An additive manufacturing based monopropellant propulsion module integrated panel structure

Abstract

The present application relates to the technical field of space propulsion, in particular to a single-component propulsion module integrated plate structure based on additive manufacturing, and provides a single-component propulsion module integrated plate structure based on additive manufacturing, which comprises an integrated plate obtained by additive manufacturing, the integrated plate comprises a plurality of interfaces, and an internal flow channel in communication with the interfaces, the flow channel comprises a gas path and a liquid path which are not in communication with each other. The single-component propulsion module integrated plate structure based on additive manufacturing can provide an integrated plate structure and improve the integration of the space propulsion system.

Description

Technical Field

[0001] This invention relates to the field of space propulsion technology, and in particular to a mono-component propulsion module integrated board structure based on additive manufacturing. Background Technology

[0002] Distributed space systems comprised of microsatellites and their constellations can be widely applied to diverse space missions such as reconnaissance, communication, joint remote sensing, and emergency rescue. Based on mission requirements, the system structure design and manufacturing must demand integrated, lightweight, mass-producible, short development cycles, and low costs for space propulsion systems. Traditional space propulsion systems exhibit a distributed layout, low integration, and are unable to achieve mass production, resulting in high development costs. Constraints of traditional manufacturing processes also make system weight reduction difficult, and the development efficiency and cycle time for fine flow channels are low. Summary of the Invention

[0003] This invention provides a mono-component propulsion module integrated board structure based on additive manufacturing, which can provide an integrated board structure to improve the integration of space propulsion systems.

[0004] In a first aspect, embodiments of the present invention provide a single-component propulsion module integrated board structure based on additive manufacturing, including an integrated board obtained by additive manufacturing, the integrated board including multiple interfaces and internal flow channels communicating with the interfaces, the flow channels including gas channels and liquid channels that are not interconnected.

[0005] Optionally, the interface includes an engine interface, a gas chamber interface, a gas path solenoid valve, and a liquid path self-locking valve. One end of the gas path solenoid valve is connected to the gas path, and the other end is connected to a storage tank for holding propellant. One end of the gas chamber interface is connected to the gas path, and the other end is connected to the gas chamber. One end of the liquid path self-locking valve is connected to the liquid path and is used to add propellant to the storage tank through the liquid path. One end of the engine interface is connected to the liquid path, and the other end is connected to the engine.

[0006] Optionally, the interface further includes a liquid line filling / draining valve, one end of which is connected to the liquid line for adding propellant to the tank through the liquid line.

[0007] Optionally, the interface further includes a satellite interface for connecting the entire satellite and a gas chamber installation interface for installing the gas chamber.

[0008] Optionally, the interface further includes a liquid pressure transmitter for acquiring liquid pressure and a gas pressure transmitter for acquiring gas pressure.

[0009] Optionally, the cross-section of the flow channel is circular, and when the propellant flow rate reaches the maximum preset value, the pressure drop at both ends of the flow channel is less than or equal to 0.05 MPa, while the diameter of the flow channel is ≥1 mm.

[0010] Optionally, the length of a single internal flow channel is less than or equal to 100 mm, and the flow channel bending angle is ≤120°.

[0011] Secondly, embodiments of the present invention provide a method for fabricating a single-component propulsion module integrated board structure based on additive manufacturing, used for assembling any of the integrated board structures described above, the fabrication method comprising: Multi-objective topology optimization technology was used to optimize the structure of the integrated board, thereby achieving a lightweight integrated board structure. The integrated board is manufactured as a blank using a laser melting additive manufacturing process. The internal flow channels are polished, followed by mechanical interface processing. During the interface processing, protective measures are taken to prevent the internal flow channels from being contaminated by foreign matter.

[0012] Optionally, the internal flow channel polishing includes: The internal flow channels are polished using electrochemical polishing or fluid polishing.

[0013] Optionally, the interface processing procedure shall employ protective measures, including: The internal flow channel outlet is sealed with low-melting-point metal or paraffin. After the mechanical interface is processed, the sealing material is removed by high-temperature melting and cleaning.

[0014] Compared with the prior art, the present invention has at least the following beneficial effects: Based on the characteristics of additive manufacturing processes, this patent proposes an integrated plate structure suitable for single-component propulsion modules. Through the interfaces and internal flow channels connected to these interfaces on the integrated plate structure, effective integration of the space propulsion system can be achieved, while also facilitating the overall satellite structural layout. Specifically, the integrated plate achieves a high degree of integration of the entire propulsion system, and completely replaces the propellant piping in traditional propulsion systems through its internal flow channels. This effectively reduces the number of welds, development cycle, and development cost of the propulsion system, meeting the stringent requirements of microsatellites for low-cost, short-cycle, and lightweight propulsion systems. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a schematic diagram of the integrated board of the present invention.

[0017] In the picture: 1-Hydraulic circuit; 2-Air circuit; 3-Hydraulic circuit self-locking valve; 4-Air circuit solenoid valve; 5-Engine interface; 6-Hydraulic circuit pressure transmission; 7-Air chamber interface; 8-Hydraulic circuit filler / drainer valve; 9-Air circuit pressure transmission; 10-Star interface; 11-Air chamber mounting interface. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are some embodiments of the present invention, but not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0019] In the description of the embodiments of the present invention, unless otherwise expressly specified and limited, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance; unless otherwise specified or stated, the term "multiple" refers to two or more; the terms "connected," "fixed," etc., should be interpreted broadly. For example, "connected" can be a fixed connection, a detachable connection, an integral connection, or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the present invention according to the specific circumstances.

[0020] In this specification, it should be understood that the directional terms such as "upper" and "lower" used in the description of the embodiments of the present invention are used to describe the angles shown in the accompanying drawings and should not be construed as limiting the embodiments of the present invention. Furthermore, in the context, it should also be understood that when it is mentioned that one element is connected "upper" or "lower" to another element, it can be directly connected to the other element "upper" or "lower," or indirectly connected to the other element "upper" or "lower" through an intermediate element.

[0021] like Figure 1 As shown, this embodiment of the invention provides a single-component propulsion module integrated board structure based on additive manufacturing, including an integrated board obtained by additive manufacturing. The integrated board includes multiple interfaces and internal flow channels communicating with the interfaces. The flow channels include gas channels 2 and liquid channels 1 that are not interconnected.

[0022] Based on the characteristics of additive manufacturing processes, this patent proposes an integrated plate structure suitable for single-component propulsion modules. Through the interfaces and internal flow channels connected to these interfaces on the integrated plate structure, effective integration of the space propulsion system can be achieved, while also facilitating the overall satellite structural layout. Specifically, the integrated plate achieves a high degree of integration of the entire propulsion system, and completely replaces the propellant piping in traditional propulsion systems through its internal flow channels. This effectively reduces the number of welds, development cycle, and development cost of the propulsion system, meeting the stringent requirements of microsatellites for low-cost, short-cycle, and lightweight propulsion systems.

[0023] In this embodiment, the main body of the integrated plate is a rectangular plate with an envelope size of 150mm × 100mm, which matches the envelope size of the propulsion system.

[0024] In some embodiments of the present invention, the interface includes an engine interface 5, an air chamber interface 7, an air path solenoid valve 4, and a liquid path self-locking valve 3. One end of the air path solenoid valve 4 is connected to the air path 2, and the other end is connected to a storage tank for holding propellant. One end of the air chamber interface 7 is connected to the air path 2, and the other end is connected to the air chamber. One end of the liquid path self-locking valve 3 is connected to the liquid path 1 and is used to add propellant to the storage tank through the liquid path. One end of the engine interface 5 is connected to the liquid path 1, and the other end is connected to the engine.

[0025] In this embodiment, the gas chamber interface 7 connects the gas chamber and the gas passage 2. The high-pressure gas provided by the gas chamber enters the storage tank through the gas passage 2 to drive the propellant in the storage tank into the liquid passage 1. The gas passage solenoid valve 4 is used to open and close the gas passage 2. The liquid passage self-locking valve 3 is used to connect or disconnect the liquid passage 1 and the storage tank. When the liquid passage 1 and the gas passage 2 are unobstructed, the gas passage 2 provides high-pressure gas to drive the propellant in the storage tank into the liquid passage 1, and then into the engine through the engine interface 5 of the liquid passage 1.

[0026] In some embodiments of the present invention, the interface further includes a liquid line filling and draining valve 8, one end of which is connected to the liquid line 1 for adding propellant to the tank through the liquid line.

[0027] It should be noted that the filler valve is only used when adding propellant to the tank.

[0028] In some embodiments of the present invention, the interface further includes a satellite interface 10 for connecting the entire satellite and a gas chamber mounting interface 11 for mounting the gas chamber.

[0029] In some embodiments of the present invention, the interface further includes a liquid pressure transmitter 6 for acquiring the pressure of liquid path 1 and a gas pressure transmitter 9 for acquiring the pressure of gas path 2.

[0030] In summary, the functional implementation process of the integrated plate structure is as follows: First, propellant is added to the tank through the filler / discharge valve on the integrated plate; during system operation, pressurized gas enters the tank through the gas chamber interface 7 and internal flow channels under the control of the gas solenoid valve 4, pressurizing the tank; the propellant in the tank is compressed and enters the thruster under the control of the liquid circuit self-locking valve 3. The liquid circuit pressure transmitter 6 and the gas circuit pressure transmitter 9 on the integrated plate monitor the pressure of the tank and the gas chamber, respectively.

[0031] In some embodiments of the present invention, the cross-section of the flow channel is circular, and when the propellant flow rate reaches the maximum preset value, the pressure drop at both ends of the flow channel is less than or equal to 0.05 MPa, while the diameter of the flow channel is ≥1 mm.

[0032] In some embodiments of the present invention, the length of a single internal flow channel is less than or equal to 100 mm, and the flow channel bending angle is ≤120°.

[0033] Secondly, embodiments of the present invention provide a method for fabricating a single-component propulsion module integrated board structure based on additive manufacturing, used for assembling any of the integrated board structures described above, the fabrication method comprising: Multi-objective topology optimization technology was used to optimize the structure of the integrated board, thereby achieving a lightweight integrated board structure. The integrated board is manufactured as a blank using a laser melting additive manufacturing process; whereby, each functional component interface position should have a machining allowance for the interface; The internal flow channels are polished, followed by mechanical interface processing. During the interface processing, protective measures are taken to prevent the internal flow channels from being contaminated by foreign matter.

[0034] In some embodiments of the present invention, the internal flow channel polishing includes: The internal flow channels are polished using electrochemical polishing or fluid polishing.

[0035] In this embodiment, after polishing the internal flow channels of the integrated board structure, electrochemical polishing is used to polish the outer surface of the integrated board, requiring a surface roughness ≤ Ra3.2.

[0036] In some embodiments of the present invention, the interface processing procedure is protected by measures, including: The internal flow channel outlet is sealed with low-melting-point metal or paraffin. After the mechanical interface is processed, the sealing material is removed by high-temperature melting and cleaning.

[0037] In this embodiment, all internal flow channel outlets of the integrated board can be sealed with paraffin wax, followed by mechanical interface processing. After completion, the integrated board is placed in a temperature chamber and heated to approximately 60°C. Subsequently, the internal flow channels are flushed with gasoline. After all the paraffin wax is removed, anhydrous ethanol is used to clean the entire integrated board and its internal flow channels. After drying, the outlet of the flow channel is sealed with plastic wrap in preparation for subsequent system assembly.

[0038] After machining, the cleanliness of the mechanical interface needs to be assessed. The cleanliness must meet the following requirements: Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A mono-component propulsion module integrated board structure based on additive manufacturing, characterized in that, The integrated board obtained by additive manufacturing includes multiple interfaces and internal flow channels communicating with the interfaces, the flow channels including gas passages (2) and liquid passages (1) that are not interconnected.

2. The single-component propulsion module integrated board structure based on additive manufacturing according to claim 1, characterized in that, The interface includes an engine interface (5), an air chamber interface (7), an air passage solenoid valve (4), and a liquid passage self-locking valve (3). One end of the air passage solenoid valve (4) is connected to the air passage (2), and the other end is connected to a tank for holding propellant. One end of the air chamber interface (7) is connected to the air passage (2), and the other end is connected to the air chamber. One end of the liquid passage self-locking valve (3) is connected to the liquid passage (1) and is used to add propellant to the tank through the liquid passage. One end of the engine interface (5) is connected to the liquid passage (1), and the other end is connected to the engine.

3. The single-component propulsion module integrated board structure based on additive manufacturing according to claim 2, characterized in that, The interface also includes a liquid line filling and draining valve (8), one end of which is connected to the liquid line (1) and is used to add propellant to the tank through the liquid line.

4. The single-component propulsion module integrated board structure based on additive manufacturing according to claim 1, characterized in that, The interface also includes a satellite interface (10) for connecting the entire satellite and a gas chamber installation interface (11) for installing the gas chamber.

5. The single-component propulsion module integrated board structure based on additive manufacturing according to claim 1, characterized in that, The interface also includes a liquid pressure transmitter (6) for collecting the pressure of the liquid path (1) and a gas pressure transmitter (9) for collecting the pressure of the gas path (2).

6. The single-component propulsion module integrated board structure based on additive manufacturing according to claim 1, characterized in that, The cross-section of the flow channel is circular, and when the propellant flow rate reaches the maximum preset value, the pressure drop at both ends of the flow channel is less than or equal to 0.05 MPa, while the diameter of the flow channel is ≥1 mm.

7. The single-component propulsion module integrated board structure based on additive manufacturing according to claim 1, characterized in that, The length of a single internal flow channel is less than or equal to 100 mm, and the bending angle of the flow channel is ≤120°.

8. A method for fabricating a single-component propulsion module integrated board structure based on additive manufacturing, characterized in that, The preparation method for assembling the integrated board structure according to any one of claims 1-7 includes: Multi-objective topology optimization technology was used to optimize the structure of the integrated board, thereby achieving a lightweight integrated board structure. The integrated board is manufactured as a blank using a laser melting additive manufacturing process. The internal flow channels are polished, followed by mechanical interface processing. During the interface processing, protective measures are taken to prevent the internal flow channels from being contaminated by foreign matter.

9. The method for preparing a single-component propulsion module integrated board structure based on additive manufacturing according to claim 8, characterized in that, The internal flow channel polishing includes: The internal flow channels are polished using electrochemical polishing or fluid polishing.

10. The method for preparing a single-component propulsion module integrated board structure based on additive manufacturing according to claim 8, characterized in that, The interface processing procedure employs protective measures, including: The internal flow channel outlet is sealed with low-melting-point metal or paraffin. After the mechanical interface is processed, the sealing material is removed by high-temperature melting and cleaning.

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