Novel automatic separation type satellite seat charging device

Abstract

The invention provides a novel automatic separation type satellite seat charging device, and belongs to the technical field of spaceflight. The device comprises a plug end and a socket end, the plug end is installed on a satellite side, and the socket end is installed on an arrow end or a device end. The plug end comprises a plug support, a conductive elastic needle, an elastic needle fixing seat, an elastic needle cover plate, an elastic needle printed board, a pressing block and a rear cover plate, and the socket end comprises a socket support, a conductive contact piece, a contact piece fixing plate, a contact piece printed board, a pressing block and a rear cover plate. The conductive elastic needle is provided with a spring, the top of the conductive elastic needle is driven to freely stretch out and be compressed under the action of external force, and the elastic contact function is achieved. And when the satellite is separated from the rocket, the conductive elastic needle automatically rebounds under the action of the spring and is naturally separated from the conductive contact piece, so that physical disconnection is completed. Automatic separation is achieved, assistance of initiating explosive devices such as explosive bolts is not needed, impact vibration and metal chippings are not generated, and the safety and reliability of satellite separation are improved.

Description

Technical Field

[0001] This invention belongs to the field of aerospace technology, specifically relating to a novel automatic detachable satellite seat charging device. Background Technology

[0002] After rocket launch, during the entire flight before entering its designated orbit, the satellite's internal systems, such as computers, navigation, and thermal control, must remain powered to receive commands and prepare for separation. This typically consumes battery power. To conserve the satellite's own battery power, it usually does not use its own batteries for power during flight. Instead, it relies on the rocket's upper stage power supply or other spacecraft to charge via its charging station, ensuring the satellite's power level remains fully charged. This reserves the satellite's valuable battery power for independent operation after separation, ensuring the successful execution of crucial actions such as initial attitude adjustment, solar array deployment, and communication establishment at the moment of separation.

[0003] Traditional launch pad charging systems use a mechanical hard connection to establish power and data transmission channels via electrical connectors. During satellite separation, these systems use explosive bolts for detonation, requiring auxiliary unlocking for separation. The use of explosive bolts generates impact vibrations, which can damage delicate optical and electronic instruments on the satellite. It also produces tiny metal fragments that may contaminate the satellite's optical components or sensitive equipment. Explosive bolts are single-use devices, making them untestable and preventing full-function testing before launch, increasing the risk of launch failure. If multiple explosive bolts fail to detonate synchronously, the satellite may experience rotational separation or attitude problems, affecting its subsequent normal operation.

[0004] With the development of aerospace technology, higher requirements are being placed on satellite launch and charging devices. A device is needed that can autonomously physically disconnect the connection during satellite-launcher or satellite-vehicle separation, achieving rapid and reliable automatic separation without generating any separation resistance, thus avoiding impact, vibration, and contamination to the satellite. The inherent risks associated with the use of pyrotechnics need to be eliminated, improving the device's testability and reusability. Furthermore, the satellite's mechanical separation mechanism needs to be functionally decoupled from its charging function, simplifying interface and system design, and reducing system complexity and cost. Summary of the Invention

[0005] To address the problems existing in the background art, the present invention provides a novel automatic detachable satellite charging device, comprising a plug end and a socket end;

[0006] The plug end includes a plug support, a conductive elastic pin, an elastic pin fixing seat, an elastic pin cover plate, an elastic pin printed plate, a clamping block, and a rear cover plate;

[0007] The socket end includes a socket support, conductive contacts, a contact fixing plate, a contact printed circuit board, a clamping block, and a rear cover plate;

[0008] The conductive elastic needle has a built-in spring, which allows the top of the conductive elastic needle to extend and compress freely under external force.

[0009] The plug support is used to support the elastic pin fixing seat and the elastic pin cover plate; the elastic pin printed plate is pressed into the plug support by a clamping block; the elastic pin fixing seat and the elastic pin cover plate respectively press the conductive elastic pin; the rear cover plate is connected to the clamping block;

[0010] The socket support is used to support the contact fixing plate; the contact printed circuit board is pressed into the socket support by the clamping block; the contact fixing plate positions the conductive contacts; the rear cover plate is connected to the clamping block.

[0011] In a preferred embodiment, the conductive elastic needle includes a conductive elastic needle top, an elastic needle spring, a conductive elastic needle ear, and a conductive elastic needle tail; the elastic needle spring, under the action of external force, causes the conductive elastic needle top to freely extend and compress.

[0012] In a preferred embodiment, the elastic needle holder has a first groove with the same number of conductive elastic needles, and the bottom surface of the first groove has a first through hole penetrating the elastic needle holder; the elastic needle cover plate has a second groove with the same number of conductive elastic needles, and the bottom surface of the second groove has a second through hole penetrating the elastic needle cover plate; the first groove and the second groove respectively contact the conductive elastic needle lugs to press the conductive elastic needles; the first through hole and the second through hole are used to pass through the stepped shaft of the conductive elastic needle.

[0013] In a preferred embodiment, the elastic needle cover plate is provided with a boss, which is used to limit the travel of the elastic needle spring.

[0014] In a preferred embodiment, the elastic pin printed circuit board has a first pad through-hole with the same number as the conductive elastic pins. The tail of the conductive elastic pin passes through the first pad through-hole and is connected by soldering. The other side of the elastic pin printed circuit board has a second pad through-hole, which is soldered to an external cable conductor. The first pad through-hole and the second pad through-hole are connected and conductive through printed circuit board wiring.

[0015] In a preferred embodiment, the contact fixing plate has stepped grooves of the same number as the conductive contacts for positioning the conductive contacts; the tail of the conductive contact is connected to the through hole of the pad on the contact printed circuit board by welding.

[0016] In a preferred embodiment, the plug support is provided with an anti-shear pin, which is connected to the plug support through a hole-shaft fit; the socket support is provided with a pin cone recess; the anti-shear pin fits into the pin cone recess, with a fitting clearance.

[0017] In a preferred embodiment, the end of the shear pin is tapered, and the pin recess is a tapered recess.

[0018] In a preferred embodiment, the plug end is provided with a plug cable and an electrical connector, and the socket end is provided with a socket cable and an electrical connector.

[0019] In a preferred embodiment, the plug end and the socket end are respectively provided with wire clips, which are used to clamp the cable harness soldered from the printed circuit board; the elastic pin cover plate, the elastic pin fixing seat, and the contact fixing plate are made of insulating material.

[0020] The beneficial effects achieved by this invention are as follows:

[0021] First, this invention employs a conductive elastic pin with a built-in spring and an elastic contact method with the conductive contact element, achieving automatic separation of the plug and socket ends. During satellite separation from the rocket, the conductive elastic pin automatically rebounds under the elastic force of the built-in spring, and the top of the conductive elastic pin naturally disengages from the conductive contact element, completing the physical break. The entire separation process requires no explosive bolts or other pyrotechnic aids, generates no impact vibration, avoids damage to the precision optical instruments and electronic equipment on the satellite, and produces no contaminants such as metal debris. Because the elastic force provided by the spring in the elastic pin eliminates any separation resistance, the satellite can maintain a good attitude to complete the separation, avoiding the risks of rotational separation and poor attitude that may occur with traditional explosive bolt methods, thus improving the safety and reliability of satellite separation.

[0022] This invention features an anti-shear pin on the plug support and a pin cone recess on the socket support to mate with the anti-shear pin, with a clearance between them. The engagement of the anti-shear pin and the pin cone recess ensures accurate positioning of the plug and socket ends, preventing mis-insertion. The clearance eliminates potential horizontal assembly errors during plug-socket assembly, avoiding uneven force on the conductive elastic pin due to assembly float, and ensuring the stability and reliability of the conductive elastic pin during operation. The tapered design of the anti-shear pin end and the tapered recess structure of the pin cone recess prevent additional pin-pulling resistance during satellite-rocket separation, allowing the anti-shear pin to smoothly withdraw from the pin cone recess, ensuring a smooth and rapid satellite separation process.

[0023] This invention utilizes a printed circuit board (PCB) to connect conductive elastic pins, conductive contacts, and their respective cable conductors. The tails of the conductive elastic pins and conductive contacts are respectively soldered to the PCBs of the elastic pin and the contact, respectively. The PCBs are then connected to the external cable conductors via internal wiring. This PCB connection method enhances connection reliability, while the soldering connection ensures good electrical contact and mechanical fixation, avoiding potential contact problems or loosening issues associated with traditional connectors. Furthermore, the use of PCBs makes the assembly process more convenient and efficient, facilitating mass production and maintenance, and reducing manufacturing costs and assembly complexity.

[0024] The satellite mount charging device of this invention does not use disposable explosive bolts, allowing for reusability and supporting multiple, full-function, and realistic tests before launch. This repetitive testing capability ensures the device's reliability in actual use, reducing the risk of launch failure. The device's simple structure, small size, and light weight facilitate lightweight satellite design, saving valuable launch weight and space resources. Furthermore, the device enables on-orbit reconnection and reseparation, providing technical support for future space missions such as on-orbit assembly and maintenance, enhancing the flexibility and scalability of the space system. Lower production costs reduce the overall system cost, resulting in good economic benefits and broad application prospects. Attached Figure Description

[0025] Figure 1 This is a structural diagram of the plug end of the satellite charging device described in this invention.

[0026] Figure 2 This is a structural diagram of the socket end of the satellite charging device described in this application.

[0027] Figure 3 These are cross-sectional views of the center of the satellite charging dock plug and the conductive elastic pin.

[0028] Figure 4 This is a cross-sectional view of the center of the socket end of the satellite charging dock.

[0029] Figure 5 This is a cross-sectional view of the satellite charging device.

[0030] Numbering on the map:

[0031] 1. Plug support; 2. Anti-shear pin; 3. Plug cable and electrical connector; 4. Wire clip; 5. Socket cable and electrical connector; 6. Socket support; 7. Conductive elastic pin; 701. Top of conductive elastic pin; 702. Elastic pin spring; 703. Conductive elastic pin ear; 704. Tail of conductive elastic pin; 8. Elastic pin cover plate; 9. Elastic pin fixing seat; 10. Elastic pin printed circuit board; 11. Clamping block; 12. Rear cover plate; 13. Conductive contact; 14. Contact fixing plate; 15. Contact printed circuit board. Detailed Implementation

[0032] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. In addition, the forms of the various structures described in the following embodiments are merely illustrative. The present invention is not limited to the structures described in the following embodiments. All other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] Reference Figures 1 to 5 This invention provides a novel automatic detachable satellite charging device, comprising two main parts: a plug end and a socket end. The plug end includes a plug cable and an electrical connector 3, which is installed on the satellite side. The socket end includes a socket cable and an electrical connector 5, which is installed on the rocket tip or other spacecraft end. The power transmission and charging functions between the satellite and the rocket upper stage or other spacecraft are realized through the mating and cooperation of the plug end and the socket end.

[0034] The plug end mainly consists of a plug support 1, conductive elastic pins 7, elastic pin cover plates 8, elastic pin fixing seats 9, elastic pin printed circuit boards 10, clamping blocks 11, rear cover plates 12, anti-shear pins 2, and wire clips 4. The plug support 1 serves as the basic support structure for the plug end, supporting the elastic pin fixing seats 9 and elastic pin cover plates 8. The plug support 1 itself does not have threaded holes; threaded holes are only provided on the clamping blocks 11 to facilitate the assembly connection of various parts with the plug support 1. The elastic pin printed circuit boards 10 are pressed into the plug support 1 by the clamping blocks 11. An air gap is left between the elastic pin printed circuit boards 10 and the elastic pin fixing seats 9 to facilitate solder formation during soldering. Screws pass through the through holes in the elastic pin cover plates 8, elastic pin fixing seats 9, plug support 1, and elastic pin printed circuit boards 10, and then are threadedly connected and fixed to the clamping blocks 11 with threaded holes, forming a stable assembly structure. The rear cover plate 12 is connected to the clamping block 11 by threads, sealing the rear of the entire plug end.

[0035] The conductive elastic pin 7 is a conductive component at the plug end, comprising a conductive elastic pin top 701, an elastic pin spring 702, a conductive elastic pin ear 703, and a conductive elastic pin tail 704. The elastic pin spring 702 is built into the conductive elastic pin 7, and under external force, it causes the conductive elastic pin top 701 to extend and compress freely, achieving elastic contact. The conductive elastic pin ear 703 is located in the middle of the conductive elastic pin 7, serving a positioning and fixing function. The conductive elastic pin tail 704 is used to achieve electrical connection with the elastic pin printed circuit board 10.

[0036] The elastic needle holder 9 and the elastic needle cover plate 8 together fix and support the conductive elastic needle 7. The elastic needle holder 9 has the same number of first grooves as the conductive elastic needle 7, and the bottom surface of each first groove has a first through hole penetrating the elastic needle holder 9. The elastic needle cover plate 8 has the same number of second grooves as the conductive elastic needle 7, and the bottom surface of each second groove has a second through hole penetrating the elastic needle cover plate 8. The first and second grooves respectively contact the two surfaces of the conductive elastic needle lug 703, clamping the conductive elastic needle 7 from above and below to ensure the stability of the conductive elastic needle 7 during operation. The first and second through holes are used to pass through the stepped shaft of the conductive elastic needle, allowing the top 701 and tail 704 of the conductive elastic needle 7 to extend to the outside of the elastic needle holder 9 and the elastic needle cover plate 8, respectively. The upper side of the elastic needle cover plate 8 is provided with a boss, which is used as a mechanical limiting structure. By adjusting the height of the boss, the stroke of the elastic needle spring 702 can be reasonably controlled to ensure that the spring 702 works within the effective compression range and to prevent the spring 702 from being damaged by excessive compression.

[0037] The flexible pin printed circuit board 10 has the same number of first pad through-holes as the conductive flexible pins 7. The tail 704 of the conductive flexible pin passes through the first pad through-hole and is soldered to achieve a reliable electrical and mechanical connection. On the other side of the flexible pin printed circuit board 10, there is a second pad through-hole, which is soldered to the wires of the plug cable 3 to achieve a fixed connection between the cable and the printed circuit board. The first and second pad through-holes are connected by internal wiring of the flexible pin printed circuit board 10, forming a complete electrical path from the conductive flexible pins 7 to the external cable. Connecting the conductive flexible pins 7 to the cable wires using a printed circuit board enhances the reliability of the connection and makes the assembly process more convenient and faster.

[0038] The socket terminal mainly consists of a socket support 6, conductive contacts 13, a contact fixing plate 14, a contact printed circuit board 15, a clamping block 11, a rear cover plate 12, and a wire clip 4. The socket support 6 serves as the basic support structure for the socket terminal, supporting the contact fixing plate 14. Screws pass through the through holes in the contact fixing plate 14, the socket support 6, and the contact printed circuit board 15, and are then threadedly connected to the clamping block 11, which has a threaded hole. The contact printed circuit board 15 is pressed into the socket support 6 by the clamping block 11. The rear cover plate 12 is threaded to the clamping block 11, sealing the rear of the entire socket terminal.

[0039] The conductive contact 13 mates with the conductive elastic pin 7 at the plug end to achieve electrical connection. The contact fixing plate 14 has the same number of stepped grooves as the conductive contact 13, and the shape of the stepped grooves matches the shape of the conductive contact 13 to accurately position it. The tail of the conductive contact 13 passes through the contact fixing plate 14 and is connected to the third pad through-hole on the contact printed circuit board 15 by soldering. The wiring and fixing method of the contact printed circuit board 15 are similar to those of the elastic pin printed circuit board 10. Internal wiring connects the conductive contact 13 to the wires of the socket cable 5, forming a complete electrical path.

[0040] Both the plug and socket ends are equipped with wire clips 4, which are used to secure the cable bundles soldered from the printed circuit board, preventing the solder joints from breaking due to pulling during use. Simultaneously, a wire-binding hole is provided on the printed circuit board near the wire clip 4, allowing for the bundling of the cable conductors with binding wire, further enhancing the cable's fixation and organization, and improving the reliability of the cable connection.

[0041] To prevent mis-insertion when the plug and socket ends are mated, an anti-shear pin 2 is provided on the plug support 1. The anti-shear pin 2 has a tapered end and is inserted into the mounting hole of the plug support 1 via a hole-shaft fit, achieving a reliable connection with the plug support 1 via threads. The socket support 6 has a pin cone recess that mates with the anti-shear pin 2, the cone angle of which matches the tapered end of the anti-shear pin 2. In normal assembly, the anti-shear pin 2 and the pin cone recess engage, but a suitable clearance is maintained between them to eliminate potential horizontal assembly errors during the mating process of the plug and socket ends. The tapered design of the anti-shear pin 2 and the tapered recess structure of the pin cone recess prevent additional pin-pulling resistance during satellite-rocket separation, ensuring a smooth separation process.

[0042] To achieve insulation isolation between energized conductors, the elastic needle cover plate 8, the elastic needle fixing seat 9, and the contact fixing plate 14 are all made of insulating materials, preferably polyimide, which has excellent insulation properties and mechanical strength, meeting the high reliability requirements of aerospace applications.

[0043] The working process of the satellite charging device of the present invention is as follows. During the satellite launch preparation stage, the plug end is installed on the satellite side, and the socket end is installed on the upper stage of the rocket or other satellites. During assembly, the operator aligns the plug end with the socket end, and the anti-shear pin 2 first enters the pin cone socket. Due to the tapered design of the end of the anti-shear pin 2, even if there is a certain misalignment, the anti-shear pin 2 can smoothly enter the pin cone socket and achieve initial positioning. As the plug end continues to approach the socket end, the top 701 of the conductive elastic pin 7 begins to contact the conductive contact 13. Since the conductive elastic pin 7 has a built-in elastic pin spring 702, during the contact process, the conductive contact 13 applies pressure to the top 701 of the conductive elastic pin. The top 701 of the conductive elastic pin is compressed inward under the action of the elastic pin spring 702. After being compressed, the elastic pin spring 702 generates elastic force, so that the top 701 of the conductive elastic pin always maintains close contact with the conductive contact 13, ensuring a good electrical connection. The boss on the elastic pin cover plate 8 limits the compression stroke of the elastic pin spring 702 to prevent the spring 702 from being over-compressed.

[0044] Once the plug and socket are fully aligned, the shear pin 2 and the pin cone socket engage perfectly, eliminating any floating errors during assembly and preventing uneven force distribution on the conductive elastic pin 7 caused by assembly float. At this point, the conductive elastic pin 7 and the conductive contact 13 form a stable electrical connection. Current can be transferred from the rocket's upper stage or other spacecraft's power source, through the socket cable 5, contact printed circuit board 15, conductive contact 13, conductive elastic pin 7, elastic pin printed circuit board 10, and plug cable 3, ultimately reaching the satellite's internal systems to charge its batteries. Throughout the flight, the satellite's internal systems, such as computers, navigation, and thermal control, are continuously powered, but the power is supplied by the rocket's upper stage via the charging station. The satellite's own batteries are always kept fully charged, ensuring sufficient power for independent operation after separation.

[0045] When the satellite reaches its predetermined orbit and needs to separate from the rocket, the separation mechanism is activated, causing the satellite and rocket to separate vertically. Because this invention employs an elastic contact method between the conductive elastic needle 7 and the conductive contact 13, during separation, the conductive elastic needle 7 automatically rebounds under the action of the elastic needle spring 702, and the top 701 of the conductive elastic needle naturally disengages from the conductive contact 13, completing the physical break. The entire separation process requires no explosive bolts or other pyrotechnic aids, generates no impact vibration, and will not damage the precision optical instruments and electronic equipment on the satellite, nor produce metal debris or other contaminants. Simultaneously, the conical design of the anti-shear pin 2 and the pin cone socket prevents additional pin-pulling resistance during separation, allowing the anti-shear pin 2 to smoothly exit from the pin cone socket, ensuring a smooth, rapid, and reliable satellite separation process.

[0046] Thanks to the elastic force provided by the spring 702 of the conductive elastic pin 7, no separation resistance is generated during the separation process. The satellite can maintain a good attitude to complete the separation action, avoiding the risks such as rotational separation and poor attitude that may occur with traditional explosive bolt methods. After separation, the satellite immediately uses its own battery power to perform a series of important actions such as initial attitude adjustment, solar array deployment, and communication establishment. Since the battery is fully charged before separation, the satellite has sufficient power to complete these critical operations.

[0047] This invention's satellite seat charging device transforms the traditional passive unlocking mechanism into an active separation mechanism, improving satellite safety and reliability and eliminating the inherent risks of pyrotechnic devices. It decouples the satellite's mechanical separation mechanism from its charging function, simplifying interface and system design. The device has a simple structure, small size, and light weight, enabling lightweight satellite design. Because it does not use disposable explosive bolts, the device is reusable and supports multiple, full-function, and realistic tests before launch, ensuring its reliability. Furthermore, the device allows for on-orbit reconnection and re-separation, providing greater flexibility for future space missions. Its low production cost reduces the overall system cost, resulting in good economic benefits and promising application prospects.

[0048] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A novel automatic separation type satellite constellation filling device, characterized in that Includes the plug end and the socket end; The plug end includes a plug support, a conductive elastic pin, an elastic pin fixing seat, an elastic pin cover plate, an elastic pin printed plate, a clamping block, and a rear cover plate; The socket end includes a socket support, conductive contacts, a contact fixing plate, a contact printed circuit board, a clamping block, and a rear cover plate; The conductive elastic needle has a built-in spring, which allows the top of the conductive elastic needle to extend and compress freely under external force. The plug support is used to support the elastic pin fixing seat and the elastic pin cover plate; the elastic pin printed plate is pressed into the plug support by a clamping block; the elastic pin fixing seat and the elastic pin cover plate respectively press the conductive elastic pin; the rear cover plate is connected to the clamping block; The socket support is used to support the contact fixing plate; the contact printed circuit board is pressed into the socket support by the clamping block; the contact fixing plate positions the conductive contacts; the rear cover plate is connected to the clamping block.

2. A novel automatic separation type satellite constellation filling apparatus according to claim 1, characterized in that The conductive elastic needle includes a conductive elastic needle top, an elastic needle spring, a conductive elastic needle ear, and a conductive elastic needle tail; the elastic needle spring causes the conductive elastic needle top to extend and compress freely under the action of external force.

3. A novel automatic separation type satellite constellation filling apparatus according to claim 2, characterized in that The elastic needle holder has a first groove with the same number of conductive elastic needles, and the bottom surface of the first groove has a first through hole penetrating the elastic needle holder; the elastic needle cover plate has a second groove with the same number of conductive elastic needles, and the bottom surface of the second groove has a second through hole penetrating the elastic needle cover plate; the first groove and the second groove respectively contact the conductive elastic needle lugs to press the conductive elastic needles; the first through hole and the second through hole are used to pass through the stepped shaft of the conductive elastic needle.

4. A novel automatic separation type satellite constellation filling apparatus according to claim 2, characterized in that The elastic needle cover plate is provided with a boss, which is used to limit the travel of the elastic needle spring.

5. A novel automatic separation type satellite constellation filling apparatus according to claim 2, characterized in that The elastic pin printed circuit board has a first pad through-hole with the same number of conductive elastic pins. The tail of the conductive elastic pin passes through the first pad through-hole and is connected by welding. The other side of the elastic pin printed circuit board has a second pad through-hole, which is welded to an external cable conductor. The first pad through-hole and the second pad through-hole are connected and conductive through printed circuit board wiring.

6. A novel automatic detachable satellite seat charging device according to claim 1, characterized in that... The contact fixing plate has stepped grooves in the same number as the conductive contacts for positioning the conductive contacts; the tail of the conductive contact is connected to the through hole of the pad on the contact printed circuit board by welding.

7. A novel automatic detachable satellite seat charging device according to claim 1, characterized in that... The plug support is provided with an anti-shear pin, which is connected to the plug support through a hole-shaft fit; the socket support is provided with a pin cone recess; the anti-shear pin fits into the pin cone recess, with a fitting clearance.

8. A novel automatic detachable satellite seat charging device according to claim 7, characterized in that... The shear pin has a tapered end, and the pin recess is a tapered recess.

9. A novel automatic detachable satellite seat charging device according to claim 1, characterized in that... The plug end is provided with a plug cable and an electrical connector, and the socket end is provided with a socket cable and an electrical connector.

10. A novel automatic detachable satellite seat charging device according to claim 1, characterized in that... The plug end and the socket end are respectively provided with wire clips, which are used to clamp the cable harness soldered from the printed circuit board; the elastic pin cover plate, the elastic pin fixing seat, and the contact fixing plate are made of insulating material.

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