default image
Innovation and application of assembly technology for aerospace high-reliability and long-life power supply products
Aerospace power supply technology, high reliability, long life, small, lightweight and high power, ensures manned space exploration
Type
Manufacturing process
Tags
Other resource gains
Aviation and aerospace science and technology
High reliability
Poor maintainability
Aerospace
Assembly technology
Quantization control
Solution maturity
Mass promotion / Mass production
Cooperation methods
Joint venture cooperation
Face-to-face consultation
Applicable industry
Manufacturing
Applications
Aerospace manufacturing
Key innovations
The first technology for power aggregation and distribution, highly reliable component forming and routing has significantly reduced size and weight, improved life and output power, and broke through the bottleneck of aerospace power supply technology.
Potential economic benefits
This technology improves the reliability of aerospace power supply and avoids huge accident losses; reduces size, reduces weight, improves efficiency, and saves costs; has civilian promotion value and creates new economic growth points.
Potential climate benefits
Reducing weight and reducing size significantly reduce energy consumption in material manufacturing and space launch, extend life and reduce replacement, and improve efficiency and reduce system power consumption.
Solution supplier
View more
Shanghai Space Power Research Institute
Shanghai Space Power Research Institute
The Shanghai Space Power Research Institute is committed to the research and development of spacecraft power supplies, providing core power guarantee for China's space exploration.
Shanghai,China
Solution details

At present, my country's manned spaceflight is steadily entering the era of space stations. In the field of deep space exploration, a soft landing on the moon has been achieved, and Mars exploration missions have followed one after another. As the heart of aerospace vehicles, once the power supply product fails, it will directly lead to the loss of control of the entire satellite or ship, and the country's losses will reach hundreds of millions, and even endanger the lives of the spacecraft and astronauts. According to industry statistics, the number of quality accidents caused by power system failures is as high as 20%. In July 2012, a certain model suffered a power supply system failure, resulting in direct economic losses of more than 30 million yuan. With the continuous improvement of aerospace mission requirements, the assembly technology of aerospace high-reliability and long-life power supply products has become an urgent bottleneck problem in the development of aerospace power supply products in my country. Based on the front line of production, Gu Wei carried out technological innovation activities, which solved the technical problems of strict single machine size and weight, long life and high power in one fell swoop. It achieved a 21% reduction in the size of the single machine for aerospace power supply control, a 23% reduction in weight, a 46% increase in life, and a 60% increase in output power. Innovation point 1: The first power collection and distribution technology for aerospace power control single machine has broken through the bottleneck of size and weight. In view of the problems of poor serviceability, heavy device weight and poor heat dissipation in the traditional form of power collection and distribution under the limitations of small size and light weight of the aerospace power control single machine, the project team carried out test mapping and verification work, and effectively carried out power collection and distribution through the combination of copper bars and bus pads between modules. A single machine using this technology can reduce weight by up to 23% and size by nearly 21%. Innovation point 2: Pioneering in proposing a high-reliability component forming technology for aerospace power control stand-alone to ensure on-orbit service life. Aiming at the shortcomings of high requirements for forming power devices and multi-pin devices within aerospace products, difficult quantitative control, and low pass rates, the project team designed and Made a variety of forming tooling, and through hundreds of test verifications, finally solved the technical bottleneck of low manual forming efficiency, poor coplanarity of device pins, and easy leakage of power tubes. The pass rate of surface-mount chip formation and power tube inspection have been greatly improved, and hidden dangers of component damage have been eliminated. The technical achievements have been applied to many major national tasks. The pass rate of formation has been increased from the original 72% to 95%, achieving on-orbit life. Increase by nearly 46%. Innovation point 3: Innovatively propose a single-machine routing and wiring operation method for aerospace power supply control to overcome high-power technical difficulties. In view of the complex internal structure of aerospace products, small operating space, and thick power wiring harnesses, the project team conducted various routing methods. Exploration and demonstration have solved the technical bottleneck of difficult layout and complex fixation of power wire bundles within high-power aerospace power supply products. Improve the mechanical properties of power platform products during the ascent phase of flight and ensure product quality. The efficiency of single machines using this operating method is increased by nearly 30%, and the output power is increased by as much as 60%. The innovative technologies formed by this project have developed and delivered more than 360 products in the past three years. It has been verified in models such as Shenzhou and Tiangong in my country's manned space project. It has gone through nearly 20 missions and has achieved complete success. It has been promoted and applied in the development of models such as ldquo; Chang'e rdquo; and ldquo; Mars rdquo;. This technology has obtained 1 authorized invention patent, 8 authorized utility model patents, and 2 enterprise standards for core technologies. There are still many technologies that have not been disclosed because they involve state secrets. The ldquo; Gu type wire bundle routing and wiring operation method rdquo; won the Shanghai City Employee Advanced Operation Method Innovation Award. Through the novelty search of the Shanghai Institute of Aerospace Technology Basic Research, it was determined that this project is novel and the comprehensive technology has reached the domestic leading position. This technology breaks through the long-term technical blockade imposed by foreign aerospace powers on my country in the field of aerospace power manufacturing, and provides important technical reserves for major projects such as subsequent space stations and manned lunar landing. Many of its innovative technologies have good commercial promotion and application value in civil aerospace, aviation and other manufacturing fields.

Last updated
01:46:51, Nov 05, 2025
Information contributed by

See original page on

Report