A whole-satellite temperature control system and method for high-power consumption satellite thermal cycle test
By using differentiated temperature control components such as temperature control plates, insulation plates, and temperature control covers on high-power satellites, combined with nitrogen convection heat transfer, the problem of temperature deviation limitation in traditional thermal vacuum tests has been solved, achieving efficient temperature control and cost reduction.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- INNOVATION ACAD FOR MICROSATELLITES OF CAS
- Filing Date
- 2026-04-17
- Publication Date
- 2026-07-21
AI Technical Summary
In traditional whole-satellite thermal vacuum tests, the temperature biasing effect of high-power satellites is limited, the temperature control accuracy is low, the temperature consistency is poor, and it is impossible to effectively verify the thermal performance of high-power satellites. In addition, the test cycle is long and the cost is high.
Three types of differentiated temperature control components (temperature control plate, insulation plate, and temperature control cover) are used in conjunction with nitrogen convection heat exchange to achieve differentiated temperature control for individual units of different locations and types. This includes setting a temperature control plate on the heat dissipation surface, covering the exposed surface of the individual unit with an insulation plate, and setting a temperature control cover on the outside of the antenna. Temperature control is achieved through the coordinated work of the temperature control components.
It has enabled precise temperature control of each component of high-power satellites, improving experimental efficiency, reducing experimental costs, shortening experimental cycles, and enhancing temperature biasing and heating/cooling rates.
Smart Images
Figure CN122431453A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of spacecraft thermal control technology, and specifically to a whole-satellite temperature control system and method for high-power satellite thermal cycling tests. Background Technology
[0002] Whole-satellite thermal testing is a crucial step in satellite development, verifying the effectiveness of the thermal control system design and ensuring the normal operation of each component in the space environment. It is the final system-level verification method after component-level and individual-unit-level thermal testing, directly determining the reliability and stability of the satellite's on-orbit operation. Traditional whole-satellite-level thermal testing mainly includes thermal balance testing, thermal vacuum testing, and thermal cycling testing. Thermal vacuum testing refers to testing that verifies various performance and functions of the spacecraft and its components under vacuum and specific temperature conditions, consisting of cold immersion, hot immersion, and temperature variation processes. Thermal vacuum testing is generally conducted in a vacuum chamber.
[0003] Currently, most high-power satellites have a variety of onboard units with diverse operating temperature ranges, making it difficult to use specific temperature control methods to bring the temperature of each unit close to the required specifications. When conducting whole-satellite-level thermal vacuum tests in a vacuum chamber, the heat dissipation capacity of individual satellite units is affected by radiative heat dissipation (heat dissipation area and background temperature), thus limiting the amount of heat dissipation. Therefore, the temperature deviation effect of whole-satellite thermal tests based on thermal vacuum is limited to some extent. Existing thermal cycling tests suffer from low temperature control accuracy, insufficient temperature deviation range, and poor temperature consistency among individual units, making it impossible to effectively verify the overall thermal performance of high-power satellites. Summary of the Invention
[0004] This invention provides a whole-satellite temperature control system and method for thermal cycling tests of high-power satellites, which solves the technical problems of limited temperature deviation effect, long test cycle, high cost in traditional thermal vacuum tests, and lack of standardized temperature control strategies in existing thermal cycling tests. It enables precise control and extreme deviation of the temperature of each unit of high-power satellite, improves test efficiency and reduces test costs.
[0005] The first aspect of this invention provides a temperature control method for high-power satellite thermal cycling tests. Based on different individual units inside and outside the satellite cabin (individual units of different locations and types, referring to the smallest complete equipment unit with independent functions on the satellite), three types of differentiated temperature control components are used in conjunction with nitrogen convection heat transfer to achieve temperature control. The temperature control components include at least one of a temperature control plate, an insulation plate, or a temperature control cover. The temperature control method includes the following steps: For a first unit with its mounting surface inside the cabin and its heat dissipation surface outside the cabin, a temperature control plate is installed on the heat dissipation surface to control the temperature of the first unit. And / or for a second unit exposed outside the cabin and lacking sufficient temperature control capability, an insulation plate is wrapped around the surface of the second unit, and temperature control is achieved in conjunction with an onboard active heater. And / or for antenna-type units outside the cabin, a temperature control cover is installed on the outside of its antenna to control the convective heat transfer state outside the antenna by controlling the temperature of the temperature control cover, thereby controlling the temperature of the antenna-type unit. The satellite equipped with the temperature control component is placed in a normal pressure nitrogen convection environment, and the temperature control component is activated synchronously to perform coordinated temperature control in order to complete the temperature control operation of the thermal cycling test.
[0006] Furthermore, in the second unit exposed outside the cabin and lacking sufficient self-temperature control capability, the insufficient self-temperature control capability means that some units exposed outside the cabin are equipped with on-board temperature control loops, but the unit cannot be heated to the specified temperature in the circulation chamber (nitrogen convection environment).
[0007] Furthermore, the temperature control plate includes: The first heater serves as the heating source for the temperature control plate. By adjusting the heating power, it provides heat to the temperature control plate, thereby achieving temperature compensation and regulation for the unit. The temperature control plate body is an aluminum plate and is configured to conduct the heat of the first heater to the first unit; the first heater is arranged at intervals on the temperature control plate body; A thermal pad, disposed between the temperature control plate body and the heat dissipation surface of the first unit, and configured to further conduct heat to the first unit; and A first insulating film is disposed on the outer surface of the thermal pad and is configured to provide electrical insulation between the temperature control plate and the satellite and to prevent contamination of the satellite surface.
[0008] Furthermore, the temperature control plate is also equipped with: At least one first temperature control measuring point is configured to collect the surface temperature of the temperature control plate in real time. This first temperature control measuring point provides temperature information feedback to the ground control unit, enabling precise closed-loop control of the heating power of the temperature control plate, thereby ensuring that the temperature of the controlled unit remains stable within the specified range; and / or A first temperature detection device is provided at the first temperature control point, and the first temperature detection device includes a first thermistor or a first thermocouple.
[0009] Furthermore, the first temperature control point, the first heater, the ground power supply system, and the temperature measurement system together constitute the first temperature control loop, so as to control the temperature of the temperature control plate by controlling the power supply, thereby realizing the temperature control of the first unit.
[0010] Furthermore, during the thermal cycling test, the temperature of the temperature control plate is controlled at the upper limit of the high temperature range of the first unit during the high temperature holding phase, and at the lower limit of the low temperature range of the first unit during the low temperature holding phase; the power of the first heater needs to take into account the minimum heating capacity required during both the low temperature holding phase and the high temperature holding phase of the thermal cycling test to ensure stable temperature control during the thermal cycling process; the power design of the first heater includes the following steps: During the low-temperature holding phase, the first heater must ensure that the temperature of the first unit is not lower than the low-temperature index. At this time, the power of the first heater As shown below: in, This represents the heat dissipation area on the back of the first unit; The convective heat transfer coefficient for the nitrogen convection environment was obtained experimentally. The ambient temperature during the low-temperature maintenance phase is the nitrogen environment temperature that ensures most of the first single units can undergo low-temperature testing. This represents the first unit heat consumption during the low-temperature holding phase. During the high-temperature holding phase, the first heater must ensure that the first unit does not fall below the high-temperature specification. At this time, the power of the first heater As shown below: in, This represents the heat dissipation area on the back of the first unit; The convective heat transfer coefficient of the nitrogen convection environment; This refers to the ambient temperature during the high-temperature maintenance phase, specifically the nitrogen environment temperature that ensures most of the first single units can withstand the high-temperature test. The first unit heat loss when maintaining a high temperature; and The first heater is designed with a power of [calculated power]. Then we have: .
[0011] Furthermore, the dimensions of the temperature control plate must ensure that the first heater does not exceed its rated power density. Furthermore, the temperature control board has reserved space for wiring; the size design of the temperature control board includes the following steps: The area of the first heater on the temperature control plate does not exceed 0.8, and the theoretically calculated area of the entire temperature control plate is... as follows: Right now: ;as well as The area of the temperature control plate is not less than the size of the first single-unit mounting surface, let the area of the first single-unit mounting surface be... The actual production size of the temperature control plate as follows: .
[0012] Furthermore, the first heater is a polyimide film type first heater; the power density of the first heater is ≤ .
[0013] Furthermore, the first heater includes several heating elements attached to the temperature control plate, which are connected in series and parallel by welding to form the first heater. The first heater is attached to the surface of the temperature control plate body; the first heater is attached to the surface of the temperature control plate body using silicone or double-sided adhesive.
[0014] Furthermore, the thickness of the temperature control plate body is ≥2mm.
[0015] Furthermore, the thermal pad is made of a flexible and highly compressible material, and exemplary includes silicone-based thermal pads, non-silicone-based thermal pads, graphite / graphene thermal pads, etc., with a thickness of ≥0.5mm.
[0016] Furthermore, the first insulating film is a polyimide film; the thickness of the first insulating film is ≤0.1mm.
[0017] Furthermore, the insulation board is a foam insulation board.
[0018] Furthermore, the outer side of the insulation board is also covered with: The second insulating film is configured to provide electrical insulation between the insulation board and the satellite, and to prevent contamination of the satellite surface.
[0019] Furthermore, the second insulating film is a polyimide film.
[0020] Furthermore, the second unit itself is equipped with a second heater, which is the on-board active heater; the size of the insulation board needs to take into account the biasing effect of the second unit during the low-temperature and high-temperature holding phases of the thermal cycling test (the biasing effect is to "push" the unit temperature to the required temperature range of the test); the size design of the insulation board includes the following steps: During the low-temperature holding phase, the second heater must ensure that the temperature of the second unit is not lower than the low-temperature index. At this time, the area of the insulation board being bonded is As shown below: Right now: in, The heating power of the second heater associated with the second unit; This is the second unit heat consumption during the low-temperature holding phase; This refers to the heat dissipation area associated with the second standalone unit; The convective heat transfer coefficient in a nitrogen convection environment; The ambient temperature during the low-temperature maintenance phase; During the high-temperature holding phase, the second heater must ensure that the temperature of the second unit is not lower than the high-temperature target. At this time, the area of the insulation board being bonded is As shown below: Right now: in, The heating power of the second heater associated with the second unit; This represents the second unit heat consumption during the high-temperature holding phase. This refers to the heat dissipation area on the back of the second unit; The convective heat transfer coefficient in a nitrogen convection environment; The ambient temperature during the high-temperature maintenance phase; and The coverage area of the insulation board for: .
[0021] Furthermore, the temperature control cover is made of aluminum with a thickness of ≥2mm.
[0022] Furthermore, the temperature control cover is shaped to match the antenna, and a safe distance of ≥1cm is reserved between the antenna and the temperature control cover.
[0023] Furthermore, the temperature control cover is equipped with: Multiple third heaters are configured to provide heating compensation for the antenna unit, ensuring that the antenna temperature does not fall below the required level during the low-temperature phase of thermal cycling testing. The minimum power design of the third heaters is based on the power design of the first heaters.
[0024] Furthermore, the outer surface of the temperature control cover is provided with: Multiple secondary temperature control points are configured to collect the surface temperature of the temperature control cover in real time.
[0025] Furthermore, the multiple second temperature control points, multiple third heaters, together with the ground power supply system and the temperature measurement system, constitute a second temperature control loop. The multiple second temperature control loops are evenly distributed in regions according to the shape of the antenna.
[0026] Furthermore, a second temperature detection device is provided at the second temperature control point, and the second temperature detection device includes a second thermistor or a second thermocouple.
[0027] Furthermore, the third heater includes several heating elements attached to the temperature control cover, and the several heating elements are connected in series and parallel by welding to form the third heater.
[0028] A second aspect of the present invention provides a whole-satellite temperature control system for high-power satellite thermal cycling experiments, comprising: The temperature control module is configured to actively heat and perform closed-loop temperature control on the first unit, whose mounting surface is located inside the chamber and whose heat dissipation surface is located outside the chamber, so as to stabilize its temperature within the test parameters; and / or Insulation panel modules are configured to provide thermal insulation for second units exposed to the outside of the cabin and lacking sufficient temperature control capabilities, working in conjunction with onboard active heaters to maintain temperature; and / or The temperature control shroud module is configured to enclose the antenna unit outside the cabin and actively regulate its external convection heat transfer state to achieve uniform and zoned temperature control of the antenna unit.
[0029] Furthermore, the whole-satellite temperature control system is adapted to use in a circulating chamber filled with atmospheric pressure nitrogen. Different temperature control modules are set for individual units of different locations and types of high-power satellites, and a temperature control loop and ground control unit are provided.
[0030] Full-scale thermal cycling testing refers to the temperature cycling test of the specimen under normal pressure conditions. Generally, it involves controlling the temperature and velocity of nitrogen gas to control the temperature rise and fall of the individual unit / satellite under nitrogen-filled conditions. Since the heat dissipation rate at different locations on the satellite is closely related to the temperature and velocity of nitrogen gas, and the absolute value of nitrogen convective heat transfer has a relatively large adjustable range, the temperature control range of the individual unit can be greatly expanded with certain temperature control measures. Thermal cycling testing eliminates the initial vacuuming and liquid nitrogen cooling processes, as well as the subsequent reheating and repressurization process in the vacuum chamber. This significantly saves testing time and costs. The larger size of the cycling chamber facilitates satellite entry and exit and the connection of onboard cables. In summary, compared to thermal vacuum testing, thermal cycling testing has the advantages of faster temperature rise and fall rates, shorter test cycles, and better temperature deviation control.
[0031] The thermal cycling test process in this invention is as follows: The experiment began with high-temperature conditions, followed by alternating cycles of low and high temperatures. The nitrogen convection environment was located within a circulation chamber. The satellite, equipped with temperature control components, was placed in a circulation chamber filled with atmospheric pressure nitrogen. The experiment commenced after nitrogen purging. During nitrogen purging, the temperature and velocity of the nitrogen were designed to ensure the skew performance of most onboard units; specific values were obtained experimentally. During the high-temperature holding phase, the temperature of the temperature control plate and cover was maintained at the upper limit of the corresponding unit's high-temperature range. During the low-temperature holding phase, the temperature of the temperature control plate and cover was maintained at the lower limit of the corresponding unit's low-temperature range. The power of the temperature control plate and cover could be adaptively adjusted based on the unit's operating status and temperature level. For external units where installing temperature control plates and covers was inconvenient, especially those covered with insulation panels, onboard active heaters could be used to control the unit's temperature within the high and low temperature range. During the immediate thermal cycling test, combined with the nitrogen convection heat transfer environment, a collaborative logic of adaptive adjustment of the power of the temperature control plate and temperature control cover, and auxiliary temperature control by the on-board active heater is adopted to regulate the working status of each temperature control component. In addition, the temperature and flow rate of nitrogen in the circulation chamber are regulated to achieve precise temperature control and extreme deviation of each unit of the satellite.
[0032] The temperature control plate is thermally connected to the satellite, and there are two installation methods: Installation Method 1: The temperature control plate is attached to the satellite surface using screws on the plate. Under Method 1, holes are drilled in the temperature control plate surface, and screws are passed through the plate (holes are drilled to avoid obstructing the first insulating film and thermal pad). The temperature control plate is then pressed firmly onto the satellite surface using these screws. Different screws on the same temperature control plate are installed using the same torque.
[0033] Installation Method 2: Apply pressure using nearby clamping rods (profiles, etc.) to adhere the temperature control plate to the satellite surface. If Installation Method 1 is not feasible, use Installation Method 2. In this method, the support rods (profiles) are fixed to other areas of the satellite outside the temperature control plate area. The clamping rods are connected to the temperature control plate via heat-insulating gaskets (polyimide or fiberglass). Under clamping force, the temperature control plate is pressed against the satellite surface. Installation Methods 1 and 2 can be used in combination depending on the condition of the satellite surface.
[0034] This invention conducts experiments in a circulating chamber filled with nitrogen at atmospheric pressure. For three different types of objects—the first single unit with the heat dissipation surface inside the satellite cabin as the external plane, the second single unit exposed outside the cabin with insufficient temperature control capability, and the single unit with a large external antenna—three differentiated temperature control strategies were designed: temperature control plate, insulation plate, and temperature control cover. The material parameters, precise design calculation methods, and installation specifications of each temperature control component were clarified.
[0035] This invention considers heat dissipation and temperature control measures for individual units at different locations and provides formulas for calculating heat dissipation area and heater power under different heat dissipation conditions. Specifically, for the first unit, with its mounting surface inside the cabin and its heat dissipation surface outside, its heat dissipation capacity mainly relies on the heat dissipation plane on the back of the cabin. Under nitrogen convection conditions, the heat dissipation process of the high-heat-consuming unit is completed. The design of the first heater on the heat dissipation surface considers the requirements of the first heater under high and low temperature conditions, and the design of the temperature control plate size considers the maximum power density of the first heater and the size of the mounting surface. For the second unit, exposed outside the cabin and with insufficient self-temperature control, when the external convection heat dissipation is too strong and the temperature control of the onboard active heater cannot meet the requirements, it is necessary to cover the outside of the second unit with a certain area of insulation board. The size of the insulation board considers the heating and heat dissipation requirements under high and low temperature conditions. For antenna-type units outside the cabin, the temperature control cover set on the outside of the antenna can effectively control the convective heat transfer state outside the antenna. Under the temperature control of multiple third heaters on the antenna cover, the antenna temperature can be pulled to a specified temperature range.
[0036] This invention has at least the following beneficial effects: 1) Based on the state of convective heat transfer in the thermal cycling environment and the heat consumption and heat packing status of a single unit, this invention provides auxiliary temperature control measures under different single unit conditions, and provides design methods for the dimensions of the temperature control plate, insulation plate, and temperature control cover, as well as corresponding heater design and calculation methods under different temperature control measures. The temperature control is highly targeted, solving the problem that traditional tests are difficult to accurately control the temperature of multiple types of single units, greatly improving the temperature deviation effect, and can fully verify the working performance of the single unit under extreme high and low temperature conditions; 2) This invention conducts tests in a circulating environment filled with nitrogen at atmospheric pressure, eliminating the cumbersome steps of vacuuming, liquid nitrogen cooling, and re-pressurization in traditional thermal vacuum tests, shortening the test cycle by 50%. The above; at the same time, the circulating chamber can accommodate multiple satellites placed at equal intervals, realizing multi-satellite synchronous testing, greatly improving test efficiency, and reducing test time and economic costs; 3) This invention utilizes the convective heat transfer characteristics of nitrogen gas, combined with the auxiliary role of temperature control components, and adopts the nitrogen gas convective heat transfer heat dissipation method. After adopting the nitrogen gas convective heat transfer heat dissipation method, the satellite has the characteristic of fast heating and cooling rates during the test. The heating and cooling rates of each unit of the satellite can be adjusted according to the working status of the satellite to adjust the nitrogen gas rate, thereby adjusting the overall convective heat transfer level of the satellite (the heat transfer adjustment range is large), further improving the flexibility and effectiveness of temperature deviation. Attached Figure Description
[0037] To further illustrate the above and other advantages and features of the various embodiments of the present invention, a more specific description of the embodiments of the invention will be presented with reference to the accompanying drawings. It is to be understood that these drawings depict only typical embodiments of the invention and are therefore not intended to limit its scope. In the drawings, identical or corresponding parts will be indicated by identical or similar reference numerals for clarity.
[0038] Figure 1The following are schematic diagrams of the temperature control plate mounting structure in some embodiments of the present invention; Figure 2 A schematic diagram of the temperature control plate is shown in some embodiments of the present invention; Figure 3 Schematic diagrams of insulation boards in some embodiments of the present invention are shown; Figure 4 Schematic diagrams of temperature control covers in some embodiments of the present invention are shown; Figure 5 The diagram shows the thermal cycling test status of a certain communication satellite; Figure label: 1-First unit, 2-cabin plate, 3-temperature control plate, 301-first insulating film, 302-thermal conductive pad, 303-temperature control plate body, 304-first heater, 4-mounting hole, 5-first thermocouple, 6-insulation plate, 601-second insulating film, 7-second unit, 8-temperature control cover, 801-third heater, 9-second thermocouple, 10-circulation box, 11-satellite, 12-connector. Detailed Implementation
[0039] It should be noted that the components in the accompanying drawings may be shown exaggerated for illustrative purposes and may not be to scale.
[0040] In this invention, the various embodiments are merely intended to illustrate the solutions of the invention and should not be construed as limiting.
[0041] In this invention, unless otherwise specified, the quantifiers “a” and “one” do not exclude scenarios involving multiple elements.
[0042] It should also be noted that, in the embodiments of the present invention, only a portion of the parts or components may be shown for clarity and simplicity. However, those skilled in the art will understand that, under the teachings of the present invention, the required parts or components can be added as needed for specific scenarios.
[0043] It should also be noted that within the scope of this invention, the terms "same", "equal", and "equal to" do not mean that the two values are absolutely equal, but allow for a certain reasonable error. In other words, the terms also cover "substantially the same", "substantially equal", and "substantially equal to".
[0044] It should also be noted that in the description of this invention, the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not explicitly or implicitly suggest that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.
[0045] Furthermore, the embodiments of the present invention describe the process steps in a specific order. However, this is only for the convenience of distinguishing each step, and is not a limitation on the order of each step. In different embodiments of the present invention, the order of each step can be adjusted according to the process.
[0046] In the following embodiments, the total power consumption of the satellite is not less than 2KW.
[0047] The following embodiment provides a temperature control method for a high-power satellite thermal cycling test. Based on different individual units (different locations and types of individual units, referring to the smallest complete equipment unit with independent functions on satellite 11) inside and outside the satellite 11 cabin (inside and outside the cabin panel 2), three types of differentiated temperature control components are used in conjunction with nitrogen convection heat transfer to achieve temperature control. The temperature control components include at least one of a temperature control plate 3, an insulation plate 6, or a temperature control cover 8. The temperature control method includes the following steps: For the first unit 1, whose mounting surface is inside the cabin and whose heat dissipation surface is outside the cabin and is flat, a temperature control plate 3 is installed on the heat dissipation surface to achieve effective temperature control of the first unit 1; For the second unit 7, which is exposed outside the cabin and has insufficient temperature control capabilities, if the onboard active heater (referring to the aforementioned second heater) is insufficient, certain insulation measures need to be taken for the unit. The surface of the second unit 7 is covered with a heat insulation board 6 with good insulation effect, and the temperature is controlled in conjunction with the onboard active heater to effectively reduce the heat leakage rate of the second unit 7. The insulation foam is cut into a certain size according to the shape of the unit and the heat dissipation requirements; the insulation board 6 is a foam insulation board 6. For antenna-type units located outside the cabin, a temperature control cover 8 is installed on the outside of the antenna. By controlling the temperature of the temperature control cover 8, the convective heat transfer state (convective intensity) outside the antenna is controlled, thus achieving temperature control of the antenna-type unit. The temperature control cover 8 is made of aluminum with a thickness ≥2mm. The shape of the temperature control cover 8 matches the antenna, and a safety distance of ≥1cm is reserved between the antenna and the temperature control cover 8. Satellite 11, equipped with temperature control components, was placed at equal intervals in a normal-pressure nitrogen convection environment. The temperature control components were then activated simultaneously to perform coordinated temperature control in order to complete the temperature control operation of the thermal cycling test.
[0048] Temperature control plate 3 includes: The first heater 304 serves as the heating source for the temperature control plate 3. It provides heat to the temperature control plate 3 by adjusting its heating power, thereby achieving temperature compensation and control for the individual unit. The first heater 304 is a polyimide film type heater. The power density of the first heater 304 is ≤ The first heater 304 includes several heating elements attached to the temperature control plate 3. The heating elements are connected in series and parallel and then welded together to form the first heater 304. The temperature control plate body 303 is an aluminum plate and is configured to conduct the heat of the first heater 304 to the first unit 1; the first heater 304 is spaced out on the temperature control plate body 303; the thickness of the temperature control plate body 303 is ≥2mm, and the first heater 304 is attached to the surface of the temperature control plate body 303 by silicone or double-sided adhesive. A thermal pad 302 is disposed between the temperature control plate body 303 and the heat dissipation surface of the first unit 1, and is configured to further conduct heat to the first unit 1; the thermal pad 302 is made of a highly compressible material with a thickness ≥0.5mm, and the bottom of the thermal pad 302 is attached to the aluminum plate; and The first insulating film 301 is disposed on the outer surface of the thermal pad 302 and is configured to achieve electrical insulation between the temperature control plate 3 and the satellite 11, and to prevent the surface of the satellite 11 from being contaminated, while taking into account the characteristics of being strong and wear-resistant and having a smooth surface; the first insulating film 301 is a multi-layer auxiliary material polyimide film commonly used on satellites, with a thickness ≤0.1mm.
[0049] The temperature control plate 3 is also equipped with: At least one first temperature control measuring point is configured to collect the surface temperature of the temperature control plate 3 in real time. The first temperature control measuring point provides temperature information to the ground control unit, enabling precise closed-loop control of the heating power of the temperature control plate 3, thereby ensuring that the temperature of the controlled unit remains stable within the specified range. A first thermocouple 5 is attached to the first temperature control measuring point, and the lead wire routing process is completed. The first temperature control measuring point, the first heater 304, the ground power supply system, and the temperature measuring system together constitute the first temperature control loop, which controls the temperature of the temperature control plate 3 by controlling the power supply, thereby achieving temperature control of the first unit 1.
[0050] During the thermal cycling test, the temperature of the temperature control plate 3 is controlled at the upper limit of the high temperature range of the first unit 1 during the high temperature holding phase, and at the lower limit of the low temperature range of the first unit 1 during the low temperature holding phase. Therefore, the temperature control plate 3 needs to be designed, including the design of its dimensions and the design of the first heater 304. The power of the first heater 304 needs to take into account the minimum heating capacity required during both the low temperature holding phase and the high temperature holding phase of the thermal cycling test to ensure stable temperature control during the thermal cycling process. The power design of the first heater 304 includes the following steps: During the low-temperature holding phase, the first heater 304 must ensure that the temperature of the first unit 1 is not lower than the low-temperature index. At this time, the power of the first heater 304 As shown below: in, This refers to the heat dissipation area on the back of the first single unit 1; The convective heat transfer coefficient for the nitrogen convection environment was obtained experimentally. The ambient temperature during the low-temperature maintenance phase is the nitrogen environment temperature that ensures most of the first single units can undergo the low-temperature test. This refers to the first unit heat consumption during the low-temperature holding phase. During the high-temperature holding phase, the first heater 304 must ensure that the first unit 1 does not fall below the high-temperature specification. At this time, the power of the first heater 304 As shown below: in, This refers to the heat dissipation area on the back of the first single unit 1; The convective heat transfer coefficient of the nitrogen convection environment; The ambient temperature during the high-temperature holding phase is the nitrogen environment temperature that ensures most of the first single units can withstand the high-temperature test. The first unit heat dissipation when maintaining a high temperature; and The first heater 304 has a designed calculated power of: Then we have: Figure 2 A schematic diagram of the temperature control plate 3 is shown. The dimensions of the temperature control plate 3 must ensure that the first heater 304 does not exceed its rated power density. Furthermore, the temperature control plate 3 has reserved space for wiring; the size design of the temperature control plate 3 includes the following steps: The mounting holes 4 and wiring on the temperature control plate 3 have a certain area reserved. The area ratio of the first heater 304 on the temperature control plate 3 is generally no more than 0.8. The theoretically calculated area of the entire temperature control plate 3 is... as follows: Right now: ;as well as To ensure better heating of the first unit 1 on the back by the temperature control plate 3, the area of the temperature control plate 3 shall not be less than the size of the mounting surface of the first unit 1. Let the area of the mounting surface of the first unit 1 be... The actual production size of temperature control plate 3 as follows: .
[0051] Figure 3 A schematic diagram of insulation board 6 is shown. The outer side of insulation board 6 is also covered with: The second insulating film 601 is configured to achieve electrical insulation between the insulation board 6 and the satellite 11 and to prevent the surface of the satellite 11 from being contaminated. The second insulating film 601 is a multi-layered polyimide film commonly used on satellites, which also takes into account the characteristics of being strong and wear-resistant as well as smooth surface.
[0052] The dimensions of insulation board 6 must take into account the temperature deviation during the low-temperature and high-temperature holding phases of the second unit 7 in the thermal cycling test (the temperature deviation effect is to "pull" the unit temperature to the required temperature range of the test); the design of the dimensions of insulation board 6 includes the following steps: During the low-temperature holding phase, the second heater must ensure that the temperature of the second unit 7 does not fall below the low-temperature index. At this time, the bonding area of insulation board 6 is As shown below: Right now: in, The heating power of the second heater associated with the second unit 7; This refers to the heat consumption of the second single unit during the low-temperature holding phase; For the heat dissipation area related to the second single machine 7; The convective heat transfer coefficient in a nitrogen convection environment; The ambient temperature during the low-temperature maintenance phase; During the high-temperature holding phase, the second heater must ensure that the temperature of the second unit 7 is not lower than the high-temperature target. At this time, the bonding area of insulation board 6 is As shown below: Right now: in, The heating power of the second heater associated with the second unit 7; This refers to the heat consumption of the second single unit 7 during the high-temperature holding phase; This refers to the heat dissipation area on the back of the second single-unit 7. The convective heat transfer coefficient in a nitrogen convection environment; The ambient temperature during the high-temperature maintenance phase; and In summary, for the exposed second unit 7, the coverage area of the insulation board 6 during the thermal cycling test... for: .
[0053] Multiple third heaters 801 are configured to provide heating compensation for individual antenna units, ensuring that the antenna temperature does not fall below the required level during the low-temperature phase of thermal cycling testing. The minimum power design of the third heater 801 differs from that of the first heater 304 only in that the temperature control plate 3 is replaced by a temperature control cover 8; otherwise, the power design is the same as that of the first heater 304. The third heater 801 includes several heating elements attached to the temperature control cover 8, which are connected in series and parallel and then welded together to form the third heater 801.
[0054] Figure 4 A schematic diagram of the temperature control cover 8 is shown. The outer surface of the temperature control cover 8 is provided with: Multiple second temperature control points are configured to collect the surface temperature of the temperature-controlled cover 8 in real time. These multiple second temperature control points, multiple third heaters 801, together with the ground power supply system and the temperature measurement system, constitute a second temperature control loop. The multiple second temperature control loops are evenly distributed across different areas according to the shape of the antenna. Second thermocouples 9 are installed at each of the second temperature control points.
[0055] This embodiment also provides a whole-satellite temperature control system for high-power satellite thermal cycling experiments, including: The temperature control board module 3 is configured to actively heat and control the temperature of the first unit 1, whose mounting surface is located inside the chamber and whose heat dissipation surface is located outside the chamber, so as to stabilize its temperature within the test index range. The insulation panel module 6 is configured to provide thermal insulation for the second unit 7, which is exposed to the outside of the cabin and lacks sufficient temperature control capabilities, in conjunction with the onboard active heater to maintain temperature; and The temperature control cover module 8 is configured to enclose the antenna unit outside the cabin and actively regulate its external convection heat transfer state to achieve uniform and zoned temperature control of the antenna unit.
[0056] Example 1 This embodiment takes the temperature control measures of a single unit of a certain communication satellite as an example.
[0057] A certain communication satellite 11, which has high heat consumption, has most of its electronic components located inside the cabin, with a flat, white-painted heat dissipation surface behind them; this refers to the first component 1 mentioned above. The remaining external components include a phased array component (the second component 7 mentioned above) and a large antenna component, etc.
[0058] For the electronic components located inside module 11 of the communication satellite, the heat dissipation surface is on the outside of the module and is flat. There are some mounting holes 4 on the external heat dissipation surface.
[0059] First, fabricate a 3mm thick rectangular temperature control plate 3 (its dimensions are calculated based on the dimensions of the aforementioned temperature control plate 3, similar to the size of the mounting surface). Pre-drill mounting holes 4 on the temperature control plate 3. Attach several heating elements to the temperature control plate 3 using silicone, and weld them in series and parallel to form the first heater 304. Attach a first thermocouple 5 to the center of the surface of the temperature control plate 3. Attach a 1mm thick thermal conductive pad 302 to the back of the temperature control plate 3, and then attach a 50μm polyimide film to the back of the thermal conductive pad 302. Secure these to the temperature control plate body 303 (aluminum plate) using 3M tape. Install the temperature control plate 3 on the flat surface of the heat dissipation surface on the back of the unit and tighten it with four screws. Connect the leads of the first heater 304 and the first thermocouple 5 to the outside of the circulation chamber 10, and connect them to the ground power supply system and the temperature measurement system to form the first temperature control circuit. Figure 1 A schematic diagram of the installation structure of the temperature control plate 3 is shown.
[0060] For the second unit 7 (a phased array type unit) located outside the cabin, which has strong heat dissipation capabilities, it is necessary to reduce its convective heat transfer. A layer of foam insulation board 6 (its dimensions are calculated based on the dimensions of the aforementioned insulation board 6) is applied to the exterior of the unit. The area where the foam insulation board 6 contacts the second unit 7 is isolated by a 50μm polyimide film, serving both insulation and dustproofing purposes. A schematic diagram of the installation of the second unit 7 and the insulation board 6 is shown below. Figure 2 .
[0061] For a large external antenna unit with a large outer surface profile and strong heat dissipation capacity, a matching aluminum alloy frame (2mm thick, temperature control cover 8) is installed on the outer surface. The temperature control cover 8 has only 12 openings at the connectors to provide routing space for various cables; the rest is isolated from the outside. Four second temperature control circuits and four second thermocouples 9 are attached to the top of the antenna. During the antenna's heating and cooling process, the temperature of the antenna unit is controlled within a specified temperature range. See the installation diagram of the antenna unit and temperature control cover 8. Figure 4 .
[0062] After the temperature control measures were adjusted, all three satellites (Satellite 11) were placed side-by-side into the circulating chamber 10. The thermal control cables were connected to the external power supply and temperature acquisition cables. After the chamber was closed, high and low temperature tests were conducted. The thermal test status of Satellite 11 is as follows: Figure 5 As shown.
[0063] While some embodiments of the present invention have been described in this application, those skilled in the art will understand that these embodiments are merely illustrative. Numerous variations, alternatives, and improvements will arise in those skilled in the art under the teachings of this invention without departing from its scope. The appended claims are intended to define the scope of the invention and thereby cover methods and structures within the scope of the claims themselves and their equivalents.
Claims
1. A temperature control method for high-power satellite thermal cycling experiments, characterized in that, Different temperature control components are used for different units inside and outside the satellite cabin, combined with nitrogen convection heat exchange to achieve temperature control. The temperature control components include at least one of a temperature control plate, an insulation plate, or a temperature control cover. The temperature control method includes the following steps: For a first unit with its mounting surface inside the cabin and its heat dissipation surface outside the cabin, a temperature control plate is installed on the heat dissipation surface to control the temperature of the first unit. And / or for a second unit exposed outside the cabin and lacking sufficient temperature control capability, an insulation plate is wrapped around the surface of the second unit, and temperature control is achieved in conjunction with an onboard active heater. And / or for antenna-type units outside the cabin, a temperature control cover is installed on the outside of its antenna to control the temperature of the antenna-type unit. The satellite equipped with the temperature control component is placed in a nitrogen convection environment, and the temperature control component is activated synchronously to perform coordinated temperature control in order to complete the temperature control operation of the thermal cycling test.
2. The temperature control method for high-power satellite thermal cycling experiments according to claim 1, characterized in that, The temperature control plate includes: The first heater serves as the heating source for the temperature control plate; The temperature control plate body is an aluminum plate and is configured to conduct the heat of the first heater to the first unit; the first heater is arranged at intervals on the temperature control plate body; A thermal pad, disposed between the temperature control plate body and the heat dissipation surface of the first unit, and configured to further conduct heat to the first unit; and A first insulating film is disposed on the outer surface of the thermal pad and is configured to provide electrical insulation between the temperature control plate and the satellite and to prevent contamination of the satellite surface.
3. The temperature control method for high-power satellite thermal cycling experiments according to claim 2, characterized in that, The temperature control panel is also equipped with: At least one first temperature control measuring point is configured to acquire the surface temperature of the temperature control plate in real time; and / or A first temperature detection device is provided at the first temperature control point, and the first temperature detection device includes a first thermistor or a first thermocouple.
4. The temperature control method for high-power satellite thermal cycling experiments according to claim 2, characterized in that, During the thermal cycling test, the temperature of the temperature control plate is controlled at the upper limit of the high temperature range of the first unit during the high temperature holding phase, and at the lower limit of the low temperature range of the first unit during the low temperature holding phase. The power of the first heater needs to take into account the minimum heating capacity required during both the low temperature holding phase and the high temperature holding phase of the thermal cycling test. The power design of the first heater includes the following steps: During the low-temperature holding phase, the first heater must ensure that the temperature of the first unit is not lower than the low-temperature index. At this time, the power of the first heater As shown below: in, This represents the heat dissipation area on the back of the first unit; The convective heat transfer coefficient for the nitrogen convection environment was obtained experimentally. The ambient temperature during the low-temperature maintenance phase is the nitrogen environment temperature that ensures most of the first single units can undergo low-temperature testing. This represents the first unit heat consumption during the low-temperature holding phase. During the high-temperature holding phase, the first heater must ensure that the first unit does not fall below the high-temperature specification. At this time, the power of the first heater As shown below: in, This represents the heat dissipation area on the back of the first unit; The convective heat transfer coefficient of the nitrogen convection environment; This refers to the ambient temperature during the high-temperature maintenance phase, specifically the nitrogen environment temperature that ensures most of the first single units can withstand the high-temperature test. The first unit heat loss when maintaining a high temperature; and The first heater is designed with a power of [calculated power]. Then we have: 。 5. The temperature control method for high-power satellite thermal cycling experiments according to claim 2, characterized in that, The size of the temperature control plate must meet the requirement that the first heater does not exceed its rated power density. Furthermore, the temperature control board has reserved space for wiring; the size design of the temperature control board includes the following steps: The area of the first heater on the temperature control plate does not exceed 0.8, and the theoretically calculated area of the entire temperature control plate is... as follows: Right now: ;as well as The area of the temperature control plate is not less than the size of the first single-unit mounting surface, let the area of the first single-unit mounting surface be... The actual production size of the temperature control plate as follows: 。 6. The temperature control method for high-power satellite thermal cycling experiments according to claim 1, characterized in that, The outer side of the insulation board is also covered with: The second insulating film is configured to provide electrical insulation between the insulation board and the satellite, and to prevent contamination of the satellite surface.
7. The temperature control method for high-power satellite thermal cycling experiments according to claim 1, characterized in that, The second unit is equipped with a second heater, which is the on-board active heater; the size of the insulation board needs to take into account the skewness effect of the second unit during the low-temperature and high-temperature holding phases in the thermal cycling test; the size design of the insulation board includes the following steps: During the low-temperature holding phase, the second heater must ensure that the temperature of the second unit is not lower than the low-temperature index. At this time, the area of the insulation board being bonded is As shown below: Right now: in, The heating power of the second heater associated with the second unit; This is the second unit heat consumption during the low-temperature holding phase; This refers to the heat dissipation area associated with the second standalone unit; The convective heat transfer coefficient in a nitrogen convection environment; The ambient temperature during the low-temperature maintenance phase; During the high-temperature holding phase, the second heater must ensure that the temperature of the second unit is not lower than the high-temperature target. At this time, the area of the insulation board being bonded is As shown below: Right now: in, The heating power of the second heater associated with the second unit; This represents the second unit heat consumption during the high-temperature holding phase. This refers to the heat dissipation area on the back of the second unit; The convective heat transfer coefficient in a nitrogen convection environment; The ambient temperature during the high-temperature maintenance phase; and The coverage area of the insulation board for: 。 8. The temperature control method for high-power satellite thermal cycling test according to claim 1, characterized in that, The temperature control cover is equipped with: Multiple third heaters are configured to provide heating compensation for the antenna-type units.
9. The temperature control method for high-power satellite thermal cycling experiments according to claim 8, characterized in that, The outer surface of the temperature control cover is provided with: Multiple secondary temperature control points are configured to collect the surface temperature of the temperature control cover in real time.
10. A whole-satellite temperature control system for high-power satellite thermal cycling experiments, characterized in that, include: The temperature control module is configured to actively heat and perform closed-loop temperature control on the first unit, whose mounting surface is located inside the chamber and whose heat dissipation surface is located outside the chamber, so as to stabilize its temperature within the test parameters; and / or Insulation panel modules are configured to provide thermal insulation for second units exposed to the outside of the cabin and lacking sufficient temperature control capabilities, working in conjunction with onboard active heaters to maintain temperature; and / or The temperature control shroud module is configured to enclose the antenna unit outside the cabin and actively regulate its external convection heat transfer state to achieve uniform and zoned temperature control of the antenna unit.