Modular propulsion pod system for ease of assembly and testing and method of assembly

Abstract

The application provides a modular propulsion cabin system and an assembly method facilitating general assembly and testing, and belongs to the technical field of mechanical design and general assembly and testing of a spacecraft. The system decouples a traditional integrated propulsion cabin into an upper cone module, a column segment, a lower cone assembly module and an external lower computer module. The upper cone module integrates a satellite cabin connection unlocking separation device, can be docked with a satellite platform in advance and is independently tested; the column segment and the lower cone assembly module serve as a pre-integrated propulsion subsystem, internally integrating a storage tank, a gas cylinder, an engine, a pipeline and a thermal control component; and the external lower computer module undertakes a control system function. The three modules are connected through standardized mechanical interfaces and external cables, and the electrical path and the mechanical path are completely separated. The method supports parallel general assembly, integration and testing of the three modules, greatly shortens the development cycle, solves the problems of serial general assembly process, poor test accessibility and high system coupling degree of the traditional propulsion cabin, and significantly improves the general assembly efficiency and quality.

Description

Technical Field

[0001] This invention belongs to the field of spacecraft mechanical design and assembly testing technology. Specifically, it relates to a propulsion module structure for high-orbit satellites, and more particularly to a system and method that decomposes the propulsion module into multiple functional modules that can be assembled and tested in parallel and rapidly integrated through standardized interfaces. Background Technology

[0002] High-orbit satellites, due to their high orbits and the large speed increments required for orbit changes, typically require dedicated propulsion modules carrying large amounts of propellant. These propulsion modules are complex in structure, serving as the satellite's main load-bearing structure and integrating tanks, engines, piping, and valves. Traditional propulsion module designs often employ an integrated cylindrical-cone composite structure with highly integrated functions. However, in engineering practice, this design presents significant challenges to the satellite's assembly, integration, and testing (AIT) process.

[0003] The final assembly process is severely out of sequence. Due to the deep coupling between the propulsion system and the satellite platform's electrical and structural systems, equipment installation, piping welding, cable laying, testing, and verification must all be carried out in strict order. Delays or problems in any stage can disrupt the entire project process, resulting in long development cycles and high unpredictability.

[0004] Operational and testing accessibility is poor. After the propulsion module docks with the satellite platform, its critical internal equipment, especially the separation device located on the docking surface, is sealed off, making subsequent inspection, maintenance, or replacement difficult. Many tests can only be carried out after the entire satellite is fully integrated, making problem localization difficult and repair costs extremely high.

[0005] The system is highly coupled, leading to concentrated risks. The close interweaving of multiple disciplines such as mechanical, propulsion, thermal control, and electrical systems results in a wide propagation range for design changes or failures, making technical condition control complex and posing high quality risks.

[0006] In recent years, modular design has become an important development trend in the spacecraft field, aiming to improve flexibility, maintainability, and development efficiency. However, existing modular technologies mostly focus on different application scenarios and technical paths, which are fundamentally different from the assembly and testing efficiency problem that this invention aims to solve.

[0007] To clearly illustrate the innovativeness of this invention, a comparative analysis of relevant prior art is presented below: Chinese invention patent CN115837987A discloses a modular platform consisting of a propulsion module, a service module, and a payload module connected in series, aiming to support on-orbit assembly and maintenance through standardized interfaces to form a fully functional satellite. This invention, however, focuses on the propulsion module, proposing a modular design and assembly method. By dividing the propulsion module into three main modules, it achieves parallel and efficient assembly and testing of the propulsion module. The two are fundamentally different.

[0008] Chinese invention patent CN117446216A, targeting microsatellites such as CubeSats, provides a modular, pre-packaged propulsion system integrating tanks, valves, and thrusters, emphasizing non-toxicity and installation at any angle. Its modularity is centered on the internal functional integration and physical encapsulation of the subsystem (propulsion system) to achieve rapid delivery and convenient installation. In contrast, the modularity of this invention targets the modular design and assembly of the propulsion module system, decoupling the propulsion module physically, electrically, and functionally into three independent modules (upper cone structure module, propulsion function module, and control module), enabling completely parallel operation of the three modules during the ground assembly phase. The two differ significantly in their application targets and objectives.

[0009] Chinese invention patent CN110450983A discloses an agile satellite configuration comprising a propulsion module, a service module, and a payload module, aiming to achieve large propellant carrying capacity and high pointing agility through a modular design. In this invention, the propulsion module is deeply integrated with the entire satellite and is inseparable. The propulsion module system involved in this invention can both serve the host satellite entering geostationary orbit and separate from the host satellite. The innovation of this invention lies in dividing the propulsion module into three major modules, thereby enabling parallel assembly, testing, and integration of the propulsion module system, improving the development efficiency of the propulsion module. The two are fundamentally different.

[0010] Chinese invention patent CN109941459A discloses a satellite configuration composed of several modular modules connected by connecting rods, aiming to achieve rapid assembly and expansion through modular modules. Its modularity is based on the standardized splicing and quantity configuration of structural modules to achieve flexible configuration construction. In contrast, this invention focuses on the modular design and assembly method for propulsion module systems. It represents an improvement over traditional integrated design and complex assembly of propulsion modules, and can significantly improve integration efficiency by employing parallel assembly and testing methods. The two are fundamentally different.

[0011] Chinese invention patent CN112705920A discloses an assembly process, specifically including sequential integration testing and assembly to form an integrated test satellite after completing the initial prototype design and production acceptance, followed by sequential thermal testing modifications, environmental testing modifications, and pre-delivery modifications. The essence of this invention is serialized testing and assembly, a typical example of the traditional linear AIT process. In contrast, this invention focuses on modular design and parallel assembly for satellite propulsion modules, first assembling and testing each module separately, and then integrating them into a whole. This represents an innovation in traditional design and assembly methods. The two are fundamentally different.

[0012] Chinese invention patent CN115339657A discloses a replaceable spacecraft propulsion module that adopts a truss-type external load-bearing system. It can meet the requirements of large-scale loads or equipment compartments by changing the radial dimensions of the propulsion module, but it does not involve parallel assembly, integration and testing, and is difficult to adapt to the complex propulsion compartment system environment.

[0013] In summary, most existing satellite platforms or propulsion modules employ integrated design and sequential assembly methods, resulting in complex final assembly. For propulsion module systems, an innovative architectural design and assembly method is needed to fundamentally decouple physical and functional components, supporting parallel assembly operations and improving the flexibility, efficiency, and reliability of assembly and testing. Summary of the Invention

[0014] In view of the shortcomings of the prior art, the purpose of this invention is to overcome the deficiencies of the prior art in the assembly and testing process of the propulsion module, such as seriality, poor operational accessibility, and high system coupling, and to provide a propulsion module system and its assembly and testing method that is highly modular, supports parallel operation, and is easy to test and maintain.

[0015] According to the present invention, a modular propulsion cabin system that is easy to assemble and test includes: an upper cone module 200, a column section, a lower cone assembly module 300, and an external lower computer module 400. The upper cone module 200 can be connected to and separated from the satellite platform 100. It docks with the satellite platform 100 before the column segment, lower cone assembly module 300, and external lower computer module 400 to form an upper cone and satellite platform assembly, and performs interface checks and separation function tests. The column segment and lower cone assembly module 300 is a pre-integrated unit that integrates a complete propulsion and thermal control subsystem. It can be connected to the formed upper cone and satellite platform assembly to complete the integration of the main structure. The external lower-level computer module 400 is connected to the satellite platform 100, the column segment, and the lower cone assembly module 300, and can realize the power supply, command, telemetry signal transmission from the satellite platform 100 to the lower-level computer, as well as the control of the entire propulsion and thermal control system.

[0016] Preferably, a satellite compartment connection, unlocking and separation device 203 is fixedly installed on the inner side of the top of the upper cone module 200, which is used to achieve mechanical connection, locking and on-orbit unlocking and separation with the satellite platform 100; The upper cone module 200 is equipped with an independent upper instrument mounting plate and internal operating space, allowing the satellite compartment connection unlocking and separation device 203 to be installed or inspected from the inside during the later stages of final assembly. It can also dock with the satellite platform 100 before the column section, lower cone assembly module 300, and external lower computer module 400 to form an upper cone and satellite platform assembly for mechanical interface inspection and separation function test.

[0017] Preferably, the column segment and lower cone assembly module 300 is a pre-integrated unit that integrates a complete propulsion and thermal control subsystem, including the column segment cylinder and lower cone cylinder as the main load-bearing structure, all the storage tanks 305, gas cylinders, thrust engine 307, attitude control thruster, propulsion pipeline, valves and related thermal control actuators installed inside it; The module is equipped with a cable adapter bracket 313 on the outside. One side of the cable adapter bracket 313 is electrically connected to all the propulsion valves, engine igniters and thermal control components inside the module through internal cables.

[0018] Preferably, the external lower-level computer module 400 includes a lower-level computer, a set of dedicated cable bundles 402, and connectors 404; The lower-level computer is connected to the other side of the cable adapter bracket 313 via one end of a dedicated cable bundle 402 to control the entire propulsion and thermal control system; The other end of the dedicated cable bundle 402 is connected to the separate electrical connector 102 outside the docking area of ​​the satellite platform base plate 101 via a connector 404, so as to realize the transmission of power supply, command and telemetry signals from the satellite platform 100 to the lower computer.

[0019] Preferably, the upper cone module 200, column segment, lower cone assembly module 300 and external lower computer module 400 are physically, electrically and functionally decoupled and can be assembled and tested independently; The mechanical connection exists between the upper cone module 200 and the column segment and lower cone assembly module 300, and the docking is achieved through a purely mechanical interface; The electrical connection is a completely independent path: external disconnect electrical connector 102 of the satellite platform → external lower-level machine module 400 → cable adapter bracket 313 → internal equipment of the column-lower cone assembly; → represents the direction of the electrical connection path.

[0020] Preferably, the docking interface between the upper cone module 200 and the column segment and lower cone assembly module 300 adopts a purely mechanical interface, including guide pins and pin holes evenly distributed along the circumference and a matching quick-locking device to realize the positioning and locking between the two modules. This docking interface does not include an electrical connector. On the upper frame of the column segment and lower cone assembly module 300 and the lower frame of the upper cone module 200, corresponding to the positions of the guide pin and pin hole, there are pre-embedded titanium alloy or stainless steel reinforcing bushings to improve the wear resistance and repeatability of the docking interface.

[0021] Preferably, the star-rocket connecting ring at the lower end of the column segment and lower cone assembly module 300 is integrally formed with its main load-bearing structure or fixedly connected by a non-removable high-strength bolt to form an integrated star-rocket connecting interface; the mating surface of the star-rocket connecting ring is standardly matched with the launch vehicle interface and is pre-installed with a strap unlocking device adapter interface.

[0022] The assembly and testing method for a modular propulsion module system, which facilitates final assembly and testing according to the present invention, includes the following steps: S1: Parallel module-level assembly and testing, including the following steps: S1.1: The upper cone module 200 is integrated with the satellite platform 100. The upper cone module 200 is docked with the satellite platform 100 through the satellite compartment connection unlocking and separation device 203 to form an upper cone and satellite platform assembly; Operators enter through the lower opening of the upper conical module of the assembly to complete the final inspection and debugging of the satellite cabin connection unlocking and separation device 203; Independently conduct mechanical locking, releasing, and modal tests on the assembly; S1.2: Assembly and Testing of Module 300 (Column Section and Lower Cone Assembly) In the independent propulsion system assembly clean room, the installation, welding, and helium mass spectrometry leak detection of all internal propulsion equipment and thermal control components of the column section and lower cone assembly module 300 were completed. All electrical actuator cables are collected and connected to the external cable adapter bracket 313 of the module; The module underwent independent airtightness testing and functional simulation testing of some components. S1.3: External Lower-Level Machine Module 400 Test The lower-level computer is connected to the ground test system via its dedicated cable bundle 402 to simulate the power supply and communication of the satellite platform 100, and independently complete the comprehensive software and hardware testing, communication protocol matching and functional verification of the lower-level computer. S2: Modular system integration, including the following steps: S2.1: The tested upper cone and satellite platform assembly and column and lower cone assembly module 300 are precisely aligned and mechanically locked using guide pins, pin holes and quick-locking devices to complete the integration of the main structure; S2.2: Install the lower computer of the external lower computer module 400 onto the predetermined bracket on the outside of the column section cylinder, and connect and fix the two ends of its dedicated cable bundle 402 to the cable adapter bracket 313 on the column section and the lower cone assembly module 300 and the separate electrical connector 102 on the outside of the satellite platform base plate 101 respectively. S3: System-level assembly and testing, including the following steps: After all connections are completed, a full system cable continuity and insulation check is performed; Commands are sent from the satellite platform's main control computer, passing through the disconnect connector 102, the lower-level machine, and the cable adapter bracket 313 to each thruster valve and thermal control component, to conduct full-loop electrical performance testing and functional verification.

[0023] Preferably, in step S1, S1.1, S1.2, and S1.3 are carried out in parallel in time and space, and are implemented simultaneously by different professional teams in their respective dedicated facilities.

[0024] Preferably, in step S2.1, the docking operation of the upper cone and satellite platform assembly with the column segment and lower cone assembly module 300 is carried out on a general-purpose large platform in the final assembly plant. After docking, the geometric dimension accuracy of the mating surface needs to be measured and confirmed.

[0025] Compared with the prior art, the present invention has the following beneficial effects:

[0026] 1. This invention proposes a novel modular propulsion module system based on the core principles of functional decoupling, interface standardization, and forward testing. This system completely breaks away from traditional integrated design, reconstructing the propulsion module into three clearly defined and functionally independent modules. These three modules are connected to external cables via standardized mechanical interfaces, completely separating electrical and mechanical paths. This method supports parallel assembly, integration, and testing of the three modules, significantly shortening the development cycle and solving the problems of sequential assembly processes, poor test accessibility, and high system coupling in traditional propulsion module systems, thus significantly improving assembly efficiency and quality.

[0027] 2. This invention significantly shortens the development cycle by compressing the traditional serial AIT process, which can take months, through deep parallel operation of three major modules. Module-level independent testing moves a large amount of work forward, leaving only interface docking and verification in the system integration phase, thus shortening the overall project cycle by more than 40%.

[0028] 3. This invention fundamentally improves the overall assembly quality and reliability. Each module has undergone independent and thorough testing before integration, ensuring that problems do not originate within any module. Key equipment (such as the separation device) has excellent operational accessibility. This verification-before-integration approach fundamentally guarantees the first-time success rate of the final system integration and the quality of the product.

[0029] 4. The system of the present invention has greatly enhanced flexibility and maintainability. The clear interface definition between modules means that the upgrade, replacement or repair of a single module has almost no impact on other modules.

[0030] 5. This invention further reduces overall costs and risks. Parallelism reduces resource congestion on the critical path and improves the utilization rate of personnel and equipment. Modular testing decomposes and isolates the risks of complex systems in an early, controllable, and small scope, significantly reducing the overall technical risks and management costs of the project. Attached Figure Description

[0031] Other features, objects, and advantages of the present invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings: Figure 1 This is a schematic axial cross-sectional view of the modular propulsion module system of the present invention integrated with the satellite platform; Figure 2 This is a schematic diagram illustrating the operation of the internal components by the operator after the upper cone module of the present invention has been docked with the satellite platform to form a combined assembly. Figure 3 This is a schematic diagram showing the column-lower cone assembly module of the present invention being assembled independently in a propulsion cleanroom; Figure 4 This is a partial schematic diagram showing the connection relationship between the external lower-level machine module and the external interface of the satellite platform in this invention; Figure 5 This is a schematic diagram of the entire process of the modular assembly method of the present invention.

[0032] The diagram shows: Detailed Implementation

[0033] The present invention will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present invention, but do not limit the invention in any way. It should be noted that those skilled in the art can make several changes and improvements without departing from the concept of the present invention. These all fall within the protection scope of the present invention.

[0034] A modular propulsion cabin system that is easy to assemble and test includes three modules that are physically, electrically, and functionally decoupled and can be assembled and tested independently: an upper cone module 200, a column section and a lower cone assembly module 300, and an external lower-level computer module 400.

[0035] The upper cone module 200 has a satellite compartment connection, unlocking and separation device 203 fixedly installed on its inner top side, which is used to achieve mechanical connection, locking and on-orbit unlocking and separation with the satellite platform 100. There is no direct electrical connection between the upper cone module 200 and the satellite platform 100. The upper cone module 200 is equipped with an independent upper instrument mounting plate and internal operating space, which allows the satellite compartment connection, unlocking and separation device 203 to be installed or repaired from the inside in the later stage of final assembly, and can dock with the satellite platform 100 before other modules to form an upper cone and satellite platform assembly for mechanical interface inspection and separation function test.

[0036] The column section and lower cone assembly module 300 is a pre-integrated unit that integrates a complete propulsion and thermal control subsystem. It includes the column section cylinder and lower cone cylinder as the main load-bearing structure, all the storage tanks 305, gas cylinders, 490N high-thrust engine, 10N attitude control thruster, propulsion pipelines, valves, and related thermal control actuators installed inside it. The module is equipped with a cable adapter bracket 313 on the outside. One side of the cable adapter bracket 313 is electrically connected to all propulsion valves, engine igniters, and thermal control components inside the module through internal cables.

[0037] The cable adapter bracket 313 is a sealed, moisture-proof box structure with an internal power distributor and signal conditioning circuit, providing a standardized, mis-insertion-proof electrical interface to the outside. The dedicated cable bundle 402 of the external lower-level module is laid along the pre-set cable clamps or cable trays on the outer wall of the column section and the upper cone module 200 after system integration, and finally connected to the separation electrical connector 102 located on the satellite platform base plate 101 and outside the docking contour of the propulsion cabin.

[0038] The star-rocket connection ring at the lower end of the column segment and lower cone assembly module 300 is integrally formed with its main load-bearing structure or fixedly connected by a non-removable high-locking bolt to form an integrated star-rocket connection interface; the docking surface of the star-rocket connection ring is standardly matched with the launch vehicle interface and is pre-installed with a strap unlocking device adapter interface.

[0039] The interface between the upper conical module 200 and the column segment and lower conical assembly module 300 is a purely mechanical interface, including guide pins and pin holes evenly distributed along the circumference and a matching quick-locking device, to achieve precise positioning and rapid locking between the two modules. This interface does not include electrical connectors. On the upper frame of the column segment and lower conical assembly module 300 and the lower frame of the upper conical module 200, corresponding to the positions of the guide pins and pin holes, pre-embedded titanium alloy or stainless steel reinforcing bushings are provided to improve the wear resistance and repeatability of the interface.

[0040] The external lower-level computer module 400 includes a lower-level computer and a set of dedicated cable bundles 402. The lower-level computer is connected to the other side of the cable adapter bracket 313 through one end of the dedicated cable bundle 402 to control the entire propulsion and thermal control system. The other end of the dedicated cable bundle 402 is used to connect to the separate electrical connector 102 outside the docking area of ​​the satellite platform base plate 101 to realize the transmission of power supply, command and telemetry signals from the satellite platform 100 to the lower-level computer.

[0041] An assembly and testing method for a modular propulsion module system that facilitates final assembly and testing includes the following steps:

[0042] S1: Parallel module-level assembly and testing, including the following steps:

[0043] S1.1: The upper cone module 200 is integrated with the satellite platform 100. The upper cone module 200 is docked with the satellite platform 100 through the satellite compartment connection unlocking and separation device 203 to form an upper cone and satellite platform assembly; Operators enter through the lower opening of the upper conical module of the assembly to complete the final inspection and debugging of the satellite cabin connection unlocking and separation device 203; The mechanical locking, releasing, and modal testing of the assembly were conducted independently.

[0044] S1.2: Assembly and Testing of Module 300 (Column Section and Lower Cone Assembly) In the independent propulsion system assembly clean room, the installation, welding, and helium mass spectrometry leak detection of all internal propulsion equipment and thermal control components of the column section and lower cone assembly module 300 were completed. All electrical actuator cables are collected and connected to the external cable adapter bracket 313 of the module; The module underwent independent airtightness testing and functional simulation testing of some components.

[0045] S1.3: External Lower-Level Machine Module 400 Test The lower-level computer is connected to the ground test system via its dedicated cable bundle 402 to simulate the power supply and communication of the satellite platform 100, and independently complete the comprehensive software and hardware testing, communication protocol matching and functional verification of the lower-level computer.

[0046] S2: Modular system integration, including the following steps:

[0047] S2.1: Align and lock the tested upper cone and satellite platform assembly with the column segment and lower cone assembly module 300 through the mechanical interface to complete the main structure integration.

[0048] S2.2: Install the lower computer of the external lower computer module 400 onto the predetermined bracket on the outside of the column section cylinder, and connect and fix the two ends of its dedicated cable bundle 402 to the cable adapter bracket 313 and the separate electrical connector 102 respectively.

[0049] S3: System-level assembly and testing, including the following steps: After all connections are completed, a full-system cable continuity and insulation check is performed. Commands are sent from the satellite platform main control computer to each thruster valve and thermal control component via the disconnect connector 102, the lower-level machine, and the cable adapter bracket 313 to perform full-loop electrical performance testing and functional verification.

[0050] Steps S1.1, S1.2, and S1.3 are carried out in parallel in time and space, and are implemented simultaneously by different professional teams in their respective dedicated facilities. In step S2.1, the docking operation of the upper cone and satellite platform assembly with the column segment and lower cone assembly module 300 is carried out on a general-purpose large platform in the final assembly plant. After docking, the geometric dimensional accuracy of the mating surfaces needs to be measured and confirmed.

[0051] This invention, based on the core principles of functional decoupling, interface standardization, and forward testing, proposes a novel modular propulsion module system. This system completely breaks away from traditional integrated design, reconstructing the propulsion module into three clearly defined and functionally independent modules: Furthermore, the upper conical module 200 serves as a mechanical adaptation and separation module. Its sole core function is to achieve mechanical connection and safe separation from the satellite platform 100. This module integrates a purely mechanical satellite compartment connection, unlocking, and separation device 203, which can be integrated with the satellite platform 100 at the earliest stage and independently undergo comprehensive separation tests. Its funnel-shaped structure provides operators with a direct and spacious internal passage, greatly improving the operational accessibility of key separation devices.

[0052] Furthermore, the column segment and lower cone assembly module 300 serves as the physical module for propulsion. It is a complete propulsion subsystem black box, with all tanks, engines, pipelines, valves, and thermal control components installed, welded, leak-tested, and internally electrically connected before leaving the factory. All external electrical interfaces are uniformly led out through an external cable adapter bracket 313. This design allows the propulsion system team to independently complete all high-risk, high-cleanliness assembly and testing work within the propulsion assembly plant.

[0053] Furthermore, the external lower-level computer module 400 serves as a control and information exchange module. It includes an independent control computer (lower-level computer) and a dedicated cable bundle 402. Its innovation lies in the fact that it is the only electrical pathway between the entire propulsion module and the satellite platform. This module is directly connected to the separate electrical connector 102 on the outer side of the bottom of the satellite platform via cable, thereby establishing a power supply, command, and telemetry link with the satellite platform 100. This external design allows the development, debugging, and testing of the entire control system to be completely independent of the overall structural assembly, significantly accelerating the process.

[0054] The connection logic between the three main modules is clear and loosely coupled: The mechanical connection exists only between the upper cone module 200 and the column segment and lower cone assembly module 300, using a purely mechanical interface with guide pins and quick locks to achieve fast, accurate and reliable docking.

[0055] The electrical connection forms a completely independent path: external disconnect electrical connector 102 of the satellite platform → external lower-level computer module 400 → cable adapter bracket 313 → internal equipment of the column-lower cone assembly. Here, → represents the direction of the electrical connection path. This path is physically separated from the mechanical structure assembly line.

[0056] Based on the above system, this invention naturally derives a two-stage assembly method that combines parallel and integrated processes. In the first stage, the three modules are assembled and tested in parallel using their respective specialized facilities. In the second stage, system integration can be completed with only simple mechanical connections and external cable connections, culminating in a convergent full-system commissioning.

[0057] The present invention will now be described in more detail with reference to preferred embodiments, see below. Figures 1 to 5 This embodiment demonstrates a modular propulsion module system applied to a geostationary orbit communication satellite.

[0058] like Figure 1 As shown, the modular propulsion module system, after integration with the satellite platform 100, constitutes a complete aircraft. Its core consists of three main modules: The upper conical module 200 is primarily a conical cylinder made of carbon fiber composite material. On its inner top side, a star compartment connection, unlocking, and separation device 203 is mounted via a high-strength bracket. This device is driven by a pyrotechnic separation nut, achieving mechanical locking and release.

[0059] The cylindrical section and lower cone assembly module 300 is the main body of the propulsion module. The cylindrical section and lower cone utilize an aluminum alloy honeycomb sandwich structure, together forming the main load-bearing cylinder. Internally, it houses four titanium alloy tanks 305, matching gas cylinders, a 490N bicomponent liquid apogee engine 307, and multiple 10N attitude control thrusters. All piping is welded, and valves are centrally located. The module's exterior is covered with multi-layered thermal insulation components. Crucially, a cable adapter bracket 313 is fixed to the outer wall of the cylindrical section. This bracket consolidates cables from all engine solenoid valves, attitude control valves, pressure sensors, and heaters into a single, mis-pluggable rectangular electrical connector (female). At the bottom of the module is an integrated satellite-rocket connection ring, directly interfacing with the launch vehicle adapter.

[0060] External lower-level computer module 400: includes a lower-level computer that has been tested in a space environment and a custom-designed cable bundle 402. One end of the cable bundle 402 is used to connect to the interface of the cable adapter bracket 313, and the other end, namely the connector 404, is used to connect to the satellite platform 100.

[0061] like Figure 2 As shown, during the initial assembly phase, the upper cone module 200 can independently dock with the satellite platform 100 via the satellite compartment connection unlocking and separation device 203. Operators can enter its spacious interior through the opening at the lower end of the upper cone module to perform final installation, inspection, and maintenance operations on the satellite compartment connection unlocking and separation device 203, achieving excellent accessibility.

[0062] like Figure 3 As shown, simultaneously, the column segment and lower cone assembly module 300 are assembled in parallel in a dedicated propulsion system cleanroom. All propulsion components, including the storage tank 305 and engine 307, are installed, welded, and tested within this independent module, and finally, the electrical interfaces are uniformly collected and consolidated into the cable adapter bracket 313.

[0063] like Figure 4 As shown, the core of the electrical connection of the external lower-level module 400 lies in its dedicated cable bundle 402. This cable bundle 402 is directly connected to the separate electrical connector 102 located on the satellite platform base plate 101 via the connector 404 at its end. This design ensures the physical separation of the electrical path from the mechanical assembly path.

[0064] like Figure 5 As shown, the flowchart illustrates the key steps of the three stages: parallel module-level assembly and testing (paths A, B, C), modular system integration, and system-level assembly and testing.

[0065] The specific steps of the assembly and testing process are as follows:

[0066] Phase 1: Parallel Module-Level AIT

[0067] Path A Integration testing of the upper cone module 200 and satellite platform 100: This was completed in the satellite assembly hall. Figure 2 The operation and mechanical separation function test are shown.

[0068] Path B Column segment and lower cone assembly module 300 final assembly test: In the push-in cleanroom, the following was completed: Figure 3 The assembly, leak detection, and module-level testing are shown.

[0069] Path C External lower-level module 400 test: Independently complete comprehensive hardware and software testing of the controller in the electrical testing plant.

[0070] Phase Two: Modular System Integration The upper cone and satellite platform assembly and the column section and lower cone assembly module 300 are aligned and locked through a mechanical interface.

[0071] Install the external lower-level machine module 400, and press... Figure 4 The connecting cable bundle 402 is shown.

[0072] Phase 3: System-level assembly and testing Perform a full system cable continuity check.

[0073] A full-loop electrical test was conducted from the satellite platform 100 through the external lower-level computer module 400 to the propulsion components.

[0074] This invention proposes a novel modular propulsion module system based on the core principles of functional decoupling, interface standardization, and forward testing. This system completely breaks away from traditional integrated design, reconstructing the propulsion module into three clearly defined and functionally independent modules.

[0075] In the description of this application, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply 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 this application.

[0076] Specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the essence of the present invention. Unless otherwise specified, the embodiments and features described in this application can be arbitrarily combined with each other.

Claims

1. A modular propulsion module system that facilitates assembly and testing, characterized in that, include: Upper cone module (200), column segment, lower cone assembly module (300) and external lower computer module (400); The upper cone module (200) can be connected and separated from the satellite platform (100). It connects with the satellite platform (100) before the column segment, lower cone assembly module (300), and external lower computer module (400) to form an upper cone and satellite platform assembly, and performs interface checks and separation function tests. The column segment and lower cone assembly module (300) is a pre-integrated unit that integrates a complete propulsion and thermal control subsystem. It can be connected to the formed upper cone and satellite platform assembly to complete the integration of the main structure. The external lower-level computer module (400) is connected to the satellite platform (100), column segment, and lower cone assembly module (300), and can realize the power supply, command, telemetry signal transmission from the satellite platform (100) to the lower-level computer, as well as control of the entire propulsion and thermal control system.

2. The modular propulsion module system for easy assembly and testing according to claim 1, characterized in that, The upper cone module (200) is fixedly installed with a satellite compartment connection, unlocking and separation device (203) on the inner side of the top, which is used to achieve mechanical connection, locking and on-orbit unlocking and separation with the satellite platform (100); The upper cone module (200) is equipped with an independent upper instrument mounting plate and internal operating space, allowing the satellite compartment connection unlocking and separation device (203) to be installed or repaired from the inside during the later stages of final assembly. It can also dock with the satellite platform (100) before the column section, lower cone assembly module (300), and external lower computer module (400) to form an upper cone and satellite platform assembly for mechanical interface inspection and separation function test.

3. The modular propulsion module system for easy assembly and testing according to claim 1, characterized in that, The column section and lower cone assembly module (300) is a pre-integrated unit that integrates a complete propulsion and thermal control subsystem, including the column section cylinder and lower cone cylinder as the main load-bearing structure, all the storage tanks (305), gas cylinders, thrust engine (307), attitude control thruster, propulsion pipeline, valves and related thermal control actuators installed inside it; The module is equipped with a cable adapter bracket (313) on the outside. One side of the cable adapter bracket (313) is electrically connected to all the propulsion valves, engine igniters and thermal control components inside the module through internal cables.

4. The modular propulsion module system for easy assembly and testing according to claim 3, characterized in that, The external lower-level computer module (400) includes a lower-level computer, a set of dedicated cable bundles (402), and connectors (404). The lower-level computer is connected to the other side of the cable adapter bracket (313) through one end of a dedicated cable bundle (402) to control the entire propulsion and thermal control system; The other end of the dedicated cable bundle (402) is connected to the separate electrical connector (102) outside the docking area of ​​the satellite platform base plate (101) via a connector (404) to realize the power supply, command and telemetry signal transmission from the satellite platform (100) to the lower computer.

5. The modular propulsion module system for easy assembly and testing according to claim 3, characterized in that, The upper cone module (200), column segment, lower cone assembly module (300) and external lower computer module (400) are physically, electrically and functionally decoupled and can be assembled and tested independently. The mechanical connection exists between the upper cone module (200) and the column segment and lower cone assembly module (300), and the docking is achieved through a purely mechanical interface; The electrical connection is a completely independent path: external disconnect electrical connector (102) of satellite platform → external lower-level machine module (400) → cable adapter bracket (313) → internal equipment of column segment-lower cone assembly; → represents the direction of the electrical connection path.

6. The modular propulsion module system for easy assembly and testing according to claim 5, characterized in that, The interface between the upper cone module (200) and the column segment and lower cone assembly module (300) adopts a purely mechanical interface, including guide pins and pin holes evenly distributed along the circumference and a matching quick-locking device to realize the positioning and locking between the two modules. This interface does not include an electrical connector. On the upper frame of the column segment and lower cone assembly module (300) and the lower frame of the upper cone module (200), corresponding to the positions of the guide pin and pin hole, there are pre-embedded titanium alloy or stainless steel reinforcing bushings to improve the wear resistance and repeatability of the docking interface.

7. The modular propulsion module system for easy assembly and testing according to claim 1, characterized in that, The star-rocket connection ring at the lower end of the column segment and lower cone assembly module (300) is integrally formed with its main load-bearing structure or fixedly connected by a high-locking bolt in a non-removable manner to form an integrated star-rocket connection interface; the docking surface of the star-rocket connection ring is standardly matched with the launch vehicle interface and is pre-installed with a strap unlocking device adapter interface.

8. A method for assembling and testing a modular propulsion module system that facilitates final assembly and testing, characterized in that, Includes the following steps: S1: Parallel module-level assembly and testing, including the following steps: S1.1: The upper cone module (200) is integrated with the satellite platform (100). The upper cone module (200) is docked with the satellite platform (100) through the satellite compartment connection unlocking and separation device (203) to form an upper cone and satellite platform assembly; Operators enter through the lower opening of the upper conical module of the assembly to complete the final inspection and debugging of the star cabin connection unlocking and separation device (203); Independently conduct mechanical locking, releasing, and modal tests on the assembly; S1.2: Assembly and testing of column segment and lower cone assembly module (300) In the independent propulsion system assembly clean room, the installation, welding and helium mass spectrometry leak detection of all internal propulsion equipment and thermal control components of the column section and lower cone assembly module (300) were completed; All electrical actuator cables are bundled and connected to the external cable adapter bracket (313). The module underwent independent airtightness testing and functional simulation testing of some components. S1.3: External Lower-Level Machine Module (400) Test The lower-level computer is connected to the ground test system via its dedicated cable bundle (402) to simulate the power supply and communication of the satellite platform (100), and independently complete the comprehensive software and hardware test, communication protocol matching and functional verification of the lower-level computer; S2: Modular system integration, including the following steps: S2.1: The upper cone and satellite platform assembly and the column and lower cone assembly module (300) that have completed the test are precisely aligned and mechanically locked through guide pins, pin holes and quick-locking devices to complete the integration of the main structure; S2.2: Install the lower computer of the external lower computer module (400) onto the predetermined bracket on the outside of the column section cylinder, and connect and fix the two ends of its dedicated cable bundle (402) to the cable adapter bracket (313) on the column section, the lower cone assembly module (300), and the separate electrical connector (102) on the outside of the satellite platform base plate (101); S3: System-level assembly and testing, including the following steps: After all connections are completed, a full system cable continuity and insulation check is performed; Commands are sent from the satellite platform main control computer to each thruster valve and thermal control component via the separate electrical connector (102), lower computer, and cable adapter bracket (313) to perform full-loop electrical performance testing and functional verification.

9. The assembly and testing method for the modular propulsion module system facilitating final assembly and testing according to claim 8, characterized in that, In step S1, S1.1, S1.2, and S1.3 are carried out in parallel in time and space, and are implemented simultaneously by different professional teams in their respective dedicated facilities.

10. The assembly and testing method for the modular propulsion module system facilitating final assembly and testing according to claim 8, characterized in that, In step S2.1, the docking operation of the upper cone and satellite platform assembly and the column segment and lower cone assembly module (300) is carried out on a general large platform in the general assembly plant. After docking, the geometric dimension accuracy of the mating surface needs to be measured and confirmed.

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