In a recent research paper published in High-speed Railway, researchers conducted a comprehensive thermal stress simulation analysis of aerospace optical fibers, cables, and connectors, essential for reliable data transmission in space environments. The study evaluated their performance under extreme temperatures and vacuum conditions while exploring their potential for high-speed railway communication, providing a theoretical basis for these applications.
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Background
Aerospace optical cables and fiber-optic connectors provide significant benefits, including low signal loss, wide transmission bandwidth, high capacity, lightweight, and strong resistance to electromagnetic interference. These features make them important for optical communication and high-speed data transmission between optical terminals and photodetectors in space.
Ensuring stable data transmission during spacecraft operations is crucial, and thermal stress simulations assess temperature stress concentrations caused by fluctuations in extreme environments.
About the Research
The paper analyzed the thermal stress of aerospace optical cables and connectors, specifically the J599III fiber optic connectors, under various temperature conditions. Using the finite element method, the researchers simulated thermal deformation and stress from constant temperatures, temperature changes, and gradients. The analysis included aerospace optical cables and connectors, featuring multiple cable connectors and a specific length of optical cable.
The researchers created a three-dimensional (3D) model of the optical cable connector using SolidWorks, incorporating components like the plug, ceramic sleeve, spring stop ring, pin contact, and socket.
The thermal stress simulation applied constant and cyclic temperature loads to the connector, starting at an ambient temperature of 22 °C. The simulation conditions varied from low temperatures of -100 °C to high temperatures of 100 °C, with a holding time of 5 minutes and a temperature change rate of 5 °C per minute.
The study also simulated temperature gradients to evaluate stress under extreme conditions. This included scenarios with a temperature load of 100 °C on the plug and -100 °C on the socket, as well as a single temperature load of 100 °C on the outer surface of the cable connector. The authors used ANSYS software to perform thermal stress simulations, identifying the structural characteristics and stress concentration points of the connector.
Key Findings
The simulations showed that the optical cable connector experienced significant stress under constant and cyclic temperature conditions. At constant temperatures, the connector’s temperature matched the load temperature, leading to a uniform stress distribution.
However, under cyclic temperatures, stress varied widely, reaching a maximum of 342 MPa, below the aluminum alloy’s strength limit of 420 MPa. The study identified the threaded part of the plug as having a higher temperature gradient, leading to significant thermal stress concentration.
The temperature gradient stress simulation also revealed that the stresses in the four bolt holes of the connector were relatively high due to axial constraints and material expansion in the XY direction. The maximum stress was 332 MPa, still below the aluminum alloy’s strength limit but a potential weak point in the connector’s performance. Excessive local stress could cause material damage and reduce the connector’s lifespan or service life.
Furthermore, the simulation of the optical cable showed a relatively uniform stress distribution on the optical fiber core, with no significant stress concentration during temperature changes. The stress from temperature gradients did not exceed the fiber core’s strength, suggesting that the optical cable would remain intact under these conditions.
Applications
This research has significant implications for developing high-speed rail optical communication networks. Aerospace optical cables and connectors can ensure stable and reliable signal transmission, which is crucial for the safety and efficiency of high-speed rail operations.
The study’s findings also have applications in other fields like space exploration and satellite communications, where optical cables and connectors operate in extreme environments. It provides a theoretical basis for assessing the performance of cables and connectors in thermal vacuum conditions, highlighting the need for high-reliability components to maintain stable and secure signal transmission in extreme climates.
Conclusion
The thermal stress simulation provided valuable insights into the performance of aerospace optical cables and connectors in extreme temperatures and vacuum conditions. The researchers identified potential connector weaknesses and highlighted the need for reliable components in high-speed railway communication networks.
Their findings set a theoretical foundation for future research and practical applications in aerospace and railway systems, aiming to enhance performance and durability in demanding environments. Future work should focus on optimizing the design and materials of optical cables and connectors to improve their effectiveness in challenging environments.
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Journal Reference
Zhou, F., et al. (2024). Thermal stress simulation analysis of aerospace optical fibers and connectors and related extensions to high-speed railway area. High-speed Railway. DOI: 10.1016/j.hspr.2024.04.001, https://www.sciencedirect.com/science/article/pii/S2949867824000278
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