CMG cable motion simulation device and test system thereof

Abstract

The utility model discloses a CMG cable motion simulation device and a test system thereof, the CMG cable motion simulation device comprises a base, a motor, a connecting piece, a load and a control module connected with the motor, the motor is installed on the base, the connecting piece is installed above the motor, the load is detachably installed on the connecting piece, and the control module is connected with the motor. The motor, the connecting piece and the load are all provided with wire passing channels, one end of a CMG cable to be tested is installed on the base, the other end of the CMG cable to be tested sequentially penetrates through the motor, the connecting piece and the wire passing channels in the load and then is fixed to the outer surface of the load, and the control module receives a control instruction and controls the motor to drive the load to operate so as to drive the CMG cable to be tested to operate. A measurement module, an acquisition module and a processing module of the test system respectively measure, acquire, analyze and process voltage signals of the CMG cable to be tested in the operation process, and the voltage signals are displayed in real time through a man-machine interaction module. The cable testing device can be suitable for testing cables of various specifications, and is high in universality and wide in applicability.

Description

Technical Field

[0001] The utility model relates to the technical field of CMG testing, in particular to a CMG cable motion simulation device and a testing system thereof. Background Art

[0002] With the development of aerospace technology, spacecraft technology has also experienced rapid progress over the past decade or so. Spacecraft have become increasingly diverse and larger in size. Attitude control systems are key subsystems for all types of spacecraft. They generally consist of attitude sensing units, control mechanisms, and actuators. Actuators include flywheels, magnetic torquers, thrusters, and control moment gyroscopes (CMGs). CMGs achieve attitude control by rotating their high-speed rotors to exchange angular momentum with the spacecraft. The CMGs primarily consist of a rotor (reaction flywheel) and a frame (turntable). During operation, the rotor's rotation provides angular momentum, while the frame's rotation changes the direction of the angular momentum vector, generating control torque.

[0003] The CMG frame and reaction flywheel are connected by CMG cables. As the carrier of signal transmission between the CMG frame and the reaction flywheel, CMG cables often cause a series of cable failure problems due to wear of the surface insulation layer and stretching of the internal wire core in actual work. Therefore, it is very necessary to study the reliability of CMG cables.

[0004] In the existing technology, the common practice for impedance detection is to pass a large current through the conductor to be tested, detect its voltage, and finally convert it into resistance. This method requires passing a large current through the conductor to be tested, which will generate a large amount of heat in the resistor, accelerating damage to the conductor to be tested, making the test life shorter than its actual life. In addition, each conductor to be tested requires a detection system, and a CMG cable contains up to 25 conductors. Using existing detection methods will make the detection system complex and the data volume large. Utility Model Content

[0005] In order to test the reliability of CMG cables and improve the testing efficiency, the utility model proposes a CMG cable motion simulation device and a testing system thereof.

[0006] On the one hand, the utility model provides a CMG cable motion simulation device, including a base, a motor, a connector, a load and a control module electrically connected to the motor, wherein the fixed end of the motor is installed on the base, the connector is installed on the output end of the motor and is located directly above the motor, and the load is detachably installed on the connector. The motor, the connector and the load are all provided with a wire passage. One end of the CMG cable to be tested is installed in the base and extends to the outside thereof, and the other end passes through the wire passages on the motor, the connector and the load in sequence and is fixed to the outer surface of the load. The control module is used to receive external control instructions and control the motor to drive the connector to drive the load to operate. During operation, the load drives the CMG cable to be tested to stretch and twist, simulating the movement process of the CMG cable to be tested in a real scene.

[0007] Preferably, the base includes a bottom plate and a support base, which together form an accommodation space. The support base is provided with a wire outlet hole. The control module is mounted on the bottom plate and located in the accommodation space. One end of the CMG cable to be tested is mounted on the bottom plate and extends from the wire outlet hole on the support base. The fixed end of the motor is supported and fixed by the support base.

[0008] Preferably, a fixing sleeve is installed on the base plate, and a horizontal wire channel A and a longitudinal wire channel B are provided on the fixing sleeve. One end of the CMG cable to be tested passes through the longitudinal wire channel B, the horizontal wire channel A and the wire outlet hole in sequence, and is fixed to the base plate by a first wire clamp.

[0009] Preferably, the fixing sleeve includes a first fixing part and a second fixing part, the first fixing part is provided with a transverse wire passing channel A along a direction parallel to the base plate, the second fixing part and the first fixing part are respectively provided with a through hole with a semicircular cross-section along a direction perpendicular to the base plate, and the semicircular through holes on the second fixing part and the first fixing part are enclosed to form a longitudinal wire passing channel B.

[0010] Preferably, the connector includes a connecting part, a fixing part and an anti-wear sleeve, the load is detachably connected to the fixing part, the connecting part is installed at the output end of the motor, the centers of the connecting part and the fixing part are both provided with through holes to form a wire passing channel C on the connector, and the anti-wear sleeve is provided on the CMG cable to be tested and at a position corresponding to the wire passing channel C.

[0011] Preferably, the anti-wear sleeve comprises a first anti-wear portion and a second anti-wear portion that are structurally symmetrical. The first anti-wear portion and the second anti-wear portion are detachably fixed to the CMG cable to be tested at positions corresponding to the cable passage C.

[0012] Preferably, the load is generally cylindrical, and a first through hole and a second through hole are respectively provided along the axial and radial directions of the load. The first through hole and the second through hole together form a wire passage D on the load. The other end of the CMG cable to be tested passes through the wire passage D on the load and is fixed to the outer surface of the base by a second wire clamp.

[0013] On the other hand, the utility model further provides a CMG cable testing system, which includes a human-computer interaction module, a processing module, an acquisition module, a measurement module, a power supply module, and the CMG cable motion simulation device described above. The human-computer interaction module is connected to the processing module, the processing module is respectively connected to the acquisition module and the CMG cable motion simulation device, the acquisition module is connected to the measurement module, and the measurement module and the CMG cable motion simulation device are both connected to the power supply module, wherein:

[0014] The human-computer interaction module is used to set parameters and send rotation instructions and control instructions to the processing module, and is also used to receive and display the processing results sent by the processing module;

[0015] The processing module is used to receive the parameters, rotation instructions and control instructions set by the human-computer interaction module, send the rotation instructions to the control module on the CMG cable motion simulation device, send the control instructions to the acquisition module, and also receive and process the voltage data from the acquisition module, and send the processing results to the human-computer interaction module;

[0016] The power module is used to supply power to the measurement module and the CMG motion simulation device;

[0017] The control module on the CMG cable motion simulator receives the rotation command and controls the CMG cable motion simulator to operate according to the preset parameters, driving the cable to be tested to operate;

[0018] The measurement module is used to measure the voltage of the cable under test installed on the CMG cable motion simulation device during operation to obtain a voltage measurement signal;

[0019] The acquisition module is used to receive the control instructions sent by the processing module and collect the voltage measurement signal, and send the collected voltage data to the processing module.

[0020] Preferably, the measurement module in the above-mentioned CMG cable testing system includes a plurality of measurement units, the acquisition module includes analog-to-digital converters having the same number as the plurality of measurement units, the plurality of measurement units are connected in parallel to the positive and negative terminals of the power module and the input terminals of the plurality of analog-to-digital converters, and the output terminals of the plurality of analog-to-digital converters are connected to the processing module.

[0021] Several measurement units are used to measure the voltage of different conductors in the CMG cable to be tested;

[0022] Several analog-to-digital converters are used to collect voltage measurement signals of different conductors in the CMG cable to be tested to obtain voltage data;

[0023] The processing module is used to receive voltage data and calculate the resistance values ​​of different conductors in the CMG cable to be tested based on the received voltage data.

[0024] The present invention also provides a CMG cable testing method, which uses the above-mentioned CMG cable testing system to test the CMG cable to be tested. The testing method includes the following steps:

[0025] S1. Fix the CMG cable to be tested on the CMG cable motion simulation device, connect both ends of the CMG cable to the measurement module, turn on the power, and initialize the CMG cable test system.

[0026] S2. Preset the single cycle operation angle trajectory, total number of cycle operations, and resistance threshold in the human-computer interaction module, and input rotation instructions and control instructions;

[0027] S3, after receiving the rotation instruction, the CMG cable motion simulation device drives the CMG cable to be tested to perform the nth cycle along the preset single cycle operation angle trajectory;

[0028] S4, check whether the CMG cable motion simulation device completes the preset angle trajectory during the nth cycle operation. If it is completed, execute S5; otherwise, continue to execute S3;

[0029] S5. Detecting the resistance value of each conductor in the CMG cable to be tested after the nth cycle operation is completed;

[0030] S6. Compare the resistance value of each conductor in the CMG cable with a preset resistance threshold. If the resistance value of each conductor in the CMG cable is within the preset resistance threshold, execute S7; otherwise, execute S8.

[0031] S7, detecting whether the current number of cycle operations reaches the preset total number of cycle operations. If so, executing S8; otherwise, repeating steps S3 to S6 to perform the n+1th cycle operation on the CMG cable to be tested;

[0032] S8. If the current number of cycle operations reaches the preset total number of cycle operations, or the resistance value of at least one conductor is not within the preset resistance threshold range, the test is terminated and the detection data of the CMG cable to be tested is output.

[0033] Beneficial effects of the utility model:

[0034] (1) The CMG cable motion simulation device has a simple and reliable structure. By replacing loads of different weights, it can simulate the actual motion conditions of CMG cables used on CMGs with different output torques and different sizes.

[0035] (2) The measurement module and acquisition module of the CMG cable test system respectively measure and acquire the voltage signal of the CMG cable to be tested during operation. The processing module in the test system analyzes and processes the acquired voltage signal. The processing result can be displayed in real time through the human-computer interaction module during the test. There is no need to stop the test and use other devices to detect the test results. The test data is reliable. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 This is a structural diagram of a CMG cable motion simulation device in one embodiment of the present utility model;

[0037] Figure 2 This is a structural diagram of the bottom plate in one embodiment of the present utility model;

[0038] Figure 3 This is a structural diagram of a fixing sleeve in one embodiment of the present utility model;

[0039] Figure 4 This is a structural diagram of a connecting member in one embodiment of the present utility model;

[0040] Figure 5 This is a schematic structural diagram of an anti-wear sleeve in one embodiment of the present utility model;

[0041] Figure 6 This is a schematic diagram of the structure of a load in one embodiment of the present utility model;

[0042] Figure 7 is a schematic block diagram of a CMG cable testing system in one embodiment of the present invention;

[0043] Figure 8 This is a partial electrical connection diagram of the measurement module and the acquisition module in one embodiment of the present utility model;

[0044] Figure 9 This is a flow chart of a CMG cable testing method in one embodiment of the present utility model;

[0045] Description of reference numerals:

[0046] 1. Base; 11. Bottom plate; 12. Support base; 111. Fixing sleeve; 112. First wire clamp; A. Horizontal wire channel; B. Vertical wire channel;

[0047] 2. Motor;

[0048] 3. Connector; 31. Connecting portion; 32. Fixing portion; 33. Anti-wear sleeve; 331. First anti-wear portion; 332. Second anti-wear portion; C. Connector wire passage;

[0049] 4. Load; 41. First through hole; 42. Second through hole; 43. Second wire clamp; D. Load wire channel;

[0050] 5. CMG cable to be tested. DETAILED DESCRIPTION

[0051] In order to enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings.

[0052] In the description of this utility model, the relevant orientation or position relationship is based on Figure 1 The directions or positions shown, where "upper" and "lower" refer to Figure 1 The up and down direction of Figure 1 For example, upward in the vertical drawing is considered up, downward in the vertical drawing is considered down, left in the vertical drawing is considered left, right in the vertical drawing is considered right, outward in the vertical drawing is considered front, inward in the vertical drawing is considered back, left and right are considered horizontal, and up and down are considered vertical. It should be understood that these directional terms are only used to facilitate the description of the present invention and simplify the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, be constructed or operate in a specific orientation, and therefore should not be construed as limiting the present invention.

[0053] See also Figure 1 , Figure 1 This is a structural schematic diagram of a CMG cable motion simulation device in one embodiment of the present invention.

[0054] In one embodiment, a CMG cable motion simulation device includes: a base 1, a motor 2, a connector 3, a load 4, and a control module electrically connected to the motor 2. The motor 2 includes a fixed end (i.e., a stator) and an output end (i.e., a rotor). The fixed end and the output end are both cylindrical with a through hole in the center of the cylinder. The fixed end of the motor 2 is mounted on the base 1, the connector 3 is mounted on the output end of the motor 2 and is located directly above the motor 2, and the load 4 is detachably mounted on the connector 3. The motor 2, the connector 3, and the load 4 are all provided with a wire passage. One end of the CMG cable 5 to be tested is mounted in the base 1 and extends to the outside of the base 1, and the other end passes through the wire passages on the motor 2, the connector 3, and the load 4 in sequence and is fixed to the outer surface of the load 4. The control module is used to receive external control instructions and control the motor 2 to drive the connector 3 to drive the load 4 to operate. During operation, the load 4 causes the CMG cable 5 to be tested to stretch and twist, simulating the motion process of the CMG cable 5 to be tested in a real scene.

[0055] The CMG cable motion simulation device utilizes the through-holes in motor 2 as a cable passage. Base 1 simulates the CMG frame, and load 4 simulates the reaction flywheel. The control module controls the rotation of motor 2, which in turn drives load 4 via connector 3, thereby simulating the actual operation of the CMG cable under test. The detachable connection between load 4 and connector 3 allows for adjustable test loads, adapting to testing CMG cables of varying output torques and sizes.

[0056] Further, see Figure 1 and Figure 2 The base 1 includes a bottom plate 11 and a support base 12. The bottom plate 11 and the support base 12 together form an accommodating space. The support base 12 is provided with a wire outlet hole. The control module is installed on the bottom plate 11 and is located in the accommodating space. One end of the CMG cable 5 to be tested is installed on the bottom plate 11 and extends from the wire outlet hole on the support base 12. The fixed end of the motor 2 is supported and fixed by the support base 12.

[0057] To facilitate installation, the base plate 11 and the support base 12 are designed to be detachably connected. For example, a plurality of positioning posts are provided at intervals on the base plate 11, and an equal number of mounting holes are provided at corresponding positions on the support base 12. The support base 12 and the base plate 11 are detachably connected via the positioning posts and the mounting holes. The base plate 11 and the support base 12 can also be connected in other ways, such as providing a plurality of through-mounting holes at intervals on the base plate 11, and providing an equal number of threaded holes at corresponding positions on the support base 12. Screws are passed through the mounting holes on the base 11 and then tightened into the mounting holes on the support base 12.

[0058] Further, see Figure 2 , a fixing sleeve 111 is installed on the bottom plate 11, and a horizontal wire channel A and a longitudinal wire channel B are provided on the fixing sleeve 111, wherein the horizontal wire channel A is arranged parallel to the bottom plate 11, and the longitudinal wire channel B is arranged perpendicular to the bottom plate 11. One end of the CMG cable 5 to be tested passes through the longitudinal wire channel B, the horizontal wire channel A and the outlet hole on the support seat 12 in sequence ( Figure 2 (not shown) and then fixedly mounted on the bottom plate 11 by the first wire clamp 112. In order to reduce friction of the CMG cable 5 to be tested during operation and facilitate wiring, the longitudinal wire channel B is usually set in the center of the bottom plate 11, and the wire outlet hole on the support base 12 is generally set close to the outlet of the transverse wire channel A.

[0059] Further, see Figure 3The fixing sleeve 111 includes a first fixing portion 1111 and a second fixing portion 1112. The first fixing portion 1111 is provided with a transverse wire-passing channel A in a direction parallel to the base plate 11. The first fixing portion 1111 is provided with a through hole with a semicircular cross section in a direction perpendicular to the base plate 11. The second fixing portion 1112 is also provided with a through hole with a semicircular cross section. The semicircular through holes in the first and second fixing portions 1111, 1112 are of the same size. Together, the semicircular through holes in the first and second fixing portions 1111, 1112 form a longitudinal wire-passing channel B. Designing the fixing sleeve 111 as a split piece facilitates the passage of the cable 5 under test and component processing. In addition, the transverse wire-passing channel A can be a through hole with a semicircular or semi-elliptical cross section, with the radius of the circle or the length of the minor semi-axis of the ellipse slightly smaller than the outer diameter of the cable 5 under test. This design prevents the cable 5 under test from sliding within the transverse wire-passing channel A.

[0060] Further, see Figure 4 The connector 3 includes a connecting portion 31, a fixing portion 32, and an anti-wear sleeve 33. The load 4 is detachably connected to the fixing portion 32. The connecting portion 31 is mounted on the output end of the motor 2. Through holes are provided in the centers of the connecting portion 31 and the fixing portion 32, forming a wire-passing channel C on the connector 3. The anti-wear sleeve 33 is provided on the CMG cable 5 to be tested and at a position corresponding to the wire-passing channel C. After the other end of the CMG cable 5 to be tested passes through the wire-passing channel C, the anti-wear sleeve 33 is located in the wire-passing channel C on the connector 3. The connecting portion 31 and the fixing portion 32 can be designed to be integrally formed or to be split. When the connecting portion 31 and the fixing portion 32 are split, they can be detachably connected by fasteners: a mounting hole is provided on the fixing portion 32, and a mounting hole is also provided at a corresponding position of the load 4. The load 4 and the fixing portion 32 are detachably connected through the mounting hole. The connecting portion 31 is provided with a mounting hole, and a mounting hole is also provided at the output end of the motor 2. The connecting portion 31 and the output end of the motor 2 are detachably connected.

[0061] Furthermore, the anti-wear sleeve 33 includes a first anti-wear portion 331 and a second anti-wear portion 332 that are structurally symmetrical. The first anti-wear portion 331 and the second anti-wear portion 332 can be detachably fixed on the CMG cable 5 to be tested and at a position corresponding to the wire-passing channel C. By designing the anti-wear sleeve 33 as a split structure, it can be easily processed and manufactured. In addition, for better installation and positioning, the first anti-wear portion 331 and the second anti-wear portion 332 respectively include an arc-shaped body and a step protruding along one end of the arc-shaped body. The arc-shaped body is provided with a mounting hole. The first anti-wear portion 331 and the second anti-wear portion 332 are locked and fixed on the cable 5 to be tested and at a position corresponding to the wire-passing channel C through the mounting hole. At this time, the step protruding at one end of the body is stuck in the inlet end of the mounting channel C.

[0062] Further, see Figure 5The load 4 is generally cylindrical, and a first through hole 41 and a second through hole 42 are respectively opened along the axial and radial directions of the cylindrical load 4. The first through hole 41 and the second through hole 42 together form a wire passage D on the load. The other end of the CMG cable 5 to be tested passes through the wire passage D on the load and is fixed to the outer surface of the base 1 by a second wire clamp 43.

[0063] In another embodiment, see Figure 7 A CMG cable testing system includes a human-computer interaction module, a processing module, an acquisition module, a measurement module, a power supply module, and the above-mentioned CMG cable motion simulation device. The human-computer interaction module is connected to the processing module, the processing module is respectively connected to the acquisition module and the CMG cable motion simulation device, the acquisition module is connected to the measurement module, and the measurement module and the CMG cable motion simulation device are both connected to the power supply module, wherein:

[0064] The human-computer interaction module is used to set parameters and send rotation instructions and control instructions to the processing module, and is also used to receive and display the processing results sent by the processing module;

[0065] The processing module is used to receive the parameters, rotation instructions and control instructions set by the human-computer interaction module, send the rotation instructions to the control module on the CMG cable motion simulation device, send the control instructions to the acquisition module, and also receive and process the voltage data from the acquisition module, and send the processing results to the human-computer interaction module;

[0066] The power module is used to supply power to the measurement module and the CMG motion simulation device;

[0067] The control module on the CMG cable motion simulator receives the rotation command and controls the CMG cable motion simulator to operate according to the preset parameters, driving the cable to be tested to operate;

[0068] The measurement module is used to measure the voltage of the cable under test installed on the CMG cable motion simulation device during operation to obtain a voltage measurement signal;

[0069] The acquisition module is used to receive the control instructions sent by the processing module and collect the voltage measurement signal, and send the collected voltage data to the processing module.

[0070] Furthermore, the measurement module includes a plurality of measurement units, the acquisition module includes analog-to-digital converters having the same number as the measurement units, the measurement units are connected in parallel to the positive and negative terminals of the power module and the input terminals of the plurality of analog-to-digital converters, and the output terminals of the plurality of analog-to-digital converters are connected to the processing module.

[0071] Several measurement units are used to measure the voltage of different conductors in the CMG cable to be tested;

[0072] Several analog-to-digital converters are used to collect voltage measurement signals of different conductors in the CMG cable to be tested to obtain voltage data;

[0073] The processing module is used to receive voltage data and calculate the resistance values ​​of different conductors in the CMG cable to be tested based on the received voltage data.

[0074] Specifically, see Figure 8 , Figure 8 This is a partial electrical connection diagram of the measurement module and the acquisition module in one embodiment of the present invention. The measurement module includes several measurement units, and the acquisition module includes several analog-to-digital converters. Figure 8 The electrical connection diagram of a measurement unit and an analog-to-digital converter is specifically shown. Each measurement unit includes resistors 1 to 4. The CMG cable to be tested includes several conductors, which are divided into groups of four. Each group of conductors is labeled as conductors 1 to 4. Resistors 1 to 4 and conductors 1 to 4 form a bridge measurement circuit: one end of resistors 1 to 4 is connected to one end of conductors 1 to 4, respectively, the other end of resistor 1 is connected to the other end of conductor 4, and node A is connected to the positive pole of the power supply. The other end of resistor 3 is connected to the other end of conductor 2, and node B is connected to the negative pole of the power supply. The other end of resistor 2 is connected to the other end of conductor 1, and node C is connected to the first input terminal of the analog-to-digital converter. The other end of resistor 4 is connected to the other end of conductor 3, and node D is connected to the second input terminal of the analog-to-digital converter. The output terminal of the analog-to-digital converter is connected to the processing module. The analog-to-digital converter is specifically a high-precision analog-to-digital converter, and the processing module is specifically a single-chip microcomputer.

[0075] A CMG cable under test consists of 25 conductors, with each measurement unit capable of testing four conductors. This requires at least seven measurement units and seven analog-to-digital converters to test a single CMG cable simultaneously. The seven measurement units are connected in parallel to the positive and negative terminals of the power supply. The seven measurement units are also connected to the inputs of the seven analog-to-digital converters, and the outputs of the seven analog-to-digital converters are connected to the processing module. The four resistors in each measurement unit and the four conductors under test form a bridge measurement circuit. (If only one conductor remains in a group, that conductor is connected to any resistor in the measurement unit, and the remaining three resistors are connected directly.) In the bridge measurement circuit, resistors one through four (R1-R4) are high-precision resistors. The CMG cable test system operates in an air-conditioned, constant-temperature environment with minimal ambient temperature fluctuations. The CMG cable under test will be stretched and twisted under the action of external tension, causing cable damage. The resistance of the wires inside the cable will change, and a weak voltage difference signal will be generated between node C and node D. The voltage difference between nodes C and D is collected by a high-precision analog-to-digital converter. The high-precision analog-to-digital converter filters the sampled signal to remove interference and sends the voltage difference sampling signal collected by the high-precision analog-to-digital converter to the microcontroller. The microcontroller calculates the resistance values ​​of different wires in the CMG cable under test based on the received voltage sampling signal and evaluates the performance of the cable.

[0076] In one embodiment, see Figure 9 A CMG cable testing method is provided, wherein the CMG cable testing system described above is used to test the CMG cable to be tested. The testing method comprises the following steps:

[0077] S1. Fix the CMG cable to be tested on the CMG cable motion simulation device, connect both ends of the CMG cable to the measurement module, turn on the power, and initialize the CMG cable test system.

[0078] S2. Preset the single cycle operation angle trajectory, total number of cycle operations, and resistance threshold in the human-computer interaction module, and input rotation instructions and control instructions;

[0079] S3, after receiving the rotation instruction, the CMG cable motion simulation device drives the CMG cable to be tested to perform the nth cycle along the preset single cycle operation angle trajectory;

[0080] S4, check whether the CMG cable motion simulation device completes the preset angle trajectory during the nth cycle operation. If it is completed, execute S5; otherwise, continue to execute S3;

[0081] S5. Detecting the resistance value of each conductor in the CMG cable to be tested after the nth cycle operation is completed;

[0082] S6. Compare the resistance value of each conductor in the CMG cable with a preset resistance threshold. If the resistance value of each conductor in the CMG cable is within the preset resistance threshold, execute S7; otherwise, execute S8.

[0083] S7, detecting whether the current number of cycle operations reaches the preset total number of cycle operations. If so, executing S8; otherwise, repeating steps S3 to S6 to perform the n+1th cycle operation on the CMG cable to be tested;

[0084] S8. If the current number of cycle operations reaches the preset total number of cycle operations, or the resistance value of at least one conductor is not within the preset resistance threshold range, the test is terminated and the detection data of the CMG cable to be tested is output.

[0085] Specifically, first install the CMG cable to be tested and connect it: fix the CMG cable to be tested on the CMG cable motion simulation device, divide the wires in the CMG cable to be tested into a group of 4 and mark them as wires one to wire four, and connect each group of marked wires to resistors one to resistor four in each measurement unit in the measurement module in the same way as described above to form a bridge circuit, the A and B nodes on each bridge circuit are connected to the positive and negative poles of the power supply, respectively, and the C and D nodes on each bridge circuit are connected to the first input terminal and the second input terminal of the acquisition module, respectively.

[0086] After the wiring is completed, turn on the power and initialize the test system: When the test starts, perform motor zero position calibration, set the angle zero position of the load on the CMG cable motion simulation device to the motor zero position, and the load rotation direction is divided into forward and reverse. The maximum range of the rotation angle is -180°~+180°, and the value of each rotation angle is R (90°~165°). The rotation angular velocity is set to a (value of 30° / s), the angle error is ±1°, and after reaching a preset rotation angle, the pause time is t (value of 1 second). The preset angle trajectory of a single cycle operation is 0°→+R→0°→-R→0°. The assessment count increases by 1 for each rotation of R, so the assessment count for completing a cycle operation is 4 times.

[0087] Taking the load rotating from the current angle to the next preset target operating angle (for example, 0°→R) as an example, the control of the operation process is described as follows: Using the PD control algorithm, when the motor's operating angle is 0°, the motor's operating angular velocity is increased from 0° / s to 30° / s, and then it is operated at a constant speed at an angular velocity a, driving the load close to the preset target operating angle R. The motor's operating angular velocity is then reduced from 30° / s to 0° / s, with an angular error of ±1°. After reaching the preset target operating angle R, it pauses for 1 second to allow the angular velocity to approach 0° / s as much as possible to reduce the impact of rotational inertia. Through the above control method, the angular trajectory passed through in one cycle is 0°→+R→0°→-R→0°, and the test count is 4 (if the test count is not an integer multiple of 4, it means that the current cycle is not completed). After each cycle is completed, the voltage will be measured and the resistance of each conductor in the CMG cable to be tested will be calculated. The calculated resistance will be compared with the preset resistance threshold. If the resistance value of each conductor is within the preset resistance threshold range, the above steps will be repeated and the CMG cable will be tested again until the preset total number of cycles is reached, and the test data of the CMG cable to be tested will be output; if the resistance value of at least one conductor is not within the preset resistance threshold range, the test will be terminated and the test data of the CMG cable to be tested will be output.

[0088] In this scheme, the average duration of each rotation of R is about 8 seconds, the total number of test counts is 2 million times (that is, the total number of cycle operations is 500,000 times), and the total test time is 185 days (about 6 months).

[0089] In addition, during the above test process, when an emergency occurs, the test can be stopped through the human-computer interaction module; the detection data can also be recorded and stored in the human-computer interaction module, and can be directly called in subsequent new tests without repeated manual input.

[0090] During operation, the cable under test is subjected to tension, which causes the length of the conductive metal in the cable to increase. In addition, the external insulation layer may rub against contacting metal parts, and / or the multiple strands of the cable under test may rub against each other, causing the insulation layer to be damaged. The resistance change caused by insulation damage is much greater than the resistance change caused by the increase in the length of the conductive metal, and can also be detected by the online test system.

[0091] The above describes in detail the CMG cable motion simulation device and its test system provided by the present invention. This article uses specific examples to illustrate the principles and implementation methods of the present invention. The description of the above examples is intended only to facilitate understanding of the core concept of the present invention. It should be noted that those skilled in the art may make various improvements and modifications to the present invention without departing from the principles of the present invention, and such improvements and modifications also fall within the scope of protection of the claims of the present invention.

Claims

1. A CMG cable motion simulation device, characterized in that: The device comprises a base (1), a motor (2), a connector (3), a load (4), and a control module electrically connected to the motor (2); the fixed end of the motor (2) is mounted on the base (1); the connector (3) is mounted on the output end of the motor (2) and is located directly above the motor (2); the load (4) is detachably mounted on the connector (3); the motor (2), the connector (3), and the load (4) are all provided with wire passages; one end of a CMG cable (5) to be tested is mounted in the base (1) and extends to the outside thereof; the other end passes through the wire passages on the motor (2), the connector (3), and the load (4) in sequence and is then fixed to the outer surface of the load (4); the control module is used for receiving external control instructions and controlling the motor (2) to drive the connector (3) to drive the load (4) to operate; during the operation, the load (4) drives the CMG cable (5) to be tested to stretch and twist, thereby simulating the movement process of the CMG cable (5) to be tested in a real scene.

2. The CMG cable motion simulation device according to claim 1, characterized in that: The base (1) includes a bottom plate (11) and a support base (12), the bottom plate (11) and the support base (12) together form a receiving space, the support base (12) is provided with a wire outlet hole, the control module is mounted on the bottom plate (11) and is located in the receiving space, one end of the CMG cable (5) to be tested is mounted on the bottom plate (11) and extends from the wire outlet hole on the support base (12), and the fixed end of the motor (2) is supported and fixed by the support base (12).

3. The CMG cable motion simulation device according to claim 2, characterized in that: A fixing sleeve (111) is installed on the bottom plate (11), and a transverse wire-passing channel A and a longitudinal wire-passing channel B are provided on the fixing sleeve (111). One end of the CMG cable (5) to be tested passes through the longitudinal wire-passing channel B, the transverse wire-passing channel A and the wire outlet hole in sequence, and is then fixedly installed on the bottom plate (11) through a first wire clamp (112).

4. The CMG cable motion simulation device according to claim 3, characterized in that: The fixing sleeve (111) comprises a first fixing portion (1111) and a second fixing portion (1112); the first fixing portion (1111) is provided with a transverse wire-passing channel A in a direction parallel to the bottom plate (11); the second fixing portion (1112) and the first fixing portion (1111) are respectively provided with through holes with semicircular cross sections in a direction perpendicular to the bottom plate (11); the semicircular through holes on the second fixing portion and the first fixing portion are combined to form a longitudinal wire-passing channel B.

5. The CMG cable motion simulation device according to claim 1, wherein: The connecting member (3) comprises a connecting portion (31), a fixing portion (32) and an anti-wear sleeve (33); the load (4) is detachably connected to the fixing portion (32); the connecting portion (31) is mounted on the output end of the motor (2); the centers of the connecting portion (31) and the fixing portion (32) are both provided with through holes to form a wire passage C on the connecting member (3); and the anti-wear sleeve (33) is arranged on the CMG cable (5) to be tested and at a position corresponding to the wire passage C.

6. The CMG cable motion simulation device according to claim 5, characterized in that: The anti-wear sleeve (33) comprises a first anti-wear portion (331) and a second anti-wear portion (332) which are symmetrical in structure. The first anti-wear portion (331) and the second anti-wear portion (332) are detachably fixed on the CMG cable (5) to be tested at positions corresponding to the wire channel C.

7. The CMG cable motion simulation device according to claim 1, wherein: The load (4) is generally cylindrical, and is provided with a first through hole (41) and a second through hole (42) along the axial direction and the radial direction of the load (4), respectively. The first through hole (41) and the second through hole (42) together form a wire passage D on the load. The other end of the CMG cable (5) to be tested passes through the wire passage D on the load and is fixed to the outer surface of the base (1) through a second wire clamp (43).

8. A CMG cable testing system, characterized in that: The system includes a human-computer interaction module, a processing module, an acquisition module, a measurement module, a power supply module, and the CMG cable motion simulation device according to any one of claims 1 to 7, wherein the human-computer interaction module is connected to the processing module, the processing module is respectively connected to the acquisition module and the CMG cable motion simulation device, the acquisition module is connected to the measurement module, and the measurement module and the CMG cable motion simulation device are both connected to the power supply module, wherein: The human-computer interaction module is used to set parameters and send rotation instructions and control instructions to the processing module, and is also used to receive and display the processing results sent by the processing module; The processing module is used to receive the parameters, rotation instructions and control instructions set by the human-computer interaction module, send the rotation instructions to the control module on the CMG cable motion simulation device, send the control instructions to the acquisition module, and also receive and process the voltage data from the acquisition module, and send the processing results to the human-computer interaction module; The power module is used to supply power to the measurement module and the CMG motion simulation device; The control module on the CMG cable motion simulator receives the rotation command and controls the CMG cable motion simulator to operate according to the preset parameters, driving the cable to be tested to operate; The measurement module is used to measure the voltage of the cable under test installed on the CMG cable motion simulation device during operation to obtain a voltage measurement signal; The acquisition module is used to receive the control instructions sent by the processing module and collect the voltage measurement signal, and send the collected voltage data to the processing module.

9. A CMG cable testing system according to claim 8, characterized in that: The measurement module includes several measurement units, and the acquisition module includes analog-to-digital converters of the same number as the measurement units. The measurement units are connected in parallel to the positive and negative terminals of the power module and the input terminals of the analog-to-digital converters. The output terminals of the analog-to-digital converters are connected to the processing module. Several measurement units are used to measure the voltage of different conductors in the CMG cable to be tested; Several analog-to-digital converters are used to collect voltage measurement signals of different conductors in the CMG cable to be tested to obtain voltage data; The processing module is used to receive voltage data and calculate the resistance values ​​of different conductors in the CMG cable to be tested based on the received voltage data.

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