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Article(id=1249045447940186715, tenantId=1146029695717560320, journalId=1249024381851058248, issueId=1249045444509246013, articleNumber=null, orderNo=null, doi=10.11823/j.issn.1674-5795.2025.06.03, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1761753600000, receivedDateStr=2025-10-30, revisedDate=1763136000000, revisedDateStr=2025-11-15, acceptedDate=null, acceptedDateStr=null, onlineDate=1775725240930, onlineDateStr=2026-04-09, pubDate=1766851200000, pubDateStr=2025-12-28, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1775725240930, onlineIssueDateStr=2026-04-09, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1775725240930, creator=13701087609, updateTime=1775725240930, updator=13701087609, issue=Issue{id=1249045444509246013, tenantId=1146029695717560320, journalId=1249024381851058248, year='2025', volume='45', issue='6', pageStart='10', pageEnd='160', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=1, specialIssue=null, createTime=1775725240111, creator=13701087609, updateTime=1775726845897, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1249052179722609030, tenantId=1146029695717560320, journalId=1249024381851058248, issueId=1249045444509246013, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1249052179722609031, tenantId=1146029695717560320, journalId=1249024381851058248, issueId=1249045444509246013, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=41, endPage=49, ext={EN=ArticleExt(id=1249045448472863331, articleId=1249045447940186715, tenantId=1146029695717560320, journalId=1249024381851058248, language=EN, title=Design and verification of miniaturized space's optical payloads for batch production, columnId=1249045448120541791, journalTitle=Metrology & Measurement Technology, columnName=New Techniques for Precision Measurement, runingTitle=null, highlight=null, articleAbstract=

To address the bottlenecks of high cost and long development cycles in traditional aerospace product manufacturing, and to meet the urgent demand for batch production of space optical payloads in giant satellite constellations, this study adopts an integrated approach combining modular structural design, process optimization, and automated testing technology to develop a Maksutov⁃Cassegrain optical system with a small F⁃number and minute pixels. By enab⁃ling interchangeable assembly of lenses and focal plane components, along with integration into an automated assembly and testing line, the system achieves a ground pixel resolution of 4.5 m and a swath width of 13.5 km × 13.5 km at an orbital altitude of 500 km, with a total weight of only 1.1 kg. This approach has improved the overall development efficiency by 50%. The results provide crucial technical support for the low⁃cost, rapid, and batch⁃producible manufacturing of miniaturized space optical payloads.

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为突破传统航天产品高成本、长周期的研制瓶颈，满足巨型卫星星座对空间光学载荷批量化制造的迫切需求，本研究团队采用模块化结构设计、工艺优化与自动化测试技术相结合的方法，研制了一种小F数（光学系统焦距 / 通光口径）与微小像元结合的马克苏托夫⁃卡塞格林式光学系统，通过镜头与焦面组件互换装配及自动化总装总测线集成，在500 km轨道高度可实现地面像元分辨力4.5 m、幅宽13.5 km × 13.5 km的成像能力，整机重量仅1.1 kg，使整体研制效率提升50%。该成果为微小型空间光学载荷的低成本、快速批量化生产提供了重要的技术支撑。

, correspAuthors=丛杉珊, authorNote=null, correspAuthorsNote=
丛杉珊
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程鑫（1996－），男，工程师，主要研究方向为空间相机结构设计。

丛杉珊（1981－），女，正高级工程师，主要研究方向为空间遥感相机总体。

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caption=On⁃orbit imaging results, figureFileSmall=eLGW7P+fkOCeCUivKoiUlg==, figureFileBig=DONOZUzeXEGeveiON6Wt4A==, tableContent=null), ArticleFig(id=1249046224159056794, tenantId=1146029695717560320, journalId=1249024381851058248, articleId=1249045447940186715, language=CN, label=图11, caption=在轨成像结果, figureFileSmall=eLGW7P+fkOCeCUivKoiUlg==, figureFileBig=DONOZUzeXEGeveiON6Wt4A==, tableContent=null), ArticleFig(id=1249046224259720096, tenantId=1146029695717560320, journalId=1249024381851058248, articleId=1249045447940186715, language=EN, label=Tab.1, caption=

Design results of optical system

, figureFileSmall=null, figureFileBig=null, tableContent=
IndexFocal length / mmFWidth of picture / kmFOV / （°）
Parameter3606.513.5（@500 km）2.2
), ArticleFig(id=1249046224440075177, tenantId=1146029695717560320, journalId=1249024381851058248, articleId=1249045447940186715, language=CN, label=表1, caption=

光学系统设计结果

, figureFileSmall=null, figureFileBig=null, tableContent=
IndexFocal length / mmFWidth of picture / kmFOV / （°）
Parameter3606.513.5（@500 km）2.2
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Test results of centering adjustment accuracy

, figureFileSmall=null, figureFileBig=null, tableContent=
Surface numberSurface tilt / (″)
112.516
215.658
34.433
43.520
57.268
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定心调整精度测试结果

, figureFileSmall=null, figureFileBig=null, tableContent=
Surface numberSurface tilt / (″)
112.516
215.658
34.433
43.520
57.268
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Test results of optical payload wavefront aberration

, figureFileSmall=null, figureFileBig=null, tableContent=
FOVRMS
Central FOV0.044 7λ
Left FOV0.060 1λ
Right FOV0.049 9λ
Upper FOV0.044 5λ
Bottom FOV0.042 6λ
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光学载荷波像差测试结果

, figureFileSmall=null, figureFileBig=null, tableContent=
FOVRMS
Central FOV0.044 7λ
Left FOV0.060 1λ
Right FOV0.049 9λ
Upper FOV0.044 5λ
Bottom FOV0.042 6λ
), ArticleFig(id=1249046224888865723, tenantId=1146029695717560320, journalId=1249024381851058248, articleId=1249045447940186715, language=EN, label=Tab.4, caption=

Test results of MTF

, figureFileSmall=null, figureFileBig=null, tableContent=
StageAfter focal plane calibrationAfter acceptance level vibration
Upper0.143 50.142 9
Lower0.144 60.143 3
Central0.142 70.144 8
Left0.139 80.140 1
Right0.140 30.140 7
Average0.142 10.142 3
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MTF测试结果

, figureFileSmall=null, figureFileBig=null, tableContent=
StageAfter focal plane calibrationAfter acceptance level vibration
Upper0.143 50.142 9
Lower0.144 60.143 3
Central0.142 70.144 8
Left0.139 80.140 1
Right0.140 30.140 7
Average0.142 10.142 3
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Test results of dynamic MTF

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Calibration fieldDynamic MTFIndex
10.081 20.08
20.083 7
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动态传函测试结果

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Calibration fieldDynamic MTFIndex
10.081 20.08
20.083 7
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面向批产的微小型空间光学载荷设计与验证
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程鑫 , 丛杉珊 1 , 薛志鹏 , 刘金全 , 苗子健 , 王升
计测技术 | 精密测量新技术 2025,45(6): 41-49
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计测技术 | 精密测量新技术 2025, 45(6): 41-49
面向批产的微小型空间光学载荷设计与验证
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程鑫, 丛杉珊1, 薛志鹏, 刘金全, 苗子健, 王升
作者信息
  • 长光卫星技术股份有限公司，吉林长春130102

    • 程鑫（1996－），男，工程师，主要研究方向为空间相机结构设计。

    丛杉珊（1981－），女，正高级工程师，主要研究方向为空间遥感相机总体。

通讯作者:

丛杉珊
Design and verification of miniaturized space's optical payloads for batch production
Xin CHENG, Shanshan CONG1, Zhipeng XUE, Jinquan LIU, Zijian MIAO, Sheng WANG
Affiliations
  • Chang Guang Satellite Technology Co, LtdChangchun130102, China
出版时间: 2025-12-28 doi: 10.11823/j.issn.1674-5795.2025.06.03
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摘要
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为突破传统航天产品高成本、长周期的研制瓶颈，满足巨型卫星星座对空间光学载荷批量化制造的迫切需求，本研究团队采用模块化结构设计、工艺优化与自动化测试技术相结合的方法，研制了一种小F数（光学系统焦距 / 通光口径）与微小像元结合的马克苏托夫⁃卡塞格林式光学系统，通过镜头与焦面组件互换装配及自动化总装总测线集成，在500 km轨道高度可实现地面像元分辨力4.5 m、幅宽13.5 km × 13.5 km的成像能力，整机重量仅1.1 kg，使整体研制效率提升50%。该成果为微小型空间光学载荷的低成本、快速批量化生产提供了重要的技术支撑。

空间遥感技术  /  空间光学载荷  /  模块化设计  /  幅宽  /  批量化生产  /  研制效率  /  自动化总装总测

To address the bottlenecks of high cost and long development cycles in traditional aerospace product manufacturing, and to meet the urgent demand for batch production of space optical payloads in giant satellite constellations, this study adopts an integrated approach combining modular structural design, process optimization, and automated testing technology to develop a Maksutov⁃Cassegrain optical system with a small F⁃number and minute pixels. By enab⁃ling interchangeable assembly of lenses and focal plane components, along with integration into an automated assembly and testing line, the system achieves a ground pixel resolution of 4.5 m and a swath width of 13.5 km × 13.5 km at an orbital altitude of 500 km, with a total weight of only 1.1 kg. This approach has improved the overall development efficiency by 50%. The results provide crucial technical support for the low⁃cost, rapid, and batch⁃producible manufacturing of miniaturized space optical payloads.

space remote sensing technology  /  space optical payload  /  modular design  /  swath width  /  mass production  /  development efficiency  /  automated final assembly and testing
程鑫, 丛杉珊, 薛志鹏, 刘金全, 苗子健, 王升. 面向批产的微小型空间光学载荷设计与验证. 计测技术, 2025 , 45 (6) : 41 -49 . DOI: 10.11823/j.issn.1674-5795.2025.06.03
Xin CHENG, Shanshan CONG, Zhipeng XUE, Jinquan LIU, Zijian MIAO, Sheng WANG. Design and verification of miniaturized space's optical payloads for batch production[J]. Metrology & Measurement Technology, 2025 , 45 (6) : 41 -49 . DOI: 10.11823/j.issn.1674-5795.2025.06.03
正文
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0　引言
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近年来，随着空间遥感技术的飞速发展和商业航天模式的兴起，以通信、遥感、导航为代表的巨型卫星星座建设进入了高速发展期。空间应用模式正经历从“单颗大卫星”向“集群化小卫星”的重大转变。在此背景下，作为卫星“眼睛”的空间光学载荷，其研制模式也面临着根本性变革：传统定制化、长周期、高成本的研制路径已难以满足星座计划对上百甚至上千颗卫星快速、低成本部署的迫切需求。
大口径长焦距［1］空间光学载荷具有分辨力高、幅宽大的特点，但受限于体积大、生产周期长、成本高等因素，难以实现批量化快速生产。相比之下，微纳遥感观测卫星［2-3］凭借体积小、成本低、研制周期短等优势，已经成为提高遥感信息时间分辨力的重要发展方向。微小型空间相机作为微纳遥感卫星的核心光学载荷，承担着对地遥感观测的重要任务。因此，实现微小型空间光学载荷的批量化制造，已成为推动太空经济商业化、迈向大规模空间感知时代的必然选择和核心挑战。
在光学载荷微小型化技术领域，国内外研究已开展了多项研究工作。孙景旭等人［4］设计的轻小型全铝高分相机采用RC+补偿组的光学结构和全铝材料一体化设计，整机重量2 kg，在500 km轨道上可实现3.48 m地面像元分辨力，成像幅宽15 km × 15 km。王上等人［5］提出一种空间相机光机结构设计，主反射镜有效通光口径118 mm，F数6.5，光机结构整体质量为1.52 kg，实现了光机结构微型化与高轻量化。美国行星实验室研制的“DOVE”系列微卫星［6-8］采用马克苏托夫⁃卡塞格林光学系统［9］，配置1 100万像素的电荷耦合器件（Charge⁃Coupled Device， CCD），可实现3 ~ 5 m地面分辨力，卫星平台仅重5 kg，目前在轨200余颗。然而，现有研究多聚焦于微小型光学载荷的性能优化设计，对其批量化制造与测试技术鲜有涉及。
本文以面向批产的某型号光学遥感卫星微型化有效载荷为研究对象，设计了一款基于马克苏托夫⁃卡塞格林光学系统的微小型空间光学载荷，重点突破了模块化设计、定心装配工艺和自动化测试等关键技术，使研制效率较传统方法提升50%，为空间光学载荷的批量化生产提供了有效的技术解决方案。
1　微小型空间光学载荷总体设计
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微小型空间光学载荷采用小F数的马克苏托夫⁃卡塞格林光学系统，如图1所示。该光学载荷结构主要包括主镜组件、前端透镜组件（中心镀次镜反射膜）、校正镜组件、焦面组件及遮光罩组件，整体采用定心设计及装配方案。
在光学系统选型过程中，对比分析了折射式、折反式和全反式3种形式的空间光学系统。折射式系统受光学材料限制，难以适应宽波段范围的长焦距大视场光学系统，且长焦折射系统的二级光谱校正困难［10］。以离轴三反式为代表的全反式光学系统虽然性能优异，但系统尺寸和重量较大，加工装调难度高、周期长［11］。折返式光学系统则具有长焦距下极致紧凑与轻量化的优势。
综合考虑上述因素，最终选择同轴两反加校正镜结构（折返式）的光学系统设计方案。系统采用2片校正镜作为前端透镜，有效校正球差并提高成像质量。为进一步降低加工难度和成本，系统采用全球面结构，避免非球面加工周期长、成本高且需要补偿器检测等问题［12］。
光学系统设计结构及关键参数如图2所示， 图2（a）为光学系统的结构形式，光学系统由主镜、次镜反射膜及5个透镜组成（从左至右依次为透镜1至透镜5）；图2（b）显示，奈奎斯特频率处的平均调制传递函数（Modulation Transfer Function， MTF）为0.22@156 lp / mm；图2（c）表明，全视场光斑的均方根（Root Mean Square， RMS）半径值不超过3.2 μm，小于艾里斑半径；图2（d）场曲畸变设计结果显示，全视场最大畸变不超过0.02%。
如表1所示，光学系统在配备3.2 μm像元尺寸面阵CMOS探测器的基础上，在500 km轨道高度可实现4.5 m的地面像元分辨力和13.5 km × 13.5 km的成像幅宽，系统的F数为6.5、焦距为360 mm、全视场角为Φ2.2°。
2　光机结构模块化设计
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面向批量化的微小型光学载荷采用模块化结构设计，依据光机与光电的功能属性，将光学载荷分为镜头模块与焦面组件模块2大部分。镜头模块由主镜组件、前端透镜组件（中心镀次镜反射膜）、校正镜组件、承力筒组件组成，并基于定心车装配工艺进行优化设计，以适应批量化生产需求。
如图3（a）所示，主镜组件由镜体和柔性支撑2部分组成。镜体材料选用微晶玻璃，柔性支撑材料选用与微晶线胀匹配的殷钢（4J32）。主镜背部中心轴与柔性支撑通过环氧胶粘接，柔性环节设计可适应微重力及复杂空间热环境，保证光学载荷在轨成像质量的稳定性。
次镜及校正镜补偿组分别如图3（b）和3（c）所示。次镜即为透镜2的中心镀膜区域，通光口径为22 mm。透镜1与透镜2均采用镜座压圈的支撑方式，构成入射补偿组；另外3片透镜则组成焦前补偿组，其口径均小于20 mm，每个透镜均有独立的支撑镜座，采用定心设计与定心装配工艺，将同轴装配精度控制在10 μm 以内，偏心误差小于30″。
承力结构如图3（d）所示，基于基准传递的定心调整工艺路线，设计为筒式结构，材料为钛合金，承力结构为主镜、透镜补偿组、内部遮光罩组件以及焦平面组件提供安装接口，具有较高精度及刚度。
3　集成及测试
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3.1　光机系统定心装配及测试
前端透镜组件采用定心加工工艺［13］。该工艺通过自准直仪与附加镜头检测镜片的球心像［14］，将镜片光轴与定心车转轴调整至同轴后，精密修切镜座外圆与端面，确保镜片光轴与镜座机械轴统一［15］，并保证镜片间空气间隔，大幅提高了装调效率和装配精度，工艺流程如图4所示，定心加工设备如图5所示。
定心调整过程如图6所示，主镜与柔节粘接固化后，通过研磨工艺保证主镜中心孔与柔节端面垂直度优于0.01 mm，进而保证主镜光轴与柔节端面垂直，为后续主镜组件装调提供机械基准。
将主镜组件与前端透镜组件装配至承力筒内，将承力筒装夹至定心仪工作台，以前端透镜组件内透镜光轴为基准找正承力筒，通过顶丝调节主镜偏心，将主镜球心调整至透镜光轴，保证主镜光轴与前端透镜组光轴同轴，最终系统内各镜面装调精度测试结果如表2所示。
光学载荷系统的波像差和调制MTF可以客观地评价光学系统的成像性能［16-17］。使用干涉仪测试光学载荷镜头模块装调后中心视场和边缘视场的波像差，测试结果如表3所示。干涉云图如图7所示，光学载荷中心视场波像差RMS值为λ / 22.4（波长λ = 632.8 nm），所有视场系统波像差均小于λ / 16.6，系统成像质量接近衍射极限。
3.2　系统总装及MTF测试
搭建了自动化总装总测系统，其测试逻辑如图8所示，相机（光学载荷）置于两自由度转台上，通过计算机控制端实现相机上下电、视场切换、成像控制与处理以及靶标位置调整等闭环控制环节。基于该系统实现光学载荷的焦面标定和自动化测试。
光学载荷在自动化总装总测生产线上完成总装与总测，如图9所示。首先，通过平行光管将条纹靶标成像到光学载荷焦面上，软件自动计算奈奎斯特频率处的MTF值。然后通过光管的靶标自动调节机构，调节靶标轴向位置；通过二维视场调节转台切换光学载荷视场，获取不同视场下，不同靶标位置的MTF值。最后，通过Matlab拟合出最佳焦面位置。根据拟合结果调整垫片并固定焦面位置，完成焦面标定。MTF测试结果如表4所示，在经过焦面标定和验收级振动试验后，光学载荷各视场MTF值稳定，表明其具有良好的机械稳定性和环境适应性。
传统光学载荷研制周期为2个月，包括组件研制、光学装调、垫片连接等多环节人工参与耗时过程，本文通过模块化设计实现镜头与焦面组件的互换装配，依托定心装配工艺显著提升装调效率，最终在自动化总装总测系统上完成系统集成与焦面标定，研制周期缩短至1个月，且无需投入大量人员，使整体研制效率提升50%。
4　在轨验证
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该微小型光学载荷在通过各项地面验收测试后，已搭载某型号卫星平台成功发射至预定轨道，并顺利完成在轨调焦与成像测试。图10和表5为相机分别对2个目标靶场成像的刃边测试计算过程，对2个目标靶场测试的动态MTF结果均大于0.08，满足系统指标。图11为该载荷对国内某区域的在轨成像结果，光学载荷能量集中度可达0.8，成像效果良好。
5　结论
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本文面向批量化生产需求，开展了微小型空间光学载荷的集成设计与验证研究。通过模块化结构设计、定心装配工艺优化和自动化测试系统的综合应用，成功研制出重量仅1.1 kg、在500 km轨道高度实现4.5 m地面分辨力的微小型光学载荷，为大规模星座部署提供了可行的技术路径。
面向批产的设计策略包括3方面，其一，采用模块化设计理念，将光学载荷分解为镜头模块和焦面模块，实现了组件的快速互换与高效装配；其二，采用定心车装配工艺，将同轴装配误差控制在10 μm以内，满足光学系统设计指标的同时显著提升了装调效率；其三，构建自动化总装总测系统，实现了总装总测流程化作业，大幅降低了人工干预带来的质量波动。
测试结果表明：该光学载荷各视场波像差小于λ / 16.6，MTF值大于0.14，具备良好的成像性能与力学稳定性。在轨成像验证进一步表明：载荷动态传函高于0.08，且能量集中度达0.8，成像效果满足任务要求。
综上所述，本研究通过模块化、工艺创新和自动化测试的系统性集成，实现了微小型空间光学载荷从“定制开发”向“批量生产”的转变，整体研制效率提升50%。该技术路线不仅适用于当前微纳卫星星座的建设需求，也为未来大规模空间感知系统的低成本、快速部署提供了重要借鉴。后续将进一步完善工艺数据库和自适应装配策略，推动空间光学载荷制造向智能化、柔性化方向发展。
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2025年第45卷第6期
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doi: 10.11823/j.issn.1674-5795.2025.06.03
  • 接收时间：2025-10-30
  • 首发时间：2026-04-09
  • 出版时间：2025-12-28
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  • 收稿日期：2025-10-30
  • 修回日期：2025-11-15
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    长光卫星技术股份有限公司，吉林长春130102

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丛杉珊
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2种不同金属材料的力学参数
科
Family		 属数
Number of
genus		 种数
Number of
species		 占总种数比例
Percentage of
total species (%)		 属
Genus		 种数
Number of
species		 占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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