航天器柔性线缆拖拽力学建模及线缆系统布线规划研究

There is limit space to reduce parts' weight based on optimal design theory in spacecraft structure. Thus, aerospace departments begin to focus on path planning technology of cable harness recently. However, in the traditional way, the 1:1 physical prototype model of cable harness is used to determine the spacecraft structural layout. Therefore, the test results lack of general rational planning and theoretical basis. For this reason, physical characteristic of nonlinear constitutive relations and displacement strain relations are described, and the dynamic equation of motional cable harness is established considering cable winding, twisting and winding deformation. Moreover, the modeling and plan planning of flexible motional cable harness is studied in this project, and spatial constraints, performance constraints and external force constraints in spacecraft structural layout are further considered completely. Further, the kinematics and dynamics modeling and simulation of flexible cable harness are established, and the real-time dynamic simulation of 3D entity cable harness layout are realized based on C++ and OpenGL. Then, the efficient path planning algorithms considering feasible spatial domain are developed under condition of spatial constraints, performance constraints and load constraints. The laws of the path planning of different types of cables harness would be revealed on the overall feasible spatial domain. Finally, the feasibility evaluation and performance prediction methods of cable harness are proposed under all constraint conditions, and the expert prediction system of spacecraft flexible cable harness infomation is developed through the reliability analysis techniques based on various of physical test data and simulation results in the virtual environment. Above all, the conclusions would have important academic value and engineering significance in this project.

航天器结构质量优化几乎达到了极限，线缆系统总体集成规划设计已成为研究的焦点。而传统航天器布线一般采用1:1比例模拟实物样机模型通过人工模拟装配，缺乏统一总体规划及理论依据。本项目以航天器柔性活动线缆布线系统为研究对象，考虑线缆拖拽呈现蜿蜒、扭转、缠绕等几何大变形，结合非线性本构关系，建立柔性线缆力学模型；考虑空间几何约束、线缆物理性能约束和载荷约束等，研究柔性活动线缆运动学与动力学分析求解问题。通过开发相应的虚拟仿真环境，实现线缆路径规划的三维实体动态仿真。通过划界与规划研究高效的路径规划算法实现线缆在有各种约束工况下的可行空间域的求解，进而研究不同柔性线缆物理特性参数对整个可行空间域的影响规律。最后通过各种物理试验与虚拟环境仿真试验相结合，运用可靠性分析技术和方法，研究线缆在各种约束工况作用下的规划路径可行性评价与性能预测方法。研究工作对提高航天器系统可靠性及线缆布线效率具有重要意义。

柔性线缆作为航天器中控制能源与信息传递的载体，其可靠性与安全性要求极高，线缆因柔性大变形产生多变的空间形态，同时布线与装配空间内约束工况复杂，导致其出现约束下的力学拉伤或过度弯曲缠绕造成的失效。此外，航天器发射过程引发的线缆振动，会导致线缆端部脱离约束或者卡箍被拖拽离开敷设面，会引起电信号干扰甚至线缆扯断，进而影响航天器在轨运行电控性能。. 针对卫星线缆大挠度变形的特点，考虑线缆物理特性，建立了线缆的力学模型，提出一种以矢径、俯偏角表达线缆任意一点位置，以四坐标系之间互相转换描述线缆空间姿态的线缆空间位姿表达法；建立线缆在仅受自身重力和环境分布力时的静力平衡模型；根据线缆的物理特性、运动参数和受力条件建立线缆的运动学方程和动力学模型。此外，考虑布线过程中的空间约束与载荷作用，建立柔性线缆的力学模型，对线缆力学特性进行研究，分析其几何位形、运动状态及受力情况。进一步建立拖拽下运动柔性线缆的连续型力学模型，结合其自身本构关系，研究线缆的非线性力学特性，并进行仿真分析与试验验证。最后构建多约束耦合工况下线缆非线性振动模型，利用Galerkin法建立线缆面内、空间振动常微分方程，并采用多尺度法和数值方法对多约束耦合线缆非线性振动模型进行定性与定量分析，研究线缆非线性振动行为规律，可为实际布线系统的路径规划提供理论依据与实现基础，也为其它柔性体建模问题提供借鉴，具有重要的科学与工程价值。