蒙皮点阵一体化支撑结构的移动可变形组件优化设计及空间站应用

中国空间站是我国研制的系统最为复杂的载人航天器，其中有效载荷支撑结构的高效轻量化设计是工程研制过程中遇到的技术难题。本文介绍了受晶体对称性启发的增材制造自支撑三维点阵结构设计方法，发展了基于蒙皮点阵一体化结构形式的移动可变形组件（MMC）拓扑优化方法，完成了面向增材制造的中国空间站某相机支撑结构的优化设计，该结构采用激光选区熔化成形（SLM）工艺制造，通过了力学试验考核，实现结构减重50%，基频提高35%，完成了基于MMC方法的蒙皮点阵一体化结构在我国载人航天领域的首次型号应用与在轨验证。

Optimal design of shell-lattice infill integrated supporting structure based on Moving Morphable Components method and its application in China Space Station

China Space Station is the most complex manned spacecraft developed by China, in which the efficient and lightweight design of the payload supporting structure is a technical challenge encountered during the engineering development process. In order to reduce the weight of the support structure as much as possible while ensuring the service performance, an additive manufactured shell-lattice infill integrated structure is selected as its structural form, and its lightweight design is realized through topology optimization techniques. This paper summarized the design method of self-supporting lattice structure inspired by crystal symmetry for additive manufacturing; develops an optimization design approach of shell-lattice infill integrated supporting structure based on the moving morphable components (MMC) method; Taking advantage of the MMC method with explicit structural geometric parameters and the ability to obtain clear optimal force transfer paths, an additive manufacturing-oriented shell-lattice infill integrated topology optimization mathematical formulation is proposed, with the fundamental structural frequency as the constraint and the lightest weight as the optimization objective. After the optimization process, the additive manufacturing model was reconstructed by Nurbs surface based on the optimal structural force transfer path and the information of structural feature sizes on this path, which was finally fabricated by selective laser melting (SLM) process. In order to verify the effectiveness of the design, the support structure and the equipment mass simulated parts were verified by single machine vibration test. The experimental results show that the weight of the support structure is reduced by 50%, and the fundamental frequency is increased by 35% through the MMC-based topology optimization design. At present, the support structure has been successfully launched with the China space station, and the relevant equipment is operating stably in orbit. It is the first successful application and in-orbit verification of shell-lattice infill integrated structure based on the MMC topology optimization method in China's manned space field.