Testing system and method for space deployable and retractable penetration flying spear

Abstract

The invention relates to a test system and method for a space deployable and retractable penetration flying spear. Comprising a foldable main body structure, a low-interference test module, a motor rope collecting and recovering module, an electromagnetic transmitting module and a control module, the foldable main body structure comprises a bottom plate, an electric multi-stage cylinder, a target plate and an electromagnetic transmitting device; the electric multi-stage cylinder is used for driving and placing a target plate at a preset position, and the low-interference test module is used for testing and collecting impact force of a flying spear, attitude information of the flying spear, axial acceleration of the flying spear at the moment of penetration, real-time tension of a tether and an included angle between the tether and a penetration axis; the motor rope collecting and recycling module is used for recycling the flying spear after penetration; on one hand, the control module comprehensively coordinates unfolding and folding of the electric multi-stage cylinder, adjustment of electromagnetic emission parameters, synchronous acquisition of sensors and start and stop of a recovery motor to realize automation of a test process; and on the other hand, synchronous analysis and error correction are carried out on the collected data to generate a performance evaluation result. The technical blank is filled, and the development of the fragment removal technology is promoted.

Description

Technical Field

[0001] This invention belongs to the field of space debris removal, specifically relating to a testing system and method for deployable and retractable penetrating spears in space. Background Technology

[0002] The increase in human space activities has led to a surge in space debris in near-Earth orbit, posing a serious threat to spacecraft in orbit. Active space debris removal technology has become a key research focus in the global aerospace field. Space spear technology, due to its compact structure and high precision, has significant advantages in non-cooperative debris capture. However, a dedicated testing system is crucial for its engineering implementation, requiring precise characterization of the spear's penetration force and operational attitude—two core performance parameters.

[0003] Existing debris removal solutions each have their limitations. Technologies such as robotic arms, rope nets, and lasers cannot balance efficiency and applicability. The operational effectiveness of the space spear depends entirely on the coordinated performance of penetration force and operational posture. These two factors directly determine the success or failure of the removal mission, placing extremely high demands on the professionalism of the testing system.

[0004] To adapt to different types of spears and ground constraints, the testing system needs to be deployable—folded up for easy storage and transport when not in use, and unfolded to build a complete working condition simulation environment during testing. However, existing testing technologies have significant shortcomings, making it difficult to simultaneously meet the requirements of deployable structural stability, working condition simulation accuracy, and simultaneous testing of these two core indicators.

[0005] Regarding penetration force measurement, existing equipment is mostly adapted to conventional munitions and lacks adaptability to deployable structures. Deformation after deployment can easily introduce errors, and it cannot accurately simulate high-speed penetration scenarios in space, resulting in significant data deviations. In terms of operational attitude monitoring, existing external observation methods can only obtain superficial information and cannot capture dynamic parameters in real time. Furthermore, the fixed structure design makes it difficult to adjust the test range and cannot reproduce attitude changes under real-world conditions.

[0006] The existing system is unable to simultaneously measure penetration force and attitude, and lacks a mature deployable design, thus failing to provide systematic data support and hindering the iteration of flying spear technology. Summary of the Invention

[0007] The purpose of this invention is to provide a testing system and method for deployable and retractable penetrating spears in space, filling a technological gap and promoting the development of debris removal technology.

[0008] The technical solution to achieve the purpose of this invention is: a test system for a space-deployable and retractable penetrating spear, comprising a deployable and retractable main structure, a low-interference test module, a motor-driven rope recovery module, an electromagnetic launch module, and a control module;

[0009] The deployable main structure includes a base plate, an electric multi-stage cylinder, a target plate, and an electromagnetic launching device. One end of the electric multi-stage cylinder is placed on the base plate, and the other end is driven to place the target plate in a preset position. The electromagnetic launching device is used to launch flying spears to penetrate the target plate.

[0010] The low-interference test module is used to test and collect the impact force of the spear, the attitude information of the spear, the axial acceleration of the spear at the moment of penetration, the real-time tension of the tether, and the angle between the tether and the penetration axis during penetration.

[0011] The motor-driven rope recovery module is used to recover the spear after penetration. During the launch and recovery process, the rope of the motor-driven rope recovery module is coaxially stressed with the tail of the spear. When the rope is recovered, the deviation from the axis of the electric multi-stage drum does not exceed ±1°.

[0012] The electromagnetic launch module is used to launch the spear;

[0013] The control module coordinates the deployment and retrieval of the electric multi-stage drum, the adjustment of electromagnetic emission parameters, the synchronous acquisition of sensors, and the start and stop of the recovery motor to automate the testing process. On the other hand, it performs synchronous analysis and error correction on the acquired data to generate performance evaluation results.

[0014] Furthermore, the electric multi-stage cylinder is a multi-stage telescopic structure driven by a servo motor, equipped with linear guide rails and a locking mechanism. It retracts and closes when not in testing state, and extends to a preset length and locks to form a rigid platform during testing. Standardized installation interfaces are reserved at the ends.

[0015] The electromagnetic launch module includes an excitation coil, replaceable inner liner and outer shell. Multiple inner liners are made of polyetheretherketone (PEEK), and the inner diameters of multiple inner liners are designed in a gradient to adapt to various specifications of spears. Replacement is achieved through a quick-release positioning structure. The excitation coil is equipped with a high-frequency pulse power supply and a magnetic field closed-loop controller to achieve initial launch velocity adjustment.

[0016] Furthermore, the inner wall of the replaceable liner is fitted with a 2-3mm flexible silicone cushioning layer. The quick-release positioning structure between the liner and the launch channel is as follows: three sets of axial grooves are evenly opened circumferentially on the inner wall of the launch channel, and three sets of integrated bosses are set on the outer wall of the replaceable liner. The top of the boss has a 3mm diameter positioning pin hole radially opened; three sets of spring-type positioning pin assemblies are set at the port of the launch channel corresponding to the positioning pin hole position. The positioning pin is made of 45# steel, with a compression spring at the tail and a press-type unlock button on the outside. During assembly, the inner liner boss is aligned with the launch channel groove and pushed axially to the preset position. The positioning pin automatically embeds into the inner liner positioning pin hole under the action of the spring force, realizing dual axial and circumferential positioning of the inner liner. After assembly, the interference fit between the positioning pin and the boss ensures the reliability of the fixation. During disassembly, the three unlock buttons are pressed at the same time. The positioning pin compresses the spring and exits the positioning pin hole. The inner liner can be directly pulled out axially to complete the disassembly.

[0017] Furthermore, the low-interference test module includes a high-sensitivity piezoelectric dynamic force sensor that is directly fixed between the electric multistage cylinder and the target plate via a flange, a MEMS inertial measurement unit embedded in the center of gravity of the spear, a tension sensor set on the tether, and an angle sensor set on the upper surface of the electromagnetic launch module.

[0018] The MEMS inertial measurement unit is a nine-axis sensor that integrates an accelerometer, gyroscope, and magnetometer. It has a sampling frequency of 10kHz and is mounted to the spear via a mounting bracket with a sealing gasket and cushioning foam.

[0019] Furthermore, the motor-driven rope recovery module also includes a motor, a rope winding wheel, a guide device, and a pulley block.

[0020] One end of the rope is fixed to the spear via a countersunk connector at the tail, with the end face of the connector flush with the tail of the spear. The other end is wound around the rope wheel of the motor module via a guide device and a pulley system.

[0021] Furthermore, the pulley system uses ceramic bearings;

[0022] The tethering rope adopts a structure of main section-buffer section-main section. The main section is made of high-strength ultra-high molecular weight polyethylene fiber with a breaking strength ≥200kN. The buffer section is woven from 304 stainless steel wire rope with a diameter of 4-6mm and a length of 150-200mm. Its elastic modulus is 190-210GPa, its elongation at break is 8%-10%, and it can withstand a maximum instantaneous tensile force ≥300kN. The connection between the buffer section and the main section adopts a double-ring extrusion fixing structure. The rings are made of 6061 aluminum alloy, and their inner diameter matches the diameter of the tethering rope and the buffer section. The breaking strength at the connection is ≥90% of the breaking strength of the main body of the tethering rope.

[0023] The pulley block can be adjusted in height within the vertical range of 50-150mm. Combined with the elastic compensation effect of the buffer section, it ensures that the deviation between the rope and the main axis of the electric multi-stage drum does not exceed ±1° during the rope winding process.

[0024] Furthermore, the excitation coil of the electromagnetic launch module contains at least three sets of coaxial equidistant excitation units, the number of coil turns is adjustable within the range of 500-2000 turns, the initial launch velocity is adjustable within the range of 10-50 m / s, and the relative error of multiple launches is ≤±2%;

[0025] A 3±0.5mm thick elastic alloy buffer calibration pad is added between the high-sensitivity piezoelectric dynamic force sensor and the electric multistage cylinder.

[0026] A method for penetrating a flying spear using the above-mentioned testing system includes the following steps:

[0027] Step (1): Assembly and debugging phase:

[0028] Step (2): Test execution: Launch the spear, collect parameters, and calculate the theoretical penetration force of the spear and the corrected output speed of the spear based on the collected parameters, taking into account the tether and air resistance.

[0029] Step (3): Recycle and reset.

[0030] Further, step (1) specifically involves: retracting the electric multistage cylinder to its shortest state, transporting it to the designated test position, fixing the base plate with anchor bolts, and reserving a safety redundancy distance to avoid interference during extension and retraction; selecting a replaceable inner liner with the corresponding inner diameter according to the spear specifications, inserting it into the launch tube, and positioning it through the boss-groove structure; embedding the MEMS sensor into the spear's center of gravity mounting base, completing calibration and wireless pairing, and securing the tether with countersunk connectors while reserving a redundant length; selecting an adapter target plate, fixing the force sensor between the electric multistage cylinder and the target plate, and attaching a buffer calibration pad;

[0031] Main body deployment and positioning: The control module issues a command to drive the electric multi-stage drum to extend to the preset length and lock it to ensure the main body is rigid and stable; Parameter initialization: Set the test parameters, force sensor sampling frequency ≥20kHz, MEMS sensor sampling frequency 10kHz, electromagnetic launch initial velocity 10-50m / s, motor rope winding speed, and the control module data acquisition card completes parameter synchronization.

[0032] Step (3) is as follows: the control module issues a retrieval command, and the motor smoothly retracts the rope through the pulley group; after the spear is retrieved, the electric multi-stage drum unlocks and retracts to its initial state; the spear and target plate are disassembled, the sensor, pulley group and rope are cleaned, and the wear and tear of the components is checked; the test results are exported; the target plate is replaced, the spear model or test parameters are adjusted, and a new round of testing is carried out.

[0033] Furthermore, step (2) specifically includes the following steps:

[0034] Step (21) Launching the spear and acquiring basic parameters: After starting the electromagnetic launch module, the high-frequency pulse power supply outputs a current signal with a specific amplitude and frequency according to the preset test scheme. The signal flows through the variable excitation coil group, generating a uniform and controllable electromagnetic thrust, which drives the spear to be launched at high speed along the launch channel equipped with a replaceable inner liner of the corresponding specification. The coaxiality error of the launch is guaranteed to be ≤0.05mm throughout the process. Parameter acquisition is carried out simultaneously: The force sensor matched with the coil group collects the data of the change of electromagnetic launch force with the stroke x in real time, i.e., F. em(x), record the launch stroke L, unit: m; collect the real-time tension T(x) of the tether using the tension sensor on the tether, and collect the real-time angle θ(x) between the tether and the launch axis using the angle sensor; at the same time, combined with the air density ρ, unit: kg / m³, the windward area S, unit: m² and air resistance coefficient Cd in the design parameters of the flying spear, the collected data are transmitted to the control module cache in real time;

[0035] Step (22): Instantaneous parameter acquisition and core calculation during penetration: At the instant the spear penetrates the target plate at high speed, each sensor enters a high-frequency acquisition state: The high-sensitivity piezoelectric dynamic force sensor acquires the impact force and pressure distribution data in real time, i.e., the direct measurement value F of the dynamic force sensor. s Unit: N; data is transmitted to the control module; a MEMS inertial measurement unit embedded in the center of gravity of the spear synchronously acquires the spear's tilt angle, angle of attack, and attitude deflection, and captures the spear's axial acceleration at the moment of penetration. Unit: m / s², data is transmitted to the control module; the tension sensor synchronously locks the real-time tension of the tether at the moment of penetration. Unit: N; Angle sensor records the angle θ0 between the tether and the penetration axis at this moment; Unit: °; The control module calls the following algorithm, combined with the recorded total mass of the spears m; Unit: kg, to calculate the theoretical penetration force:

[0036] ,

[0037] The penetrating power F of the flying spear theory p Unit: N;

[0038] Simultaneously, based on the various parameters collected during the launch phase, the velocity is output using the flying spear theory:

[0039] ,

[0040] in This represents the total power of electromagnetic emission.

[0041] The negative work done by the tension in the rope;

[0042] (Negative work done by air resistance)

[0043] Step (23): Data fusion processing and visualization: The control module processes the collected raw sensor data and calculates the theoretical penetration force F in real time. pThe theoretical output velocity v undergoes multi-dimensional data processing: First, time synchronization calibration is performed to ensure the consistency of timestamps for all data; then, a preset error compensation algorithm is used to eliminate system errors; next, data fusion is performed to correlate penetration force data, velocity data, and attitude parameter data to generate penetration force-time curves, spear velocity-stroke curves, and attitude change trajectory diagrams; finally, the processed raw data, calculation results, and visualization charts are output.

[0044] Compared with the prior art, the significant advantages of this invention are:

[0045] Firstly, adaptability and low interference are improved synergistically. The replaceable inner liner of the electromagnetic launch module and the flexible adaptable bushing work together to achieve rapid adaptation of multiple specifications of flying spears without modifying the main structure; the tail countersunk connector, coaxial tether guide and elastic buffer section design completely eliminate component protrusions and tether interference, ensure the authenticity of attitude data, and solve the problems of poor adaptability and high interference in the existing system.

[0046] Secondly, measurement accuracy has been significantly improved. The direct-mount dynamic force sensor, combined with a buffer calibration pad, eliminates the influence of transmission errors and structural deformation at the source, resulting in a penetration force measurement error of ≤±1.5%. The MEMS sensor is integrated into the center of gravity of the spear, enabling high-frequency synchronous acquisition of attitude parameters throughout the entire process. Combined with a multi-channel data acquisition architecture, data reliability and synchronization have been greatly improved.

[0047] Third, the system's deployment and retraction capabilities and operational condition simulation capabilities are enhanced. The electric multi-stage cylinder replaces the traditional hydraulic drive, improving the precision and response speed of deployment and retraction control. The retracted state facilitates transportation, while the extended state locks in place to form a rigid platform. The electromagnetic emission closed-loop control can accurately reproduce high-speed space penetration scenarios, adapting to different testing needs and solving the problem of insufficient operational condition simulation accuracy in existing systems.

[0048] Fourth, the testing process is closed-loop and operates efficiently. The low-interference tether constraint and motor recovery linkage design allow for the smooth recovery of the spear after testing and drive the system to reset, forming a closed-loop process of "deployment-recovery-testing", avoiding equipment wear and tear, improving testing continuity and reusability, and reducing testing costs.

[0049] Fifth, integrated collaborative testing facilitates technology implementation. The control module coordinates the collaborative operation of all modules, automating the entire process of launch, acquisition, analysis, and recovery. It simultaneously completes penetration force and attitude parameter testing and analysis, solving the problem of fragmented testing indicators in existing systems and providing reliable support for the iteration and engineering implementation of the flying spear technology. Attached Figure Description

[0050] Figure 1 shows the overall diagram of the space-deployable and retractable penetrating spear test system;

[0051] Figure 2 shows the extended view of the space-deployable and retractable penetrating spear test system;

[0052] Figure 3 A detailed view of the connection between the electric multistage cylinder and the target plate;

[0053] Figure 4 A structural diagram of a space-deployable and retractable penetrating spear test system;

[0054] Figure 5 A diagram of the rope-retrieval structure for a space-deployable and retractable penetrating spear test system;

[0055] Figure 6 A diagram of the launch structure for a space-deployable and retractable penetrating spear test system;

[0056] Figure 7 Penetration diagram of a space-deployable and retractable penetrating spear test system;

[0057] Figure 8 This is a diagram of the retraction of a space-deployable penetrating spear test system. Detailed Implementation

[0058] The present invention will now be described in further detail with reference to the accompanying drawings.

[0059] This invention provides a space-deployable and retractable low-interference penetration spear testing system, which adopts an integrated design of "deployable and retractable main structure + electromagnetic launch module + low-interference testing module + motor-driven rope recovery module + control module". The specific technical solution is as follows: The testing system includes an electric multi-stage cylinder main body, an electromagnetic launch module, a low-interference testing module (including a penetration force measurement unit and an attitude monitoring unit), a rope low-interference constraint and motor-driven rope recovery module, and a control module. All modules work together to complete the entire testing process.

[0060] (I) Electric multi-stage drum body

[0061] The electric multi-stage cylinder features a multi-stage telescopic structure driven by a servo motor and equipped with a high-precision linear guide and locking mechanism, replacing traditional hydraulic drive and improving the control accuracy and response speed of the extension and retraction movements. In non-testing states, it retracts to its shortest length in multiple stages, significantly reducing space occupation and facilitating storage and transportation. During testing, it extends to a preset length and locks in position, forming a rigid and stable test reference platform that can adapt to the testing needs of different sizes and models of spears. The end has a standardized installation interface that allows for flexible adjustment of the target plate and test component installation positions.

[0062] (ii) Electromagnetic launch module

[0063] The electromagnetic launch module adopts a combination structure of variable excitation coil and replaceable inner liner, taking into account both compatibility with various types of spears and launch accuracy. The replaceable inner liner is made of high-strength, wear-resistant engineering plastic polyetheretherketone (PEEK) in one piece, in a cylindrical shape, with multiple sizes of inner diameter designed in a gradient pattern to accommodate various spears with diameters of 50-200mm and lengths of 300-1500mm. The outer diameter of the inner liner and the inner diameter of the launch channel are precisely fitted with a clearance of 0.5-1mm. The inner wall is lined with a 2-3mm thick flexible silicone buffer layer with anti-slip texture on the surface to reduce friction damage and buffer the radial impact force of the launch. The liner and launch channel adopt a combined quick-release positioning structure of "boss-groove + positioning pin". The inner wall of the launch channel has three sets of axial grooves evenly opened in the circumference (groove width 8mm, groove depth 5mm, length consistent with the axial length of the liner). Corresponding to the outer wall of the replaceable liner, three sets of integrated molded bosses are set (the boss size is precisely matched with the groove, and the fit clearance is ≤0.1mm). The top of the boss has a positioning pin hole with a diameter of 3mm in the radial direction. At the port of the launch channel, three sets of spring-type positioning pin assemblies are set at the corresponding positioning pin hole positions. The positioning pins are made of 45 steel, with a diameter of 3.9mm and a length of 15mm. The tail is equipped with a compression spring (spring stiffness 5N / mm, compression stroke 8mm). There is a push-type unlock button on the outside. The replacement time of a single liner is ≤30 seconds, realizing rapid switching of the spear specifications. The coil assembly contains at least three sets of coaxial equidistant excitation units, and the number of coil turns can be adjusted within the range of 500-2000 turns. With the high-frequency pulse power supply and magnetic field closed-loop controller, the initial launch velocity can be adjusted from 10-50m / s, and the relative error of multiple launches is ≤±2%, ensuring test repeatability.

[0064] (III) Low Interference Test Module

[0065] In the low-interference testing module, the core of the penetration force measurement unit is a high-sensitivity piezoelectric dynamic force sensor, which is directly fixed between the end of the electric multistage cylinder and the target plate via a flange. It directly collects penetration impact force and pressure distribution data, avoiding intermediate transmission errors. A 1-3mm adjustable elastic alloy buffer calibration gasket is added between the sensor and the connecting surface to adapt to the telescopic positioning accuracy of the electric multistage cylinder and offset the influence of minor deformations of the main structure on the measurement. The attitude monitoring unit uses a nine-axis MEMS inertial measurement unit as its core, integrating an accelerometer, gyroscope, and magnetometer. With a sampling frequency of 10kHz, it is embedded in a pre-set mounting slot at the center of gravity of the spear and fixed by a flexible adapter bushing. The sealed chamber is filled with buffer foam and equipped with a sealing gasket to achieve waterproof, dustproof, and impact-resistant protection. It communicates with the control module via a low-latency wireless transmission module (latency ≤10ms) to synchronously collect dynamic parameters such as tilt angle, angle of attack, attitude deflection, and acceleration during flight and penetration.

[0066] (iv) Rope low-interference constraint and motor rope recovery module

[0067] The tethered low-interference constraint and motor-driven rope recovery module includes a motor module, a tether, an elastic buffer section, and a guide pulley system. The motor module and guide pulley system are fixed to the base plate. The tether is made of high-strength ultra-high molecular weight polyethylene fiber, with a diameter of 1-2mm and a breaking strength ≥200kN. A 304 stainless steel wire rope braided elastic buffer section (diameter 4-6mm, length 150-200mm, elastic modulus 190-210GPa, elongation at break 8%-10%, capable of withstanding a maximum instantaneous tensile force ≥300kN) is installed in the middle section to absorb instantaneous tensile force and prevent posture deviation. The guide pulley system uses ceramic bearings and can be adjusted vertically within a range of 50-150mm to ensure that the tether and the tail of the spear are coaxially stressed, and that the deviation from the axis of the electric multi-stage drum during rope recovery does not exceed ±1°, minimizing lateral interference. After testing, the control module drives the motor to smoothly recover the rope through a reduction mechanism, simultaneously retracting and closing the electric multi-stage drum, achieving overall system reset.

[0068] (v) Control Module

[0069] The control module integrates data processing, motion control, and status monitoring functions. It is equipped with a data acquisition card with 16-bit precision and a cache of ≥16GB. On the one hand, it coordinates the electric multi-stage cylinder deployment and retraction, electromagnetic emission parameter adjustment, synchronous sensor acquisition, and start-stop rate of the recovery motor to automate the testing process. On the other hand, it performs synchronous analysis and error correction on penetration force data and MEMS attitude data, generates performance evaluation reports, and supports data export to MATLAB for algorithm optimization, ensuring system stability and test reliability.

[0070] like Figure 1 As shown, the spatial deployable and retractable penetrating spear testing system of the present invention consists of a deployable and retractable main structure, a low-interference testing module, a motor-driven rope recovery module, an electromagnetic launch module, and a control module. The deployable and retractable main structure comprises a base plate 1, a motorized multi-stage cylinder 2, a target plate 3, and a launching device 4. The testing module consists of a force sensor 9 and a MEMS attitude sensor 11. The motor-driven rope recovery module consists of a motor 6, a rope winding wheel 12, a guide device 13, and a pulley block 14. The electromagnetic launch module consists of an excitation coil 15, an inner liner 16, and an outer shell 17.

[0071] The electromagnetic launch module's variable excitation coil group contains at least three sets of coaxial equidistant excitation units. The number of coil turns can be adjusted within the range of 500-2000 turns. The initial launch velocity is adjustable within the range of 10-50 m / s, and the relative error of multiple launches is ≤±2%.

[0072] The replaceable inner liner has a 2-3mm flexible silicone cushioning layer attached to its inner wall. The inner liner and the launch channel utilize a quick-release positioning structure combining a boss, groove, and locating pin for rapid and precise assembly and disassembly. The specific structural design is as follows: Three sets of axial grooves (8mm wide, 5mm deep, and the same length as the inner liner's axial length) are evenly distributed along the circumference of the inner wall of the launch channel. Correspondingly, three sets of integrated bosses are provided on the outer wall of the replaceable inner liner (the boss size precisely matches the groove, with a fit clearance ≤0.1mm). A 3mm diameter locating pin hole is radially provided on the top of each boss. At the launch channel port, three sets of spring-loaded locating pin assemblies are provided corresponding to the locating pin holes. The locating pins are made of 45# steel, 3.9mm in diameter, and 15mm in length, with a compression spring at the tail (spring stiffness 5N / mm, compression stroke 8mm). An external push-button unlocking mechanism is also provided. During assembly, align the inner liner boss with the firing channel groove and push it axially to the preset position. The locating pin automatically engages with the locating pin hole under the spring force, achieving dual axial and circumferential positioning of the inner liner. After assembly, the interference fit between the locating pin and the boss ensures reliable fixation. During disassembly, press the three unlocking buttons simultaneously. The locating pin compresses the spring and exits the locating pin hole, allowing the inner liner to be pulled out axially to complete disassembly. This quick-release positioning structure is easy to operate, with a single inner liner replacement time of ≤30 seconds. It is compatible with various specifications of throwing spears with diameters of 50-200mm and lengths of 300-1500mm.

[0073] As shown in Figures 1 and 2, the electric multistage drum is retracted when not in use and unfolded when testing is required.

[0074] As shown in Figures 3 and 4, the force sensor 9 is installed between the electric multistage cylinder 2 and the target plate 3. A 3mm thick elastic alloy buffer calibration pad 8 is added between the sensor and the multistage cylinder to offset the influence of the main body deformation. This not only adapts to the telescopic positioning accuracy of the electric multistage cylinder, but also offsets the influence of the small deformation of the main body structure on the measurement. The MEMS sensor 11 is installed at the center of gravity of the spear 10. The chamber is filled with buffer foam. The mounting base is fastened to the spear by threads and equipped with a sealing gasket. It collects dynamic parameters such as tilt angle, angle of attack, attitude deflection, and acceleration during the flight and penetration of the spear.

[0075] like Figure 5 Figure 6 As shown, the motor-driven rope recovery module consists of a motor 6, a rope winding wheel 12, a guide device 13, a pulley block 14, and a rope. One end of the rope is fixed to the spear via a countersunk connector at the tail, with the end face of the connector flush with the tail of the spear. The other end is wound around the motor module's winding wheel 12 via the guide device 13 and the pulley block 14.

[0076] The guide pulley system uses ceramic bearings, and the tethering rope is made of high-strength ultra-high molecular weight polyethylene fiber with a breaking strength ≥200kN. The middle section of the tethering rope features an integrated elastic buffer section. Specific structural and connection requirements are as follows: The buffer section is woven from 304 stainless steel wire rope, with a diameter of 4-6mm and a length of 150-200mm. Its elastic modulus is 190-210GPa, and its elongation at break is 8%-10%. It can withstand a maximum instantaneous tensile force ≥300kN, effectively absorbing the instantaneous impact force during the launch and recovery of the spear. The connection between the buffer section and the main body of the tethering rope uses a double-ring compression fixing structure. The rings are made of 6061 aluminum alloy, with an inner diameter precisely matched to the diameter of the tethering rope and the buffer section (fitting gap ≤0.1mm). The breaking strength at the connection point is ≥90% of the breaking strength of the main body of the tethering rope. The guide pulley system can extend vertically by 50-150mm. The height can be adjusted within a certain range, and with the elastic compensation of the buffer section, the deviation between the rope and the main axis of the electric multi-stage drum during the rope winding process does not exceed ±1°, thus minimizing lateral interference.

[0077] like Figure 7 Figure 8 As shown, during the test, the spear was launched at high speed along the launch tube and penetrated the target plate. After the test, the motor module was started and the rope was smoothly retrieved through the guide pulley group. During the rope retrieval process, the deviation between the rope and the axis of the electric multi-stage drum was ≤±1°. After the retrieval was completed, the electric multi-stage drum retracted to the initial state step by step.

[0078] The specific testing method of this invention is as follows:

[0079] Preparation stage

[0080] First step, such as Figure 1 As shown, the equipment is transported and secured: the electric multistage cylinder is retracted to its shortest state and transported to the designated test location. The base plate is secured with anchor bolts, leaving a safety margin to avoid interference during extension and retraction. The second step is the assembly of test components: a replaceable inner liner with the corresponding inner diameter is selected according to the spear specifications and installed into the launch tube, positioned using a boss-groove structure; the MEMS sensor is embedded into the spear's center-of-gravity mounting base, calibration and wireless pairing are completed, and the tether is secured with countersunk connectors, leaving a margin of safety; a matching target plate is selected, and the force sensor is fixed between the electric multistage cylinder and the target plate, with a buffer calibration pad attached to ensure accurate force transmission. The third step is wiring and connection checks: the sensor wiring is connected to the control module, and the power supply and signal continuity of the electromagnetic launch module and motor module are checked to ensure stable operation of each module.

[0081] Debugging phase

[0082] First step, such as Figure 2As shown in the figure, the main body is unfolded and positioned: the control module issues an instruction to drive the electric multi-stage cylinder to extend to a preset length and lock it, ensuring the rigidity and stability of the main body. In the second step, parameter initialization: set the test parameters, the sampling frequency of the force sensor ≥ 20 kHz, the sampling frequency of the MEMS sensor 10 kHz, the initial velocity of electromagnetic emission 10 - 50 m / s, the rope winding rate of the motor, and the control module data acquisition card (16-bit precision, buffer ≥ 16 GB) completes parameter synchronization to ensure the coordinated operation of each module.

[0083] Test execution stage

[0084] First step, as shown in Figure 7, flying spear launch and basic parameter acquisition: After starting the electromagnetic emission module, the high-frequency pulse power supply outputs a current signal with a specific amplitude and frequency according to the preset test plan, flowing through the variable excitation coil group (including at least three coaxial and equally spaced excitation units, and the number of coil turns is adjusted within the range of 500 - 2000 turns according to the initial velocity requirement of emission), generating a uniform and controllable electromagnetic thrust to drive the flying spear to shoot out at high speed along the launch channel equipped with a replaceable inner lining of the corresponding specification, ensuring that the coaxiality error of the launch is ≤ 0.05 mm throughout the process. During this process, start the multi-parameter acquisition mechanism synchronously: use the force sensor supporting the coil group to collect the change data of the electromagnetic emission force with the stroke x (i.e., F em (x)), record the launch stroke L (unit: m); collect the real-time tension T(x) of the tether by the tension sensor on the tether, and collect the real-time included angle θ(x) between the tether and the launch axis by the angle sensor; at the same time, combined with the air density ρ (unit: kg / m³) preset in the test environment, the windward area S (unit: m²) in the design parameters of the flying spear, and the air resistance coefficient Cd, provide complete parameter support for the calculation of the actual output velocity of the flying spear, and all the collected data is transmitted to the control module buffer in real time through the industrial bus.

[0085] Second step, synchronous acquisition of parameters at the moment of penetration and core calculation: At the moment when the flying spear penetrates the target board at high speed (the time node is accurate to the millisecond level), each sensor enters the high-frequency acquisition state: the high-sensitivity piezoelectric dynamic force sensor in the low-interference test module (directly fixed between the electric multi-stage cylinder and the target board through a flange, and there is a 1 - 3 mm adjustable elastic alloy buffer calibration gasket between the sensor and the connection surface) collects the impact force and pressure distribution data in real time, that is, the direct measurement value F of the dynamic force sensor s (unit: N), and the data is transmitted to the control module without delay through a shielded cable; the MEMS inertial measurement unit (nine-axis sensor, integrating accelerometer, gyroscope, and magnetometer, sampling frequency 10 kHz) embedded in the center of gravity of the flying spear synchronously collects the attitude parameters such as the inclination angle, angle of attack, and attitude deflection of the flying spear, and accurately captures the axial acceleration of the flying spear at the moment of penetration (Unit: m / s²), data is uploaded to the control module via a low-latency wireless transmission module (latency ≤ 10ms); the tension sensor synchronously locks the real-time tension of the tether at the moment of penetration. (Unit: N), the angle sensor records the angle θ0 (unit: °) between the tether and the penetration axis at this moment. The control module calls the preset algorithm, combined with the recorded total mass m of the spear (unit: kg), and calculates the penetration force accurately according to the formula:

[0086]

[0087] Real-time calculation yields the theoretical penetration force F of the flying spear. p (Unit: N); Simultaneously, based on the parameters collected during the launch phase, a velocity correction formula is output using the flying spear theory:

[0088]

[0089] in This represents the total power of electromagnetic emission.

[0090] The negative work done by the tension in the rope;

[0091] (Negative work done by air resistance)

[0092] The theoretical output velocity v of the spear (unit: m / s) is obtained by precise correction through numerical integration. During the calculation, data validity is checked simultaneously to remove outliers.

[0093] The third step is data fusion processing and visualization: the control module processes the collected raw sensor data and calculates the theoretical penetration force F in real time. p The theoretical output speed v undergoes multi-dimensional data processing: First, time synchronization calibration is performed to ensure the consistency of timestamps for all data, with a synchronization error ≤0.01s. Then, a preset error compensation algorithm is used to eliminate systematic errors caused by factors such as minor deformation of the deployable structure and temperature drift of sensors, thereby improving data accuracy. Next, data fusion is performed, linking penetration force data, velocity data, and attitude parameter data to generate various visualization charts such as penetration force-time curves, spear velocity-stroke curves, and attitude change trajectory diagrams. Finally, the processed raw data, calculation results, and visualization charts are output, and real-time export to professional analysis software such as MATLAB is supported, providing complete data support for in-depth analysis of spear performance and algorithm optimization.

[0094] Recovery and reset phase

[0095] First step, such as Figure 7As shown, the spear retrieval process involves four steps: First, the control module issues a retrieval command, and the motor module smoothly retracts the rope via the pulley system, preventing spear misalignment and collision damage until the spear stops at the designated position. Second, the system retracts: After spear retrieval, the electric multi-stage drum unlocks and retracts to its initial state. Third, equipment reset and inspection: Disassemble the spear and target plate, clean the sensors, pulley system, and rope, and check for component wear; export and archive the test report. Fourth, preparation for subsequent testing: Replace the target plate, adjust the spear model or test parameters, and repeat the above steps to conduct a new round of testing.

Claims

1. A testing system for space-deployable and retractable penetrating spears, characterized in that, It includes a deployable main structure, a low-interference testing module, a motor-driven rope recovery module, an electromagnetic launch module, and a control module; The deployable main structure includes a base plate (1), an electric multi-stage cylinder (2), a target plate (3), and an electromagnetic launching device (4); one end of the electric multi-stage cylinder (2) is placed on the base plate (1), and the other end is driven to place the target plate (3) in a preset position; the electromagnetic launching device (4) is used to launch flying spears to penetrate the target plate (3). The low-interference test module is used to test and collect the impact force of the spear, the attitude information of the spear, the axial acceleration of the spear at the moment of penetration, the real-time tension of the tether, and the angle between the tether and the penetration axis during penetration. The motor-driven rope recovery module is used to recover the spear after penetration. During the launch and recovery process, the rope of the motor-driven rope recovery module is coaxially stressed with the tail of the spear. When the rope is recovered, the deviation from the axis of the electric multi-stage drum (2) does not exceed ±1°. The electromagnetic launch module is used to launch the spear; The control module coordinates the deployment and retrieval of the electric multi-stage drum, the adjustment of electromagnetic emission parameters, the synchronous acquisition of sensors, and the start and stop of the recovery motor to automate the testing process. On the other hand, it performs synchronous analysis and error correction on the acquired data to generate performance evaluation results.

2. The testing system according to claim 1, characterized in that, The electric multi-stage cylinder (2) is a multi-stage telescopic structure driven by a servo motor. It is equipped with a linear guide rail and a locking mechanism. It retracts and closes when not in the test state, and extends to a preset length and locks to form a rigid platform during the test. The end is reserved with a standardized installation interface. The electromagnetic launch module includes an excitation coil (15), a replaceable inner liner (16), and an outer shell (17). The inner liners (16) are made of polyether ether ketone (PEEK). The inner diameters of the inner liners are designed in a gradient to accommodate various specifications of spears. Replacement is achieved through a quick-release positioning structure. The excitation coil (15) is equipped with a high-frequency pulse power supply and a magnetic field closed-loop controller to achieve initial launch velocity adjustment.

3. The testing system according to claim 2, characterized in that, The replaceable inner liner has a 2-3mm flexible silicone cushioning layer attached to its inner wall. The quick-release positioning structure between the inner liner and the launch channel is as follows: three sets of axial grooves are evenly distributed circumferentially on the inner wall of the launch channel, and three sets of integrated bosses are provided on the outer wall of the replaceable inner liner. The top of the boss has a 3mm diameter positioning pin hole radially. At the launch channel port, three sets of spring-loaded positioning pin assemblies are provided at the corresponding positioning pin hole positions. The positioning pins are made of 45# steel, with a compression spring at the tail and a push-to-unlock button on the outside. During assembly, align the inner liner boss with the launch channel groove and push it axially to the preset position. The positioning pin automatically engages with the positioning pin hole under the spring force, achieving dual axial and circumferential positioning of the inner liner. After assembly, the interference fit between the positioning pin and the boss ensures reliable fixation. During disassembly, press the three unlock buttons simultaneously. The positioning pin compresses the spring and exits the positioning pin hole. The inner liner can then be pulled out axially to complete the disassembly.

4. The testing system according to claim 2, characterized in that, The low-interference test module includes a high-sensitivity piezoelectric dynamic force sensor that is directly fixed between the electric multistage cylinder and the target plate via a flange, a MEMS inertial measurement unit embedded in the center of gravity of the spear, a tension sensor set on the tether, and an angle sensor set on the upper surface of the electromagnetic launch module. The MEMS inertial measurement unit is a nine-axis sensor that integrates an accelerometer, gyroscope, and magnetometer. It has a sampling frequency of 10kHz and is mounted to the spear via a mounting bracket with a sealing gasket and cushioning foam.

5. The testing system according to claim 1, characterized in that, The motor-driven rope recovery module also includes a motor (6), a rope winding wheel (12), a guide device (13), and a pulley block (14). One end of the rope is fixed to the spear through a countersunk connector at the tail, with the end face of the connector flush with the tail of the spear. The other end is wound around the rope wheel (12) of the motor module via a guide device (13) and a pulley block (14).

6. The testing system according to claim 5, characterized in that, The pulley system uses ceramic bearings; The tethering rope adopts a structure of main section-buffer section-main section. The main section is made of high-strength ultra-high molecular weight polyethylene fiber with a breaking strength ≥200kN. The buffer section is woven from 304 stainless steel wire rope with a diameter of 4-6mm and a length of 150-200mm. Its elastic modulus is 190-210GPa, its elongation at break is 8%-10%, and it can withstand a maximum instantaneous tensile force ≥300kN. The connection between the buffer section and the main section adopts a double-ring extrusion fixing structure. The rings are made of 6061 aluminum alloy, and their inner diameter matches the diameter of the tethering rope and the buffer section. The breaking strength at the connection is ≥90% of the breaking strength of the main body of the tethering rope. The pulley block can be adjusted in height within the vertical range of 50-150mm. Combined with the elastic compensation effect of the buffer section, it ensures that the deviation between the rope and the main axis of the electric multi-stage drum does not exceed ±1° during the rope winding process.

7. The testing system according to claim 2, characterized in that, The excitation coil (15) of the electromagnetic launch module contains at least three sets of coaxial equidistant excitation units. The number of coil turns is adjustable in the range of 500-2000 turns. The initial launch velocity is adjustable in the range of 10-50m / s. The relative error of multiple launches is ≤±2%. A 3±0.5mm thick elastic alloy buffer calibration pad is added between the high-sensitivity piezoelectric dynamic force sensor and the electric multistage cylinder.

8. A method for penetrating a flying spear using the testing system according to any one of claims 1-7, characterized in that, Includes the following steps: Step (1): Assembly and debugging phase: Step (2): Test execution: Launch the spear, collect parameters, and calculate the theoretical penetration force of the spear and the corrected output speed of the spear based on the collected parameters, taking into account the tether and air resistance. Step (3): Recycle and reset.

9. The method according to claim 8, characterized in that, Step (1) is as follows: The electric multistage cylinder is retracted to its shortest state and transported to the designated test position. The base plate is fixed with anchor bolts, and a safety redundancy distance is reserved to avoid interference during extension and retraction. The corresponding inner diameter replaceable liner is selected according to the specifications of the spear and installed into the launch tube and positioned by the boss-groove structure. The MEMS sensor is embedded into the spear center of gravity mounting seat, and calibration and wireless pairing are completed. The tether is tightened through the countersunk connector and a redundancy length is reserved. The appropriate target plate is selected, and the force sensor is fixed between the electric multistage cylinder and the target plate. The buffer calibration pad is attached. Main body deployment and positioning: The control module issues a command to drive the electric multi-stage drum to extend to the preset length and lock it to ensure the main body is rigid and stable; Parameter initialization: Set the test parameters, force sensor sampling frequency ≥20kHz, MEMS sensor sampling frequency 10kHz, electromagnetic launch initial velocity 10-50m / s, motor rope winding speed, and the control module data acquisition card completes parameter synchronization. Step (3) is as follows: the control module issues a retrieval command, and the motor smoothly retracts the rope through the pulley group; after the spear is retrieved, the electric multi-stage drum unlocks and retracts to its initial state; the spear and target plate are disassembled, the sensor, pulley group and rope are cleaned, and the wear and tear of the components is checked; the test results are exported; the target plate is replaced, the spear model or test parameters are adjusted, and a new round of testing is carried out.

10. The method according to claim 9, characterized in that, Step (2) specifically includes the following steps: Step (21) Launching the spear and acquiring basic parameters: After starting the electromagnetic launch module, the high-frequency pulse power supply outputs a current signal with a specific amplitude and frequency according to the preset test scheme. The signal flows through the variable excitation coil group, generating a uniform and controllable electromagnetic thrust, which drives the spear to be launched at high speed along the launch channel equipped with a replaceable inner liner of the corresponding specification. The coaxiality error of the launch is guaranteed to be ≤0.05mm throughout the process. Parameter acquisition is carried out simultaneously: The force sensor matched with the coil group collects the data of the change of electromagnetic launch force with the stroke x in real time, i.e., F. em (x), record the launch stroke L, unit: m; collect the real-time tension T(x) of the tether using the tension sensor on the tether, and collect the real-time angle θ(x) between the tether and the launch axis using the angle sensor; at the same time, combined with the air density ρ, unit: kg / m³, the windward area S, unit: m² and air resistance coefficient Cd in the design parameters of the flying spear, the collected data are transmitted to the control module cache in real time; Step (22): Instantaneous parameter acquisition and core calculation during penetration: At the instant the spear penetrates the target plate at high speed, each sensor enters a high-frequency acquisition state: The high-sensitivity piezoelectric dynamic force sensor acquires the impact force and pressure distribution data in real time, i.e., the direct measurement value F of the dynamic force sensor. s Unit: N; data is transmitted to the control module; a MEMS inertial measurement unit embedded in the center of gravity of the spear synchronously acquires the spear's tilt angle, angle of attack, and attitude deflection, and captures the spear's axial acceleration at the moment of penetration. Unit: m / s², data is transmitted to the control module; the tension sensor synchronously locks the real-time tension of the tether at the moment of penetration. Unit: N; Angle sensor records the angle θ0 between the tether and the penetration axis at this moment; Unit: °; The control module calls the following algorithm, combined with the recorded total mass of the spears m; Unit: kg, to calculate the theoretical penetration force: ， The penetrating power F of the flying spear theory p Unit: N; Simultaneously, based on the various parameters collected during the launch phase, the velocity is output using the flying spear theory: ， in This represents the total power of electromagnetic emission. The negative work done by the tension in the rope; (Negative work done by air resistance) Step (23): Data fusion processing and visualization: The control module processes the collected raw sensor data and calculates the theoretical penetration force F in real time. p The theoretical output velocity v undergoes multi-dimensional data processing: First, time synchronization calibration is performed to ensure the consistency of timestamps for all data; then, a preset error compensation algorithm is used to eliminate system errors; next, data fusion is performed to correlate penetration force data, velocity data, and attitude parameter data to generate penetration force-time curves, spear velocity-stroke curves, and attitude change trajectory diagrams; finally, the processed raw data, calculation results, and visualization charts are output.

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