Optimization of Pyroshock Test Conditions for Aerospace Components to Enhance Repeatability by Genetic Algorithms

Abstract

Electronic components assembled in satellites should be able to withstand the vibration, noise, and impact loads generated by space vehicles during launch. To simulate the impact loading in a laboratory environment, a pyroshock test simulates an impact load resulting from explosions during the stage and pairing separation of launch vehicles, which imposes significant stress on the components, potentially leading to failures and damage. To ensure component reliability before the flight model (FM) stage, where components are mounted on the actual launch vehicle and sent into orbit, a pyroshock test is conducted during the qualification model (QM) stage using identical parts and specifications. This process involves measurements of the acceleration induced by pyroshock to calculate the shock response spectrum (SRS) and evaluate the components’ reliability against the required SRS to confirm their ability to endure the shock and operate normally in post-tests. The aerospace developer determines the SRS requirements based on the space launch vehicle and the installation location of the electronic components. Configuring a suitable pyroshock test to meet these requirements typically involves extensive trial and error. This study aims to minimize such trial and error by examination of SRS changes through a numerical approach by table structural vibration analysis. The structure is subjected to in-plane impacts using a steel ball via a pendulum method. Various SRS profiles are calculated by test factors such as the weight of the steel ball, the pendulum angle, and the installation position of the test specimen. Furthermore, a genetic algorithm is utilized to derive the optimal test conditions that satisfy the required SRS. An automated pyroshock test system is developed to enhance repeatability and reduce human errors.