviate from the configuration package data within acceptable limits. If deviations exist, the system returns to the corresponding parameter configuration unit for readjustment. Finally, the test pre-run unit is started, controlling the rocket engine controller to enter low-power test mode and triggering a short-term analog signal acquisition process. This checks whether the data acquisition channel can function normally based on the reused configuration parameters. After confirming that the acquired signal baseline matches the error assessment data in the configuration package, the reuse setting of all test parameters is completed. At this point, the rocket engine controller can directly start the formal hardware-in-the-loop simulation test based on the reused parameters.

[0077] like Figure 2 The diagram shown is a functional block diagram of a reusable rocket engine controller hardware-in-the-loop simulation test system provided in an embodiment of the present invention.

[0078] In this embodiment, the functions of each module / unit are as follows: The capacitance modeling module is used to calculate the local coaxial capacitance between the PTFE liner and the outer metal shell in a rocket engine propulsion system, and to calculate the equivalent capacitance of the wiring side formed by the shielded cable relative to the grounding path of the cabinet in the electrical connection link on the controller side. The baseline calculation module is used to calculate the baseline of the independent data acquisition channel; The injection quantity calculation module is used to calculate the equivalent injected charge based on the baseline of the data acquisition channel and the reference capacitance of the controller acquisition module; The error assessment module is used to determine the updated one-time lift amount based on the equivalent injected charge, reference capacitance, local coaxial capacitance and wiring-side equivalent capacitance, and to calculate the lift amount error based on the updated one-time lift amount; The reuse configuration generation module is used to generate a reuse configuration package for the semi-physical simulation test process based on the lifting error and the preset error threshold. The parameter reuse setting module is used to reuse and set the test parameters of the rocket engine controller according to the reuse configuration package.

[0079] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A hardware-in-the-loop simulation test method for a reusable rocket engine controller, characterized in that, Includes the following steps: S1. In the rocket engine propulsion system, calculate the local coaxial capacitance between the PTFE inner liner and the outer metal shell, and calculate the equivalent capacitance of the wiring side formed by the shielded cable relative to the grounding path of the cabinet in the electrical connection link on the controller side. S2. Calculate the baseline of the independent data acquisition channel; S3. Calculate the equivalent injected charge based on the baseline of the data acquisition channel and the reference capacitance of the controller acquisition module; S4. Determine the updated one-time lift amount based on the equivalent injected charge, reference capacitance, local coaxial capacitance and wiring-side equivalent capacitance, and calculate the lift amount error based on the updated one-time lift amount; S5. Generate a reusable configuration package for the hardware-in-the-loop simulation test process based on the lifting error and the preset error threshold. S6. Reuse the test parameters of the rocket engine controller according to the reuse configuration package.

2. The hardware-in-the-loop simulation test method for a reusable rocket engine controller according to claim 1, characterized in that, Calculate the local coaxial capacitance between the PTFE liner and the outer metal shell, including: Obtain the effective axial length of the overlapping structure of the PTFE liner and outer metal shell of the cryogenic rapid disconnection seat in the rocket engine propulsion system; Measure the radius of the inner channel of the PTFE liner; Measure the outer radius of the contact point between the outer surface of the PTFE liner and the outer metal shell; The natural logarithm of the ratio between the inner channel radius and the outer radius is used to obtain the structural geometric proportionality coefficient. Based on the effective axial length of the structure and the geometric proportionality coefficient of the structure, the local coaxial capacitance between the PTFE liner and the outer metal shell is calculated. The formula for calculating the local coaxial capacitance between the PTFE liner and the outer metal shell is as follows: In the formula, It is the absolute dielectric constant of PTFE material. It is the effective axial length of the structure. It is the geometric scale factor on the structural side. It is a local coaxial capacitance between the PTFE inner liner and the outer metal shell.

3. The hardware-in-the-loop simulation test method for a reusable rocket engine controller according to claim 1, characterized in that, The equivalent capacitance on the cabling side of the shielded cable in the electrical connection link on the controller side relative to the cabinet grounding path is calculated, including: Obtain the effective axial length of the shielded cable on the wiring side in the electrical connection link on the controller side under approximately coaxial wiring conditions; Obtain the outer radius of the metal conductive coating layer inside the shielded cable; Obtain the average radial gap between the outer surface of the metal conductive coating inside the shielded cable and the external metal reference surface; The sum of the outer radius of the conductive metal coating and the average radial gap is divided by the outer radius of the conductive metal coating to obtain the radius ratio of the coaxial structure. The natural logarithm of the radius ratio of the coaxial structure is used to obtain the geometric scale coefficient on the wiring side. Obtain the absolute dielectric constant of the dielectric material between the conductive metal cladding layer and the external metal reference surface; Based on the absolute dielectric constant, the effective axial length of the cabling side, and the geometric scaling factor of the cabling side, the equivalent capacitance of the shielded cable relative to the cabinet grounding path in the controller-side electrical connection link is calculated. The formula for calculating the equivalent capacitance of the cabling side is as follows: In the formula, It is the absolute permittivity. It is the effective axial length of the k-th shielded cable under approximately coaxial cabling conditions. This is the geometric scaling factor on the cabling side, where k is the shielded cable number. It is the equivalent capacitance on the wiring side.

4. The hardware-in-the-loop simulation test method for a reusable rocket engine controller according to claim 2, characterized in that, Calculate the baseline of the independent data acquisition channel, including: The controller acquisition module for locating the rocket engine controller; Four wires are simultaneously drawn from the reference potential node of the controller acquisition module; Determine the shielding path of the rocket engine propulsion system; Insert compliant shielded breakpoint jumpers at the reserved locations in the shielded path, and record the electrical connection status bits of the shielded breakpoint jumpers in the shielded path; Two of the four wires are connected to the analog-to-digital converter of the controller's acquisition module, while the other two wires are connected to an independent data acquisition channel through a high-impedance isolation network. The reference potential signal of the independent data acquisition channel is continuously sampled and recorded to obtain the real-time trajectory of the data acquisition channel; Acquire real-time trajectory data of the data acquisition channel before the start of the hardware-in-the-loop test exercise; The baseline of the data acquisition channel is obtained by averaging the sampled data over time.

5. The hardware-in-the-loop simulation test method for a reusable rocket engine controller according to claim 4, characterized in that, Based on the baseline of the data acquisition channel and the reference capacitance of the controller acquisition module, the equivalent injected charge is calculated, including: The opening, closing, and locking of the cryogenic rapid disconnector were practiced under conditions where no fluid was introduced into the rocket engine propulsion system. After the opening, closing and locking drills are completed, the potential offset is calculated based on the real-time trajectory and baseline of the data acquisition channel. The maximum value of all potential offsets is calculated to obtain the initial one-time rise. The reference capacitance of the controller acquisition module is added to the equivalent capacitance on the wiring side to obtain the total equivalent capacitance. The equivalent injected charge is obtained by multiplying the total equivalent capacitance by the initial one-time rise.

6. The hardware-in-the-loop simulation test method for a reusable rocket engine controller according to claim 4, characterized in that, The update one-time lift amount is determined based on the equivalent injected charge, reference capacitance, local coaxial capacitance, and wiring-side equivalent capacitance, including: The capacitance allocation coefficient is calculated based on the reference capacitance, local coaxial capacitance, and equivalent capacitance on the wiring side of the controller acquisition module. Divide the equivalent injected charge by the capacitance distribution factor to obtain the total injected charge; Switch the electrical connection status of the shielded breakpoint jumper and re-perform the opening, closing and locking drills of the low-temperature quick-disconnect socket to obtain the updated one-time lifting amount.

7. The hardware-in-the-loop simulation test method for a reusable rocket engine controller according to claim 5, characterized in that, The uplift error is calculated based on the updated one-time uplift measurement, including: The reconstructed wiring-side equivalent capacitance is determined based on the initial one-time lift, the updated one-time lift, the reference capacitance of the controller acquisition module, and the wiring-side equivalent capacitance. The reference capacitance, local coaxial capacitance, and reconstructed wiring-side equivalent capacitance of the controller acquisition module are added together to obtain the total equivalent capacitance after reconstruction. Divide the total injected charge by the reconstructed total equivalent capacitance to obtain the predicted one-time lift. Under the condition that no fluid was introduced into the rocket engine propulsion system, the opening, closing and locking of the cryogenic rapid disconnect seat was conducted for the third time to obtain the measured one-time lift. The difference between the measured one-time lift and the predicted one-time lift is calculated to obtain the lift error.

8. The hardware-in-the-loop simulation test method for a reusable rocket engine controller according to claim 1, characterized in that, Based on the lift error and the preset error threshold, a reusable configuration package for the hardware-in-the-loop simulation test process is generated, including: The difference between the lifting error and the preset error threshold is calculated to obtain the error comparison result; When the error comparison results meet the tolerance requirements of the hardware-in-the-loop simulation test process, a reuse configuration package for the hardware-in-the-loop simulation test process is generated based on the sampling parameters of the controller acquisition module and the shielded connection status of the rocket engine propulsion system. When the error comparison result does not meet the tolerance requirements, a correction command for the equivalent capacitance on the wiring side is output. The opening, closing and locking drills of the low-temperature fast disconnector are repeated according to the correction command until the error comparison result meets the tolerance requirements of the hardware-in-the-loop simulation test process.

9. The hardware-in-the-loop simulation test method for a reusable rocket engine controller according to claim 6, characterized in that, The formula for calculating the capacitance distribution factor is as follows: In the formula, It is the reference capacitor for the controller's data acquisition module. It is a local coaxial capacitance. It is the equivalent capacitance on the wiring side.

10. A reusable rocket engine controller hardware-in-the-loop simulation test system, characterized in that, The system includes: The capacitance modeling module is used to calculate the local coaxial capacitance between the PTFE liner and the outer metal shell in a rocket engine propulsion system, and to calculate the equivalent capacitance of the wiring side formed by the shielded cable relative to the grounding path of the cabinet in the electrical connection link on the controller side. The baseline calculation module is used to calculate the baseline of the independent data acquisition channel; The injection quantity calculation module is used to calculate the equivalent injected charge based on the baseline of the data acquisition channel and the reference capacitance of the controller acquisition module; The error assessment module is used to determine the updated one-time lift amount based on the equivalent injected charge, reference capacitance, local coaxial capacitance and wiring-side equivalent capacitance, and to calculate the lift amount error based on the updated one-time lift amount; The reuse configuration generation module is used to generate a reuse configuration package for the semi-physical simulation test process based on the lifting error and the preset error threshold. The parameter reuse setting module is used to reuse and set the test parameters of the rocket engine controller according to the reuse configuration package.

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