Research On Potting Technology Of Aerospace Cable Assembly

The aerospace cable assembly is an important part of space systems, but in recent years, quality problems emerge in endlessly. Aiming at the characteristics of the space cable assembly in China and the existing problems of technology, referencing the domestic and foreign standards for electric connector assemblies, this paper completed the research of space cable assembly potting technology. The main research about this paper contents:According to the working environment of space cable assembly, the past experience of space model selection, the performance of potting materials of various sizes, and vacuum outgassing analysis about the selection of potting material, the potting material selection is completed. This paper studied the low pressure injection molding technique, completed the design of injection mold, and made different technological experimental scheme, through the analysis of experimental results, determined the low pressure injection molding process parameters. By studying aerospace cable assembly koala cover potting and extravehicular hood with tail potting process, solved the two key problems as follows: The mold design and optimization of koala cover potting and the research of removing air bubbles process. Integrated the generating mechanism of potting gum bubbles and the analysis of different experimental results by contrast, determined the process method, the parameters to remove the air bubble, solved the problem of filling the air bubble defect, using ultrasonic testing mether. Finally, all potting cable assembly reliability tests have been carried out, analysis of the potting cable assembly of the microstructure of joint section, topography, energy spectrum diagram, using metallographic microscope and scanning electron microscopy(sem) to verify the of the three kinds of process method, and laid a solid foundation to form the space cable component potting process specifications.The process methods which this paper studies reinforced the solder joints of space cable assembly, reduced the tail cover processing difficulty; through process improvement and innovation, shortened the production cycle of the cable network, reduced the production cost. improved cable network quality and stability, can serve model task well, and has a certain practical significance. So the research results of this paper not only can directly apply to all kinds of electric network product electric connector assemblies of military and satellite spacecraft which our country develop in the future, but also can apply to the civil cable assembly product.