3.1. Physical Field Solving Method
When the ambient temperature remains constant, meaning that the internal temperature of the IFOG, the internal temperature of the spacecraft, and the temperature around the fiber coil are all in thermal equilibrium, there is no temperature gradient in the fiber coil and, thus, no zero-point drift caused by thermally induced errors. However, during the spacecraft’s orbital operation, changes in solar radiation intensity and the heat generated by internal components of the spacecraft and the IFOG result in the IFOG being in a variable temperature state for most of the time. When the ambient temperature changes, the heat transfer between the fiber coil and the external environment creates a temperature gradient within the fiber coil, which, in turn, generates thermally induced errors. To determine the magnitude of the thermally induced errors in the fiber coil, the temperature field distribution of the fiber coil must first be solved. To establish the transmission conditions between the interior of the fiber coil and the external environment, the heat transfer laws of the overall system must first be determined.
When the IFOG operates in space, its working environment is a vacuum with no air medium present. Additionally, the fiber coil is not a heat-generating component; the fiber does not heat up during operation. Therefore, the temperature changes around the fiber are due to heat transfer from external components that generate heat to the fiber coil. According to thermodynamics, whenever there is a temperature difference between materials, heat will transfer from the higher-temperature substance to the lower-temperature substance [
17,
18,
19]. The three basic methods of heat transfer are conduction, convection, and radiation. Heat conduction occurs due to the random movement of free electrons in conductive solids and the vibration of the lattice in non-conductive solids, facilitating heat transfer, while heat convection involves the heat exchange caused by the molecular movement between fluids of different temperatures. In non-vacuum conditions, heat convection is one of the primary modes of heat transfer. However, since the spacecraft operates in a dry vacuum environment with no air or other fluid mediums, there is no heat convection. Heat radiation refers to the emission of heat from a body with a temperature above absolute zero, which is an ongoing process and does not rely on a medium. Therefore, this mode of transfer is still present in a vacuum environment. Consequently, the modes of heat transfer for IFOGs in a vacuum are conduction and radiation. According to the theory of heat conduction, the primary mode of heat exchange within the fiber coil is heat conduction [
18]. The fiber is an isotropic material, and the internal temperature field transfer of the fiber coil in the Cartesian coordinate system satisfies the following heat conduction equation:
where
represents internal temperature field of the fiber coil,
represents the thermal conductivity of the fiber material,
represents the specific heat capacity of the fiber material, and
represents the density of the fiber material.
The above equation represents the balance between the heat required to raise the temperature of the fiber coil and the heat transferred into the fiber coil from external contact. The right side of the equation indicates the total amount of heat needed to raise the temperature of the fiber per unit of time, conforming to the principle of energy conservation. The operating range of the IFOG is typically from −40 °C to 80 °C, and the operating temperature range in the low Earth orbit is from −25 °C to 55 °C. Within this temperature range, the heat transfer efficiency of thermal conduction and convection is significantly greater than that of thermal radiation. For ease of calculation, thermal radiation is usually neglected in research. However, since there is no convection in a vacuum environment, thermal radiation cannot be ignored. The heat transfer between objects by radiation can be calculated using the Stefan–Boltzmann law [
20]:
where
represents absorptivity, and
represents the Stefan–Boltzmann constant. In summary, the heat transfer between a space IFOG and its working environment mainly consists of the following types: thermal radiation from the interior of the spacecraft to the outer surface of the gyro structure; thermal radiation within the fiber optic gyro cavity between various structural components and from these components to the fiber coil; conductive heat transfer at the bottom surface of the fiber optic gyro, heat conduction from various heat-generating electronic components in the PCB board to the PCB board, and thermal conduction between the light source, PCB board, and structural components; and heat conduction between the gyro structure and the fixed surface of the fiber coil.
3.2. Structural Design of Fiber IMU
The IFOG component should comply with the mechanical design requirements specified in the satellite construction standards, such as requirements for layout, weight, fixation, and alignment. The mounting surfaces of the structure should retain their metallic appearance, while the surfaces of other equipment enclosures, except for the mounting surfaces, should undergo black anodizing or be coated with black paint. The hemispherical emissivity must be no less than 0.85. The design should enhance internal heat transfer within the equipment, ensuring that the heat generated by components is transferred to the mounting surface with minimal thermal resistance.
Since the payload capacity of a spacecraft is precisely calculated based on its orbital path and the carrying capacity of the launch vehicle, there are stringent requirements regarding the weight, volume, and fixation methods of the IFOG and the inertial navigation system (INS) as a whole. This paper adopts the commonly used space INS in engineering as the standard, with a total mass of less than 300 g and an overall volume not exceeding 74.7 mm × 74.7 mm × 53.5 mm. The remaining IFOG components should comply with the mechanical design requirements specified in the satellite construction standards.
In the structural design of INS, a Mg-Li alloy with a low density, high strength-to-weight ratio, and high modulus-to-weight ratio is chosen as the supporting structural material. The density of the Mg-Li alloy is between one-third to one-half that of the Al alloy, and the rigidity of the Mg-Li alloy is 22.68 N/m compared to 8.19 N/m for the Al alloy. Thus, the Mg-Li alloy possesses outstanding vibration-damping and heat dissipation properties, along with excellent machinability, which ensures the high machining precision and long-term stability of the equipment. This material is widely used in the aviation sector and is a mature material in the aerospace industry.
To meet the spacecraft’s volume requirements, the fiber coil, as a core component, must be miniaturized, which means using small-diameter fibers and reducing the initial bending radius of the fiber coil. The fiber used is YOFC’s PM1310-80-16/135-PM1016-G polarization-maintaining fiber, wound into a fiber coil using a non-stepped quadrupole symmetric winding method. The parameters of the Mg-Li alloy and the fiber coil used in the finite element simulation experiments are shown in
Table 2.
Based on the above design requirements, the design of the fiber optic INS was completed. Using the Creo 3D modeling software, the structural design process was carried out according to the physical dimensions, and the established 3D model of the fiber optic inertial measurement unit (IMU) was imported into the Ansys Workbench finite element simulation software. The mechanical structure of the fiber optic IMU is shown in
Figure 2. Except for the bottom installation surface, the surfaces of other parts of the equipment are treated with black anodizing.
Figure 2a shows the effect after surface treatment, and
Figure 2b shows the effect after transparency processing, clearly revealing the arrangement of the internal components of the fiber optic IMU. The fiber optic IMU contains three IFOGs, which are installed on the bottom, left side, and right side and are mutually perpendicular. To optimize space and component usage, all IFOGs use the SLD at the bottom as the input light source. To optimize the heat dissipation process, heating components are installed at the bottom to accelerate heat dissipation through thermal conduction. In addition to the three IFOGs, the fiber optic IMU is also equipped with three MEMS accelerometers, three gyroscope circuit boards, and one system circuit board. For the fiber optic IMU, the most important optical components are the three IFOG fiber coils on the bottom, left, and right sides, which are also the main objects of analysis in the subsequent finite element simulation experiments.
In order to improve computational efficiency, after importing the completed fiber IMU structure into the finite element analysis software, it is necessary to de-edge the entire structure. Components and design elements that do not affect the simulation results, such as screws, chamfers, top engravings, and aviation connectors, should be removed. Some manufacturing processes required in actual applications can make the shapes of non-essential structural parts irregular, reducing mesh uniformity, significantly increasing finite element computation time, and having a minimal impact on the results. Therefore, these elements should be processed before constructing the analysis elements. According to the mesh division principles, the entire fiber IMU structure should be meshed. Since the temperature distribution of the fiber coils is the focus of finite element analysis, the three IFOG fiber coils should be finely meshed, with an average mesh size not exceeding 0.5 mm², ensuring a mesh correlation greater than 95%. The final overall total mesh node count is 1,103,075, with 262,703 mesh elements and an overall correlation greater than 80%. The mesh division results of the entire structure are shown in
Figure 3a, and the optimized mesh results of the fiber coils are shown in
Figure 3b.
Firstly, the base of the fiber inertial module is set as a fixed constraint and is in thermal contact with the environment. In a vacuum environment, the fiber inertial group exchanges heat with the ambient temperature through thermal radiation. Secondly, according to the technical requirements, the operating temperature range of the IFOG is from 55 °C to −25 °C. To obtain a complete temperature cycle, the initial environmental temperature is set to 55 °C. After reaching equilibrium, the temperature is decreased at a rate of 1.5 °C/min until it reaches −25 °C, and then this temperature is maintained for 140 min. Subsequently, the temperature is increased at the same rate of 1.5 °C/min until it reaches 55 °C, and then it is maintained for 280 min. The entire temperature variation process can be divided into four segments: cooling process, low-temperature holding process, heating process, and high-temperature holding process. To ensure a comprehensive analysis, this paper selects a moment in each segment for a detailed analysis.
Figure 4 shows the temperature distribution of the IFOG fiber coil at 2400 s. Due to the low heat transfer effect of thermal radiation and the presence of heat sources within the fiber inertial group, the cooling rate in a vacuum environment is slower during the cooling process. At the same time, the temperature of the fiber coil in a vacuum is higher than that in a non-vacuum environment. This is because there is thermal conduction between the bottom surface of the fiber coil and the structural components, and its heat conduction effect is much higher than that of thermal radiation.
Figure 5 shows the temperature distribution of the IFOG fiber coil at 7200 s. In this case, the external environment’s temperature has reached −25 °C. Due to poor heat dissipation in the vacuum environment, the overall temperature of the fiber inertial group and the fiber coil is higher than −25 °C. The principles of other temperature distribution conditions are similar to those in the previous stage.
Figure 6 shows the temperature distribution of the IFOG fiber coil at 9900 s. Due to convective heat dissipation between fluids, the internal temperature of the fiber inertial group rises sharply in a vacuum state. Since the system enters the following stage after 10,800 s, the analysis is conducted after 9900 s.
Figure 7 shows the temperature distribution of the IFOG fiber coil after 14,400 s. After 14,400 s, the external environment’s temperature has reached 55 °C, and the internal temperature distribution of the fiber coil also tends to stabilize.
Figure 8 shows the high-temperature expansion and low-temperature contraction of the fiber coil. It can be observed that, since the thermal expansion coefficient of the Mg-Li alloy is smaller than that of the fiber and the bottom surface of the fiber coil is connected to the structural component, the deformation of the bottom surface of the fiber coil is less than that of the top surface. Additionally, the heat sources around the bottom fiber coil are more concentrated, resulting in a steady-state temperature higher than that of the left and right fiber coils. Therefore, during low temperatures, its contraction is less than that of the other two fiber coils, and during high temperatures, its expansion is greater. Because the heat sources at the bottom of the fiber inertial group are symmetrically distributed, the deformation of the bottom fiber coil is essentially centrosymmetric, whereas the deformation distribution of the left and right fiber coils is asymmetric.
By exporting the temperature data of the fiber coil throughout the entire temperature cycle from the simulation software and performing fitting processing, the temperature distribution of the fiber coil at fixed moments can be obtained through the fitted function. The midpoint of the fiber coil is selected as the reference point for output, and the fitted temperature cycle is shown in
Figure 9.
Temperature output at the reference point. As shown in the figure, the temperature changes in the right and left fiber coils are essentially the same, while the bottom fiber coil shows a slightly different behavior. In the vacuum state, the minimum temperature of the fiber coils is −14.51 °C, and the maximum temperature is 64.59 °C. By deriving the fitted function to obtain the slope, which is the rate of temperature change, and substituting the rate of temperature change obtained from the simulation experiments into Formula (15), the distribution of thermally induced errors for the three IFOGs in both vacuum and non-vacuum environments can be obtained, as shown in
Figure 10. It can be seen that the bottom fiber coil, due to thermal contact, experiences greater temperature variations compared to the left and right fiber coils, resulting in larger thermally induced errors. This also indicates that the thermally induced error is mainly caused by temperature changes rather than deformation. Additionally, since the fiber IMU itself generates heat, the rate of temperature change in the heating phase is higher than in the cooling phase, which leads to the peak thermally induced error during the cooling phase being lower than that during the heating phase, consistent with the theoretical analysis in the previous section.