Design and Analysis of Optical-Mechanical-Thermal Systems for a High-Resolution Space Camera

To meet the requirements of high resolution, compact size, and ultra-lightweight for micro-nano satellite optoelectronic payloads while ensuring high structural stability during launch and in-orbit operation, mirrors were designed with high surface accuracy. The opto-thermo-mechanical system of the space camera was designed and analyzed accordingly. First, an optical system was designed to achieve high resolution and a compact form factor. A coaxial triple-reflector configuration with multiple refractive paths was adopted, which significantly shortened the optical path and laid the foundation for a lightweight, compact structure. This design also defined the accuracy and tolerance requirements for the primary and secondary mirrors. Subsequently, mathematical models for topology optimization and dimensional optimization were established to optimize the design of the main support structure, primary mirror, and secondary mirror. Two design schemes for the main support structure and primary mirror were compared. Steady-state thermal analysis and thermal control design were carried out for both mirrors. Simulations were then performed on the main system (including the primary/secondary mirror assemblies and the main support structure). Under the combined effects of gravity, a 4 °C temperature increase, and an assembly flatness deviation of 0.01 mm, the surface accuracy of both mirrors, the displacement of the secondary mirror relative to the primary mirror reference, and the tilt angle all met the overall specification requirements. The system's first-order natural frequency was 156.731 Hz. After precision machining, fabrication, and assembly, wavefront aberration testing was conducted on the main system with the optical axis horizontal. Under gravity, the root mean square (RMS) wavefront error at the center of the field of view was 0.073λ, satisfying the specification of ≤1/14λ. The fundamental frequency measured during vibration testing was 153.09 Hz, which aligned closely with the simulated value and well exceeded the requirement of 100 Hz. Additionally, in-orbit imaging verification was conducted. All results satisfied the technical specifications of the satellite's overall requirements.