Optimization of pump-valve combined regulation strategy for electric pump-fed system in a hybrid rocket motor

Abstract

Advances in motor and battery technologies have driven the implementation of electric pumps in propulsion systems. Hybrid rocket motors, distinguished by simplified thrust modulation capabilities, substantially improve spacecraft maneuverability. The thrust regulation capacity can be enhanced through electric pump-fed systems that enable rapid, large-scale thrust adjustments. This study presents the design of a hydrogen peroxide electric pump-fed system for variable-thrust hybrid rocket motors. However, the system demonstrates significant parameter variations and encounters unsteady dynamic processes. During rapid parameter fluctuations, multiple subsystems demonstrate stiffness characteristics leading to numerical instability in solutions. Achieving accurate dynamic simulations while optimizing stable start-up processes and wide-range thrust regulation remains a critical challenge. In this research, simulation models of the basic components and the overall hydrogen peroxide electric pump-fed system were developed, with experimental validation performed through cold flow tests. Comparative analysis revealed less than 2 % deviation between experimental and simulated key parameters, confirming model validity. Building on validated multi-disciplinary models, an integrated optimization framework was established featuring: high-fidelity system modeling, efficient surrogate model development, multi-objective optimization, and multi-criteria evaluation for pump-valve coordinated control during start-up and thrust adjustment phases. Results indicate the multilayer perceptron-based optimization strategy decreases high-frequency current pulses by 27 % during start-up and reduces energy consumption by 5.4 % during thrust adjustment compared to conventional linear methods. These improvements significantly enhance system efficiency and operational safety. This work establishes a methodological framework for electric pump-fed system design and advances hybrid propulsion technology development.