航天电连接器空间环境可靠性试验与评估的研究
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摘要
空间环境是诱发航天产品在轨故障的主要原因。电连接器在航天领域应用范围大,数量可观,地位重要。随着航天器可靠性要求的不断提高,如东方红-4号通信卫星要求在轨寿命达到15年,对电连接器的空间环境可靠性也提出了更高的要求。由于我国目前尚未就电连接器的空间环境可靠性开展系统研究,对电连接器空间环境性能参数的变化规律尚未完全掌握、失效模式和失效机理不清、缺少相应的空间环境性能和可靠性指标,在航天器的可靠性设计中,只能基于经验或借鉴国外标准对电连接器进行可靠性分析、设计和选用,这已成为我国发展宇航级电连接器的瓶颈。本文以东方红-4号为应用背景,以型号上广泛使用且结构和材料具有代表性的Y11P型圆型低频电连接器为研究对象,研究电连接器的空间环境效应,以及电连接器空间环境可靠性的地面模拟试验评估方法,为快速评定电连接器的空间环境可靠性提供理论依据,为提高航天器的系统可靠性设计水平提供技术储备。全文共分8章,各章的主要工作如下：第1章,阐述了论文的研究背景、目的和意义,从可靠性工程、空间环境可靠性和电连接器可靠性三个方面分析了相关领域的国内外研究现状及存在的问题,提出了论文的研究思路和主要研究内容。第2章,从电连接器的结构、材料和功能,以及电连接器在轨工作时受到的应力出发,全面分析了电连接器的空间环境效应和失效模式,为建立电连接器的空间环境地面模拟试验方法、研究电连接器的空间环境效应和可靠性奠定了基础。第3章,基于电连接器的空间环境效应和失效模式分析,从现有的地面模拟试验技术出发,根据试验可激发效应的数目、可行性和系统地开展机理研究的需要,建立了电连接器的空间环境地面模拟试验方法,为系统地研究电连接器的空间环境效应和可靠性提供了地面模拟试验方面的总体思路。第4章,通过地面模拟试验和数据分析,确定了电连接器的绝缘电阻和接触电阻随气压和温度变化的规律；以此为依托,建立了研究电连接器空间环境性能特性的地面模拟试验方法和试验数据分析方法。第5章,通过地面模拟试验和数据分析,确定了接触电阻和绝缘电阻在真空-温度-通电应力作用下随时间变化的规律,确定了造成电连接器性能退化的原因；以此为依托,建立了研究电连接器空间环境性能蜕化规律的地面模拟试验方法和试验数据分析方法。第6章,分析了在真空-温度-通电应力作用下,电连接器性能退化的机理,以此为基础,建立了基于性能退化过程的电连接器热真空环境可靠性模型；以此为依托,探讨了基于性能变化机理、面向退化数据分析的电连接器空间环境可靠性建模方法。第7章,建立并验证了基于退化数据的电连接器热真空环境可靠性统计模型,建立了相应的模型参数估计方法,评估了电连接器在热真空环境下的可靠度。第8章,总结了全文的工作,提出了对进一步研究工作的建议。
Space environment is the main reason inducing failure to space product in-orbit. Electrical connector is widely used in aerospace area with large amounts and plays an important role. As reliability requirements for spacecraft continue to improve, some communication satellites, such as DFH-4, require of the in-orbit life 15 years, which proposes an even higher requirement for space environment reliability of electrical connector.Currently, as China has not yet carried out systematic research on space environment reliability of electrical connector, there is not enough knowledge about degradation rule of performance parameters; the failure modes and mechanism are unclear; and there is lack of appropriate indicators for performance and reliability in space environment. In reliability design of spacecraft, the reliability analysis, design and selection of electrical connector is mainly base on experiences or foreign standards, which has become a bottleneck restricting the development of aerospace electrical connectors in China.In this dissertation, the application background is based on DFH-4. The widely used Y11P type of round low-frequency electrical connector is taken as the research object, as its structure and material is representative. The space environment effect of electrical connector is studied, and the reliability evaluation method, using simulation tests on ground to evaluate the space environment reliability, is researched. This research provides a theoretical foundation to rapidly assess reliability of electrical connector in space environment, and technical reserves to improve the system reliability design level for spacecraft.This dissertation is divided into eight chapters, and the main work of each chapter is as follows:In Chapter 1, the research background, purpose and significance are described. The historical investigations and existed problems in related field are analyzed from the following three aspects:reliability engineering, space environment reliability and the reliability of electrical connectors. Then, the idea and contents of this dissertation are proposed.In Chapter 2, the space environment effects and failure modes are analyzed comprehensively based on the structure, materials and functions of electrical connector and the stresses existing in-orbit. It provides a foundation to formulate a test method to simulate space environment on ground, and to research the space environment effects and reliability.In Chapter 3, on the base of space environment effects and failure modes and the existing simulation test techniques on ground, the simulation effects and feasibility of tests and the demands to carry out systematic research for mechanism are analyzed. The test method to simulate space environment on ground is formulated. It provides a general idea of test to research space environment effects and reliability of electrical connector systematically.In Chapter 4, on the base of the simulation test on ground and data analysis, the rules of insulation resistance and contact resistance varying with atmospheric pressure and temperature are determined. Then, the simulation test methods on ground and data analysis methods are formulated to research the performance characters of electrical connector in space environment.In Chapter 5, on the base of the simulation test on ground and data analysis, the rules of insulation resistance and contact resistance varying with time under the multiple stresses of vacuum-temperature-current-voltage are determined. The reasons that induce performance degradation of electrical connector are determined. Then, the simulation test methods on ground and data analysis methods are formulated to research performance degradation rules of electrical connector in space environment.In Chapter 6, the performance degradation mechanism of electrical connector under the multiple stresses of vacuum-temperature-current-voltage is analyzed. The reliability model of thermal-vacuum environment based on performance degradation process is formulated. Then, the modeling method based on performance degradation mechanism and degradation data analysis is discussed for space environment reliability of electrical connector.In Chapter 7, the reliability statistical model based on degradation data is formulated and proved for electrical connector under thermal-vacuum environment. The corresponding estimation techniques for model parameters are formulated. The reliability of electrical connector under thermal-vacuum environment is assessed.In Chapter 8, the works of this dissertation are summarized; suggestions for further research are proposed.
Space environment is the main reason inducing failure to space product in-orbit. Electrical connector is widely used in aerospace area with large amounts and plays an important role. As reliability requirements for spacecraft continue to improve, some communication satellites, such as DFH-4, require of the in-orbit life 15 years, which proposes an even higher requirement for space environment reliability of electrical connector.Currently, as China has not yet carried out systematic research on space environment reliability of electrical connector, there is not enough knowledge about degradation rule of performance parameters; the failure modes and mechanism are unclear; and there is lack of appropriate indicators for performance and reliability in space environment. In reliability design of spacecraft, the reliability analysis, design and selection of electrical connector is mainly base on experiences or foreign standards, which has become a bottleneck restricting the development of aerospace electrical connectors in China.In this dissertation, the application background is based on DFH-4. The widely used Y11P type of round low-frequency electrical connector is taken as the research object, as its structure and material is representative. The space environment effect of electrical connector is studied, and the reliability evaluation method, using simulation tests on ground to evaluate the space environment reliability, is researched. This research provides a theoretical foundation to rapidly assess reliability of electrical connector in space environment, and technical reserves to improve the system reliability design level for spacecraft.This dissertation is divided into eight chapters, and the main work of each chapter is as follows:In Chapter 1, the research background, purpose and significance are described. The historical investigations and existed problems in related field are analyzed from the following three aspects:reliability engineering, space environment reliability and the reliability of electrical connectors. Then, the idea and contents of this dissertation are proposed.In Chapter 2, the space environment effects and failure modes are analyzed comprehensively based on the structure, materials and functions of electrical connector and the stresses existing in-orbit. It provides a foundation to formulate a test method to simulate space environment on ground, and to research the space environment effects and reliability.In Chapter 3, on the base of space environment effects and failure modes and the existing simulation test techniques on ground, the simulation effects and feasibility of tests and the demands to carry out systematic research for mechanism are analyzed. The test method to simulate space environment on ground is formulated. It provides a general idea of test to research space environment effects and reliability of electrical connector systematically.In Chapter 4, on the base of the simulation test on ground and data analysis, the rules of insulation resistance and contact resistance varying with atmospheric pressure and temperature are determined. Then, the simulation test methods on ground and data analysis methods are formulated to research the performance characters of electrical connector in space environment.In Chapter 5, on the base of the simulation test on ground and data analysis, the rules of insulation resistance and contact resistance varying with time under the multiple stresses of vacuum-temperature-current-voltage are determined. The reasons that induce performance degradation of electrical connector are determined. Then, the simulation test methods on ground and data analysis methods are formulated to research performance degradation rules of electrical connector in space environment.In Chapter 6, the performance degradation mechanism of electrical connector under the multiple stresses of vacuum-temperature-current-voltage is analyzed. The reliability model of thermal-vacuum environment based on performance degradation process is formulated. Then, the modeling method based on performance degradation mechanism and degradation data analysis is discussed for space environment reliability of electrical connector.In Chapter 7, the reliability statistical model based on degradation data is formulated and proved for electrical connector under thermal-vacuum environment. The corresponding estimation techniques for model parameters are formulated. The reliability of electrical connector under thermal-vacuum environment is assessed.In Chapter 8, the works of this dissertation are summarized; suggestions for further research are proposed.
引文
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