航天用导电滑环失效建模与工艺优化研究

doi:10.3901/JME.2020.16.001

摘要/Abstract

摘要： 航天信号传输系统是航天系统的生命线，而导电滑环是航天系统信号传输系统的重要组成部件，是整星少数几个单点失效环节之一。由于导电滑环的工作环境中涉及电流和摩擦影响，使得滑环处于多场耦合的复杂环境，导致对其进行物理建模尤为困难；同时由于滑环价格高、试验过程复杂的特点，更进一步增加滑环研究的难度。为了提升航天信号传输系统稳定性与可靠性，对航天系统中重要的信号传输部件导电滑环进行失效物理建模，并基于模型对滑环工艺进行优化。针对导电滑环运行原理和失效特点，将滑环失效的关键部位摩擦副产生的磨屑量作为滑环性能退化特征量；应用赫兹接触理论和传热学方法分别计算摩擦副磨损过程中的接触区域变化和温度变化，量化热力电多场耦合对摩擦副磨损的影响；同时结合磨损计算方法建立多物理场耦合磨损模型，对摩擦副磨损寿命进行预测，达到对滑环可靠性与稳定性提升的目的。通过与真实滑环磨损试验数据进行对比，验证模型的正确性，并将该模型应用于实际的滑环摩擦副工艺设计。结果表明，多场耦合模型可有效揭示滑环摩擦副微观运作机理并实施寿命预测，进而可靠地实施滑环工艺优化，提高滑环寿命与运作可靠性，满足新一代长寿命卫星空间无故障长期可靠运行的需求。

关键词: 导电滑环, 摩擦副, 多物理场耦合, 寿命预测, 工艺优化

Abstract: The space signal transmission system is the lifeline of the space system and the conductive slip ring is an important component of the signal transmission system in the space system. It is one of the few single point failure links of the whole satellite. Because of the influence of current and friction in the working environment, the slip ring is in the complex environment of multi-field coupling, which makes its physical modelling particularly difficult. At the same time, its high price and the complexity of the test process further increase the difficulty of the study of the slip ring. In order to improve the stability and reliability of the space signal transmission system, the failure physical model of the conductive slip ring is established, which is an important part of the space signal transmission system. The process of the slip ring is optimized based on the model, so as to enhance the stability and reliability of the whole space system. According to the running principle and failure characteristics, the amount of debris produced by the friction pairs of the slip ring is taken as its degradation characteristic. The contact zone and temperature changes during the wear process are calculated by Hertz contact theory and heat transfer method respectively and the influence of thermal electric multi-field coupling on the wear of the friction pair is quantified. The multi-physical field coupling wear model is used to predict the wear life of friction pairs so as to improve the reliability and stability of slip rings. The correctness of the model is verified by comparing with the real wear test data. The model is applied to the actual process design of slip ring friction pairs. The proposed multi-field coupling model can effectively reveal the micro-operation mechanism of the slip ring friction pair and implement life prediction and then reliably optimize the slip ring process and improve the life and operational reliability. It meets the needs of the new generation of long-life satellite space fault-free long-term reliable operation.

Key words: conductive slip ring, friction pair, multi-physical field coupling, life prediction, process optimization

中图分类号:

孙远航, 王永松, 孙习武, 刘贤军, 余建波. 航天用导电滑环失效建模与工艺优化研究[J]. 机械工程学报, 2020, 56(16): 1-12.

SUN Yuanhang, WANG Yongsong, SUN Xiwu, LIU Xianjun, YU Jianbo. Research on Failure Modeling and Process Optimization of Transmission Conductive Slip Ring for Aerospace[J]. Journal of Mechanical Engineering, 2020, 56(16): 1-12.

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