In-situ deformation correction-based gradient curing bonding device and bonding method for mirrors

Abstract

This invention proposes a gradient curing and bonding device and method for reflectors based on in-situ deformation correction, belonging to the field of optical precision manufacturing technology. This invention solves the problems of interfacial thermal stress mismatch and interfacial bonding dynamics defects existing in traditional bonding and curing processes. It includes a temperature control chamber, a control center, and an industrial camera, laser interferometer, a first position adjustment mechanism, a second position adjustment mechanism, a positioning and clamping mechanism, a force-thermal coupling control module, and an adhesive mechanism, all located inside the temperature control chamber and connected to the control center. The main control unit controls the movement of the composite temperature control component and the piezoelectric ceramic actuator. The composite temperature control component controls the curing temperature of the adhesive layer, and the piezoelectric ceramic actuator applies a compensating force to the reflector. This invention is used for the curing and bonding of reflectors and reflector frames.

Description

Technical Field

[0001] This invention relates to a gradient curing bonding device and method for reflectors based on in-situ deformation correction, belonging to the field of optical precision manufacturing technology. Background Technology

[0002] In high-precision spacecraft payloads and high-energy laser systems, the reliability of the bonding interface between the mirror and the metal base (i.e., the mirror mount) directly affects the accuracy and operational stability of the optical system. However, traditional curing processes lack real-time positioning accuracy and stress control mechanisms, leading to the following defects in the mirror bonding process:

[0003] 1. Interfacial thermal stress mismatch:

[0004] Traditional bonding and curing processes lack temperature gradient control, leading to nonlinear imbalances in the adhesive's phase transformation process. The non-equilibrium glass transition induced by the decline in polymer chain mobility causes the adhesive layer to become brittle and fail, unable to accommodate the differences in thermal expansion coefficients between dissimilar materials. Residual stress evolves into localized shear stress concentration under thermal shock, becoming a driving force for the initiation and propagation of microcracks, ultimately resulting in irreversible deterioration of the parallelism between the bonding surfaces of the mirror and the mirror frame after bonding.

[0005] 2. Interfacial bonding dynamics defects:

[0006] Temperature control timing mismatch leads to an imbalance in the wetting dynamics of the adhesive on the substrate, resulting in a weak, poorly bonded boundary layer. This defect significantly reduces the interfacial bonding energy, lowers the critical energy threshold for triggering interfacial debonding under high-frequency dynamic loads, and greatly increases the risk of debonding.

[0007] 3. Uncontrollable stress accumulation:

[0008] Traditional bonding and curing processes lack a real-time in-situ feedback mechanism. The shrinkage stress of the adhesive layer and the thermal stress are superimposed nonlinearly in the time domain, causing an offset angle at the mirror-base interface and reducing the accuracy of the optical system. Furthermore, the unreleased residual stress couples with external loads during service, accelerating interface fatigue failure.

[0009] 4. Loss of control over adhesive layer uniformity:

[0010] Traditional bonding and curing processes use manual dispensing, but manual dispensing results in uneven adhesive layer thickness distribution and micro-bubble defects, causing the elastic modulus of the adhesive layer to become discrete. Under dynamic conditions, the mechanical properties decrease exponentially, which cannot meet the stringent requirements of high-precision optical systems.

[0011] Therefore, there is an urgent need for a new type of gradient curing bonding device and bonding method for reflectors to solve the above-mentioned problems existing in traditional reflector bonding processes. Summary of the Invention

[0012] The present invention aims to solve the aforementioned technical problems of traditional mirror bonding technology, and thereby provides a mirror gradient curing bonding device and bonding method based on in-situ deformation correction.

[0013] The technical solution adopted by the present invention to solve the above-mentioned technical problems is as follows:

[0014] A gradient curing and bonding device for a reflector based on in-situ deformation correction includes a temperature control chamber, a control center, and an industrial camera, a laser interferometer, a first position adjustment mechanism, a second position adjustment mechanism, a positioning and clamping mechanism, a force-thermal coupling control module, and an adhesive mechanism, all located inside the temperature control chamber and signal-connected to the control center. The industrial camera and laser interferometer are mounted parallel to each other on top of the first position adjustment mechanism, and the reflector frame is mounted on top of the second position adjustment mechanism. The first and second position adjustment mechanisms are arranged side-by-side along the length of the temperature control chamber. The force-thermal coupling control module is located on the side of the reflector frame furthest from the laser interferometer.

[0015] Adhesive is applied to the mirror frame using an adhesive bonding mechanism.

[0016] The mirror is clamped to the mirror mount using a positioning and clamping mechanism.

[0017] The force-thermal coupling control module includes a control body, a composite temperature control component, and a piezoelectric ceramic actuator. The control body controls the operation of the composite temperature control component and the piezoelectric ceramic actuator. The composite temperature control component controls the curing temperature of the adhesive layer. The piezoelectric ceramic actuator applies a compensating force to the reflector.

[0018] Furthermore, the positioning and clamping mechanism includes a first driving mechanism, a first robotic arm, and a clamping body. The first driving mechanism controls the clamping body to adjust its angle through the first robotic arm. The clamping body includes a bracket, a first telescopic adjustment rod, multiple second telescopic adjustment rods, and multiple clamping blocks. The bracket is rotatably mounted at the end of the first robotic arm. The first telescopic adjustment rod is mounted on the bracket on the side away from the first robotic arm and is coaxially arranged with the rotation center of the bracket. The multiple second telescopic adjustment rods are arranged circumferentially along the bracket, and each second telescopic adjustment rod is rotatably connected to the bracket. The multiple clamping blocks are correspondingly mounted on the ends of the second telescopic adjustment rods away from the bracket.

[0019] Furthermore, the bracket includes four third telescopic adjustment rods arranged in an X-shape.

[0020] Furthermore, a secondary telescopic adjustment mechanism is also provided between the clamping block and the second telescopic adjustment rod.

[0021] Furthermore, a V-shaped through groove is provided on the clamping surface of the clamping block.

[0022] Furthermore, the composite temperature control component includes a second robotic arm and a temperature control plate installed at the end of the second robotic arm, and the control body adjusts the position of the temperature control plate through the second robotic arm.

[0023] Furthermore, the piezoelectric ceramic actuator includes a third robotic arm and a piezoelectric ceramic column installed at the end of the third robotic arm, with a second flexible pad installed on one end of the piezoelectric ceramic column near the reflector.

[0024] Furthermore, the adhesive mechanism includes a liquid storage chamber, a second drive mechanism, a fourth robotic arm, and a dispensing nozzle. The second drive mechanism is mounted on the liquid storage chamber, and the fourth robotic arm has a flow channel inside. The second drive mechanism controls the dispensing nozzle to adjust its position through the fourth robotic arm.

[0025] Furthermore, the dispensing nozzle includes a straight cylindrical section and a conical section that are connected and fixed end to end. The conical section is provided with a clamping mechanism on its outside. The clamping mechanism includes multiple linear motors and multiple clamping blocks. The multiple clamping blocks are arranged circumferentially along the conical section. The sliding control of the multiple clamping blocks along the generatrix direction of the conical section is realized by the multiple linear motors.

[0026] A gradient curing bonding method for a reflector, using the aforementioned gradient curing bonding device for a reflector, includes the following steps:

[0027] First, the bonding surfaces between the reflector and the reflector frame are pretreated;

[0028] After pretreatment, the dispensing mode is determined based on the difference in the coefficient of thermal expansion between the reflector material and the reflector frame material, and the adhesive mechanism is activated to perform dispensing.

[0029] Then, the positioning and clamping mechanism is activated to perform the mirror positioning and calibration operation;

[0030] Finally, the composite temperature control component is activated to perform the stepped curing procedure;

[0031] During the bonding process, the position and angle changes of the reflector are monitored in real time by a laser interferometer. When the position and angle changes of the reflector exceed the safety threshold, the force-thermal coupling control module is automatically triggered.

[0032] Compared with the prior art, the present invention has the following advantages:

[0033] A temperature-controlled chamber provides a sealed and constant-temperature environment for the bonding process of the reflector, thus isolating it from external environmental and temperature interference.

[0034] An industrial camera is used to photograph the edge of the reflector and the positioning marks on the reflector frame. The center offset is calculated by an image processing algorithm, which drives the first and second position adjustment mechanisms to perform submicron-level position compensation.

[0035] In the dispensing process, the adhesive mechanism applies adhesive to the interface between the mirror frame and the mirror during the dispensing process. Compared with the existing manual dispensing method, the adhesive layer thickness distribution is more uniform. Furthermore, this invention can select the dispensing mode based on the differences in the thermal expansion system of the materials. For example, for combinations with low expansion coefficient differences, continuous ring dispensing is used to reduce stress concentration; for combinations with high expansion coefficient differences, a discrete point layout is used to reserve space for thermal deformation compensation.

[0036] The present invention provides a gradient curing and bonding device for a reflector based on in-situ deformation correction. By employing a positioning and clamping mechanism, it can meet the rapid clamping requirements of reflectors of different specifications and sizes, and ensure the positioning accuracy between the reflector and the reflector frame.

[0037] By utilizing the adjustment function of the force-thermal coupling control module, the interface temperature gradient is precisely controlled to match the adhesive curing kinetics, minimizing internal stress accumulation and dynamically correcting the bonding position between the reflector and the mirror frame, ensuring assembly accuracy. Specifically, the use of a composite temperature control component enables precise control of the interface temperature, achieving gradient curing and effectively alleviating interface thermal stress. Combined with real-time monitoring of the bonding position between the reflector and the mirror frame using a laser interferometer, and the linkage of a piezoelectric ceramic actuator to dynamically compensate for curing shrinkage deformation, the parallelism of the bonding surfaces of the reflector and the mirror frame after bonding meets the requirements of the optical system.

[0038] The present invention provides a gradient curing and bonding device for reflectors based on in-situ deformation correction. Throughout the bonding process, the position and angle changes of the reflector are monitored in real time by a laser interferometer. When the position and angle changes of the reflector exceed the safety threshold, the force-thermal coupling control module is automatically triggered through a negative feedback adjustment loop to dynamically correct the deformation deviation, optimize the interface temperature field distribution, and achieve real-time in-situ dynamic compensation for curing shrinkage deformation. This ensures that the parallelism between the bonding surface of the reflector and the reflector frame after bonding continues to meet the stringent requirements of the optical system. Attached Figure Description

[0039] Figure 1 This is a first three-dimensional structural schematic diagram of the reflector gradient curing and bonding device based on in-situ deformation correction of the present invention (temperature control box not shown).

[0040] Figure 2 This is a schematic diagram of the second three-dimensional structure of the reflector gradient curing and bonding device based on in-situ deformation correction of the present invention (temperature control box not shown).

[0041] Figure 3 This is a schematic diagram of the three-dimensional structure of the temperature control box;

[0042] Figure 4 A three-dimensional structural diagram of the positioning and clamping mechanism;

[0043] Figure 5 This is a schematic diagram of the first three-dimensional structure of the clamping body;

[0044] Figure 6 This is a schematic diagram of the second three-dimensional structure for holding the main body;

[0045] Figure 7 This is a schematic diagram of the first three-dimensional structure of the force-thermal coupling control module.

[0046] Figure 8 This is a schematic diagram of the second three-dimensional structure of the force-thermal coupling control module;

[0047] Figure 9 This is a three-dimensional structural diagram of the adhesive mechanism;

[0048] Figure 10 This is a half-sectional view of the dispensing nozzle;

[0049] Figure 11 This is a schematic diagram illustrating the working principle of the present invention.

[0050] In the picture:

[0051] 100. Reflector; 200. Reflector frame; 1. Temperature control box; 2. Industrial camera; 3. Laser interferometer; 4. First position adjustment mechanism; 41. Lifting frame; 42. Lateral moving platform; 5. Second position adjustment mechanism; 6. Positioning and clamping mechanism; 61. First drive mechanism; 62. First robotic arm; 63. Bracket; 64. First telescopic adjustment rod; 65. Second telescopic adjustment rod; 66. Clamping block; 661. V-shaped through groove; 67. First flexible pad; 68. Secondary telescopic adjustment mechanism; 681. Mounting plate; 682. Fourth telescopic adjustment rod; 69. Third telescopic adjustment rod 7. Force-thermal coupling control module; 71. Control body; 72. Composite temperature control component; 721. Second robotic arm; 722. Temperature control board; 723. Cooling block; 724. Heating block; 73. Piezoelectric ceramic actuator; 731. Third robotic arm; 732. Piezoelectric ceramic column; 733. Second flexible pad; 8. Adhesive mechanism; 81. Liquid storage chamber; 82. Second drive mechanism; 83. Fourth robotic arm; 84. Dispensing nozzle; 841. Straight cylinder section; 842. Conical cylinder section; 843. Linear motor; 844. Clamping block; 845. Limiting block; 846. Slide rail; 9. First vibration isolation pad. Detailed Implementation

[0052] Specific implementation method one: Combining Figures 1-11This description of embodiments provides a clear and complete description of the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0053] It should be noted that the descriptions of "front," "rear," "left," "right," "inner," "outer," "left side," "right side," "upper part," "lower part," "top," and "bottom" in this invention are defined based on the orientation or positional relationships shown in the accompanying drawings. They are merely for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the described structure must be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0054] In the description of this invention, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0055] A gradient curing and bonding device for a reflector based on in-situ deformation correction includes a temperature control chamber 1, a control center, and an industrial camera 2, a laser interferometer 3, a first position adjustment mechanism 4, a second position adjustment mechanism 5, a positioning and clamping mechanism 6, a force-thermal coupling control module 7, and an adhesive bonding mechanism 8, all located inside the temperature control chamber 1 and signal-connected to the control center. The industrial camera 2 and laser interferometer 3 are mounted parallel to each other on top of the first position adjustment mechanism 4, and the reflector frame 200 is mounted on top of the second position adjustment mechanism 5. The first position adjustment mechanism 4 and the second position adjustment mechanism 5 are arranged side-by-side along the length of the temperature control chamber 1. The force-thermal coupling control module 7 is located on the side of the reflector frame 200 furthest from the laser interferometer 3.

[0056] Adhesive is applied to the mirror frame 200 by the adhesive bonding mechanism 8.

[0057] The positioning and clamping mechanism 6 is used to clamp the reflector 100 to the reflector frame 200.

[0058] The force-thermal coupling control module 7 includes a control body 71, a composite temperature control component 72, and a piezoelectric ceramic actuator 73. The control body 71 controls the operation of the composite temperature control component 72 and the piezoelectric ceramic actuator 73. The composite temperature control component 72 controls the curing temperature of the adhesive layer. The piezoelectric ceramic actuator 73 applies a compensating force to the reflector 100.

[0059] The control center is used to receive signals from each component and send corresponding instructions to control the actions of each component based on the received signals. The components include a temperature control box 1, an industrial camera 2, a laser interferometer 3, a first position adjustment mechanism 4, a second position adjustment mechanism 5, a positioning clamping mechanism 6, a force-thermal coupling control module 7, and an adhesive mechanism 8.

[0060] The temperature control chamber 1 provides a sealed and constant temperature environment for the bonding process of the reflector 100, so as to isolate the interference of the external environment and temperature.

[0061] The industrial camera 2 is used to capture images of the edge of the reflector 100 and the positioning marks of the reflector frame 200. The center offset is calculated by the image processing algorithm, and the first position adjustment mechanism 4 and the second position adjustment mechanism 5 are driven to perform submicron-level position compensation.

[0062] In the dispensing process, the adhesive mechanism 8 applies adhesive to the interface on the mirror frame 200 that is bonded to the mirror 100. Compared with the existing manual dispensing method, the adhesive layer thickness distribution is more uniform. Furthermore, the present invention can select the dispensing mode based on the differences in the thermal expansion system of the materials. For example, for combinations with low expansion coefficient differences, continuous ring dispensing is used to reduce stress concentration; for combinations with high expansion coefficient differences, a discrete layout is used to reserve space for thermal deformation compensation.

[0063] The present invention provides a gradient curing and bonding device for a reflector based on in-situ deformation correction. By employing a positioning and clamping mechanism 6, it can meet the rapid clamping requirements of reflectors 100 of different specifications and sizes, and ensure the positioning accuracy between the reflector 100 and the reflector frame 200.

[0064] The adjustment function of the force-thermal coupling control module 7 precisely controls the interface temperature gradient, matches the adhesive curing kinetics, minimizes internal stress accumulation, and dynamically corrects the bonding position between the reflector 100 and the mirror frame 200, ensuring assembly accuracy. Specifically, the composite temperature control component 72 can precisely control the interface temperature to achieve gradient curing, effectively alleviating interface thermal stress. Combined with the laser interferometer 3, which monitors the bonding position between the reflector 100 and the mirror frame 200 in real time, and links the piezoelectric ceramic actuator 73 to dynamically compensate for curing shrinkage deformation, it ensures that the parallelism of the bonding surfaces of the reflector 100 and the mirror frame 200 after bonding meets the requirements of the optical system.

[0065] The present invention provides a gradient curing and bonding device for a reflector based on in-situ deformation correction. Throughout the bonding process, the laser interferometer 3 monitors the surface deformation (PV value) of the reflector 100 in real time. When the position and angle changes of the reflector 100 exceed the safety threshold, the force-thermal coupling control module 7 is automatically triggered through the negative feedback adjustment loop to dynamically correct the deformation deviation, optimize the interface temperature field distribution, and realize real-time in-situ dynamic compensation for curing shrinkage deformation. This ensures that the parallelism between the bonding surfaces of the reflector 100 and the reflector frame 200 after bonding continues to meet the stringent requirements of the optical system.

[0066] Preferably, both the first position adjustment mechanism 4 and the second position adjustment mechanism 5 are slidably arranged along the length of the temperature control box 1. The first position adjustment mechanism 4 and the bottom of the temperature control box 1, as well as the second position adjustment mechanism 5 and the bottom of the temperature control box 1, can be connected by electrically controlled slide rails, allowing the first position adjustment mechanism 4 and the second position adjustment mechanism 5 to slide or stop along the length of the temperature control box 1. This design facilitates adjustment of the distance between the first position adjustment mechanism 4 and the second position adjustment mechanism 5, thereby enabling adjustment of the distance between the laser interferometer 3 and the reflector frame 200.

[0067] A first vibration isolation pad 9 is arranged at the top of the first position adjustment mechanism 4. The industrial camera 2 and the laser interferometer 3 are both mounted on the first vibration isolation pad 9 to further ensure the installation accuracy of the reflector 100. Similarly, a second vibration isolation pad is preferably arranged at the top of the second position adjustment mechanism 5 to ensure the stability of the reflector frame 200 above it, thereby further ensuring the installation accuracy of the reflector 100. Both the first position adjustment mechanism 4 and the second position adjustment mechanism 5 are used to achieve two-dimensional position adjustment. The first position adjustment mechanism 4 includes a lifting frame 41 and a transverse moving platform 42 fixed to the top of the lifting frame 41. The second position adjustment mechanism 5 has the same structure as the first position adjustment mechanism 4.

[0068] The positioning and clamping mechanism 6 includes a first drive mechanism 61, a first robotic arm 62, and a clamping body. The first drive mechanism 61 controls the clamping body to adjust its angle via the first robotic arm 62. The clamping body includes a bracket 63, a first telescopic adjustment rod 64, multiple second telescopic adjustment rods 65, and multiple clamping blocks 66. The bracket 63 is rotatably mounted at the end of the first robotic arm 62. The first telescopic adjustment rod 64 is mounted on the bracket 63 on the side away from the first robotic arm 62 and is coaxially arranged with the rotation center of the bracket 63. The multiple second telescopic adjustment rods 65 are arranged circumferentially around the bracket 63, and each second telescopic adjustment rod 65 is rotatably connected to the bracket 63. The multiple clamping blocks 66 are mounted one-to-one on the ends of the second telescopic adjustment rods 65 away from the bracket 63. This design achieves clamping of the reflector 100 through the multiple circumferentially arranged clamping blocks 66. Both the first telescopic adjustment rod 64 and the second telescopic adjustment rods 65 are piezoelectric ceramic rods. Preferably, the multiple second telescopic adjustment rods 65 are evenly distributed circumferentially around the bracket 63 to ensure more uniform force on the reflector 100. The number of second telescopic adjustment rods 65 is preferably four, and the bracket 63 is preferably an X-shaped structure. This reduces the weight of the device while minimizing obstruction of the reflector 100, making it easier to monitor the deformation of the reflector 100 surface during the bonding process. The rotatable connection between the second telescopic adjustment rods 65 and the bracket 63 facilitates adjustment of the clamping angle of the reflector 100. The rotatable connection between the second telescopic adjustment rods 65 and the bracket 63 is preferably achieved through a rotary motor, facilitating clamping operations on reflectors 100 of different shapes. The cooperation of the first telescopic adjustment rod 64 and multiple second telescopic adjustment rods 65 ensures uniform force distribution on the reflector 100 during the bonding process between the reflector 100 and the reflector frame 200. A first flexible pad 67 is installed on the end of the first telescopic adjustment rod 64 facing the reflector 100 to achieve flexible contact between the first telescopic adjustment rod 64 and the reflector 100, thereby preventing damage to the reflector 100 surface during installation. The first flexible pad 67 is preferably made of rubber. Pressure sensors and displacement sensors are installed inside the first telescopic adjustment rod 64 and each of the second telescopic adjustment rods 65 to achieve precise adjustment. The first robotic arm 62 includes a first arm and a second arm arranged in an L-shape. The two arms are rotatably connected by a joint motor. Joint motors are also provided between the first arm and the first drive mechanism 61, and between the second arm and the clamping body to achieve rotatable connection. This facilitates the angle adjustment of the clamping body. Preferably, the first and second arms can also be telescopic, thereby better realizing the position adjustment between the reflector 100 and the reflector frame 200.

[0069] The bracket 63 includes four third telescopic adjustment rods 69 arranged in an X-shape. This design allows each third telescopic adjustment rod 69 to be telescopically adjustable along its length, facilitating the clamping of reflectors 100 of different sizes. Alternatively, two third telescopic adjustment rods 69 can be arranged in an X-shape, in which case each rod 69 can be bidirectionally telescopically adjustable along its length. The third telescopic adjustment rods 69 can be any rod-shaped structure capable of telescopic adjustment, or they can be piezoelectric ceramic rod structures. Each third telescopic adjustment rod 69 is equipped with a pressure sensor and a displacement sensor for precise adjustment.

[0070] A secondary telescopic adjustment mechanism 68 is also connected between the clamping block 66 and the second telescopic adjustment rod 65. This design allows for primary adjustment of the installation distance between the reflector 100 and the reflector frame 200 via the second telescopic adjustment rod 65, and secondary precision adjustment via the secondary telescopic adjustment mechanism 68, thereby effectively improving the installation accuracy of the reflector 100 and the reflector frame 200. The secondary telescopic adjustment mechanism 68 includes a mounting plate 681 and two fourth telescopic adjustment rods 682. The mounting plate 681 is fixed to the end of the second telescopic adjustment rod 65 away from the bracket 63, and the two fourth telescopic adjustment rods 682 are fixed between the clamping block 66 and the mounting plate 681. Preferably, the two fourth telescopic adjustment rods 682 are evenly distributed between the clamping block 66 and the mounting plate 681 to further ensure clamping accuracy. Each fourth telescopic adjustment rod 682 is equipped with a pressure sensor and a displacement sensor to achieve precise adjustment.

[0071] A V-shaped through groove 661 is provided on the clamping surface of the clamping block 66. With this design, it is preferable that the corner of the V-shaped through groove 661 is a right angle, so as to achieve stable clamping of the square reflector 100.

[0072] The composite temperature control component 72 includes a second robotic arm 721 and a temperature control plate 722 mounted at the end of the second robotic arm 721. The control body 71 adjusts the position of the temperature control plate 722 via the second robotic arm 721. With this design, the temperature control plate 722 includes a plate body and several cooling blocks 723 and several heating blocks 724 mounted on the plate body. The cooling blocks 723 and heating blocks 724 are arranged alternately, enabling rapid temperature adjustment within the range of sub-zero and above-zero temperatures using a single temperature control plate 722, covering an extreme temperature range of -40℃ to +150℃. The control body 71 is preferably positioned on the side of the reflector frame 200 away from the reflector 100, and the composite temperature control component 72 is preferably positioned between the control body 71 and the reflector frame 200. The second robotic arm 721 may include a third to a fifth arm, connected end-to-end in a Z-shape. Each pair of arms is rotatably connected by a joint motor. Joint motors can also be installed between the third arm and the control body 71, and between the fifth arm and the temperature control plate 722, to achieve rotatable connections. During the bonding process, the temperature control plate 722 is attached to the back of the reflector frame 200, i.e., the side away from the reflector 100. Preferably, each arm on the second robotic arm 721 may also have a telescopic function, thereby better enabling position adjustment of the temperature control plate 722.

[0073] The piezoelectric ceramic actuator 73 includes a third robotic arm 731 and a piezoelectric ceramic column 732 mounted at the end of the third robotic arm 731. A second flexible pad 733 is mounted on the end of the piezoelectric ceramic column 732 near the reflector 100. This design allows the piezoelectric ceramic column 732 to apply a compensating force to the reflector 100, further ensuring assembly accuracy. A pressure sensor and a displacement sensor are also installed inside the piezoelectric ceramic column 732. Two piezoelectric ceramic actuators 73 are symmetrically distributed on both sides of the reflector 100. The second flexible pad 733 forms a flexible pressure head at the end of the piezoelectric ceramic column 732. The second flexible pad 733 enables flexible contact between the piezoelectric ceramic column 732 and the mirror surface of the reflector 100, avoiding damage to the mirror surface. The second flexible pad 733 is preferably made of rubber. The third robotic arm 731 is preferably arranged on both sides of the control body 71. It may include a U-shaped sixth arm and an L-shaped seventh arm. The piezoelectric ceramic column 732 is fixed to one end of the seventh arm. The other end of the seventh arm is rotatably mounted on one end of the sixth arm via a joint motor. The other end of the sixth arm is rotatably mounted on one side of the control body 71 via a joint motor.

[0074] The adhesive bonding mechanism 8 includes a liquid storage chamber 81, a second drive mechanism 82, a fourth robotic arm 83, and a dispensing nozzle 84. The second drive mechanism 82 is mounted on the liquid storage chamber 81, and the fourth robotic arm 83 has a flow channel inside. The second drive mechanism 82 controls the position adjustment of the dispensing nozzle 84 through the fourth robotic arm 83. This design, by setting up the second drive mechanism 82, the fourth robotic arm 83, and the dispensing nozzle 84, allows the adhesive bonding mechanism 8 to select the dispensing mode based on the difference in the thermal expansion coefficients of the materials: for combinations with low expansion coefficient differences, continuous ring dispensing is used to reduce stress concentration; for combinations with high expansion coefficient differences, a discrete dispensing layout is used to reserve space for thermal deformation compensation. The second drive mechanism 82 can also control the outflow and stoppage of the adhesive in the liquid storage chamber 81.

[0075] The dispensing nozzle 84 includes a straight cylindrical section 841 and a conical section 842 that are connected and fixed end to end. The conical section 842 has a clamping mechanism on its exterior. This clamping mechanism includes multiple linear motors 843 and multiple clamping blocks 844. The clamping blocks 844 are arranged circumferentially along the conical section 842, and the sliding control of the clamping blocks 844 along the generatrix of the conical section 842 is achieved by the multiple linear motors 843. With this design, the through holes inside the straight cylindrical section 841 and the conical section 842 serve as the flow channels for the adhesive. Multiple linear motors 843 are arranged circumferentially along a conical section 842, and each linear motor 843 is fixedly mounted on the surface of the conical section 842. Multiple slide rails 846 are also formed on the outer conical surface of the conical section 842, each slide rail 846 being formed along the generatrix of the conical section 842. Multiple slide rails 846 are slidably connected to the conical section 842 via multiple limiting blocks 845 and multiple slide rails 846. When the linear motors 843 extend to their limit positions, the multiple clamping blocks 844 splice into a conical structure with the cone tip sealed, thereby achieving instantaneous clamping of the adhesive, precisely controlling the adhesive flow rate, and further optimizing the adhesive curing process. More importantly, compared with the traditional stretching and breaking method used in manual dispensing, this invention, through the clamping mechanism, instantly clamps the adhesive, effectively reducing micro-bubble defects in the adhesive layer and further ensuring the continuity and uniformity of the adhesive layer. The adhesive is a liquid adhesive. A reset spring can also be fitted onto the push rod of the linear motor 843 to better achieve the reset of the clamping block 844.

[0076] A gradient curing bonding method for a reflector, using the aforementioned gradient curing bonding device for a reflector, includes the following steps:

[0077] First, the bonding surfaces of the reflector 100 and the reflector frame 200 are pretreated. This process aims to improve the bonding strength and employs a combined plasma activation and chemical etching strategy. A composite process of plasma activation and chemical etching can be used to enhance surface energy and adhesive wettability. Sandblasting optimizes the microstructure of the reflector frame 200, strengthens the mechanical interlocking effect, and suppresses the risk of electrochemical corrosion at the bonding surfaces. The pretreatment process is existing technology and will not be described in detail here.

[0078] After pretreatment, the dispensing mode is determined based on the difference in thermal expansion coefficients between the materials of the reflector 100 and the reflector frame 200, and the adhesive mechanism 8 is activated to perform dispensing. For material combinations with low thermal expansion coefficient differences, a continuous ring dispensing mode is adopted, with the dispensing nozzle 84 moving at a constant speed along the outer contour of the bonding surface. A closed-loop pressure control system maintains a constant glue line width, and a flow rate gradient algorithm is used to eliminate glue layer accumulation in the overlapping area between the endpoint and the starting point, achieving uniform stress distribution. For combinations with high thermal expansion coefficient differences, a discrete dot layout mode is used. Based on the finite element thermal deformation simulation results, the glue dot density is reduced in high stress concentration areas, and the glue dot diameter is increased in edge areas to reserve space for thermal deformation compensation. During the dispensing process, the second drive mechanism 82 precisely extrudes the glue liquid, and the clamping mechanism achieves precise control of the glue layer thickness. At the same time, it can suppress air gaps inside the glue liquid, ensuring the continuity and uniformity of the glue layer.

[0079] Then, the positioning and clamping mechanism 6 is activated to perform the positioning and calibration operation of the reflector 100; the industrial camera 2 captures the positioning marks of the edge of the reflector 100 and the reflector frame 200, calculates the center offset through the image processing algorithm, and drives the first position adjustment mechanism 4 and the second position adjustment mechanism 5 to perform sub-micron level position compensation; the flexible pressure head of the piezoelectric ceramic actuator 73 is attached to the mirror surface of the reflector 100 with a constant contact force, and the pressure sensor provides real-time feedback on the stress distribution and automatically adjusts the inclination angle of the pressure head to eliminate assembly off-center load.

[0080] Finally, the composite temperature control component 72 is activated to execute the stepped curing program. The composite temperature control component 72 controls different temperature conditions. Specifically, activating the composite temperature control component 72 maintains a constant temperature environment, allowing the adhesive to initially establish a cohesive network. The gradient heating stage adopts a three-stage stepped heating strategy to gradually approach the optimal crosslinking temperature range and match the curing kinetics of the adhesive. The isothermal maintenance stage promotes the homogenization of crosslinking density. The nonlinear slow cooling stage avoids stress abrupt changes in the glass transition region by gradually reducing the cooling rate.

[0081] During the bonding process, the deformation of the reflector 100 is monitored in real time by the laser interferometer 3. When the position and angle changes of the reflector 100 exceed the safety threshold, the force-thermal coupling control module 7 is automatically triggered. The piezoelectric ceramic actuator 73 applies reverse compensation pressure to the convex area of ​​the deformed area and releases pressure to the concave area according to the surface distribution, dynamically correcting the deformation deviation. The power ratio of the composite temperature control component 72 is adjusted synchronously to optimize the temperature field distribution of the bonding surface, realize in-situ dynamic compensation for curing shrinkage deformation, and ensure that the parallelism between the bonding surfaces of the reflector 100 and the reflector frame 200 after bonding continues to meet the stringent requirements of the optical system.

[0082] The bonding operation of this invention is performed entirely within a sealed temperature-controlled chamber 1 to isolate it from external environmental interference.

[0083] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A gradient curing and bonding device for reflectors based on in-situ deformation correction, characterized in that: The system includes a temperature control box (1), a control center, an industrial camera (2) installed inside the temperature control box (1) and connected to the control center via signal, a laser interferometer (3), a first position adjustment mechanism (4), a second position adjustment mechanism (5), a positioning clamping mechanism (6), a force-thermal coupling control module (7), and an adhesive mechanism (8). The industrial camera (2) and the laser interferometer (3) are installed parallel to each other on the top of the first position adjustment mechanism (4), and the mirror frame (200) is installed on the top of the second position adjustment mechanism (5). The first position adjustment mechanism (4) and the second position adjustment mechanism (5) are arranged side by side along the length of the temperature control box (1). The force-thermal coupling control module (7) is located on the side of the mirror frame (200) away from the laser interferometer (3). Adhesive is applied to the mirror frame (200) by the adhesive bonding mechanism (8). The positioning and clamping mechanism (6) is used to clamp the reflector (100) to the reflector frame (200). The force-thermal coupling control module (7) includes a control body (71), a composite temperature control component (72), and a piezoelectric ceramic actuator (73). The control body (71) controls the operation of the composite temperature control component (72) and the piezoelectric ceramic actuator (73), the composite temperature control component (72) controls the curing temperature of the adhesive layer, and the piezoelectric ceramic actuator (73) applies a compensating force to the reflector (100).

2. The reflector gradient curing and bonding device based on in-situ deformation correction according to claim 1, characterized in that: The positioning and clamping mechanism (6) includes a first drive mechanism (61), a first robotic arm (62), and a clamping body. The first drive mechanism (61) controls the clamping body to adjust the angle through the first robotic arm (62). The clamping body includes a bracket (63), a first telescopic adjustment rod (64), multiple second telescopic adjustment rods (65), and multiple clamping blocks (66). The bracket (63) is rotatably mounted at the end of the first robotic arm (62). The first telescopic adjustment rod (64) is mounted on the bracket (63) on the side away from the first robotic arm (62) and is arranged coaxially with the rotation center of the bracket (63). Multiple second telescopic adjustment rods (65) are arranged circumferentially along the bracket (63), and each second telescopic adjustment rod (65) is rotatably connected to the bracket (63). Multiple clamping blocks (66) are installed one-to-one on the second telescopic adjustment rods (65) at the end away from the bracket (63).

3. The reflector gradient curing and bonding device based on in-situ deformation correction according to claim 2, characterized in that: The bracket (63) includes four third telescopic adjustment rods (69) arranged in an X-shape.

4. The reflector gradient curing and bonding device based on in-situ deformation correction according to claim 2, characterized in that: A secondary telescopic adjustment mechanism (68) is also provided between the clamp (66) and the second telescopic adjustment rod (65).

5. The reflector gradient curing and bonding device based on in-situ deformation correction according to claim 2, characterized in that: A V-shaped through groove (661) is provided on the clamping surface of the clamping block (66).

6. The reflector gradient curing and bonding device based on in-situ deformation correction according to claim 1, characterized in that: The composite temperature control component (72) includes a second robotic arm (721) and a temperature control plate (722) installed at the end of the second robotic arm (721). The control body (71) adjusts the position of the temperature control plate (722) through the second robotic arm (721).

7. The reflector gradient curing and bonding device based on in-situ deformation correction according to claim 1, characterized in that: The piezoelectric ceramic actuator (73) includes a third robotic arm (731) and a piezoelectric ceramic column (732) installed at the end of the third robotic arm (731). A second flexible pad (733) is installed on one end of the piezoelectric ceramic column (732) near the reflector (100).

8. The reflector gradient curing and bonding device based on in-situ deformation correction according to claim 1, characterized in that: The adhesive mechanism (8) includes a liquid storage chamber (81), a second drive mechanism (82), a fourth robotic arm (83), and a dispensing nozzle (84). The second drive mechanism (82) is installed on the liquid storage chamber (81), and the fourth robotic arm (83) has a flow channel inside. The second drive mechanism (82) controls the dispensing nozzle (84) to adjust its position through the fourth robotic arm (83).

9. The reflector gradient curing and bonding device based on in-situ deformation correction according to claim 8, characterized in that: The dispensing nozzle (84) includes a straight cylindrical section (841) and a conical section (842) that are connected and fixed end to end. The conical section (842) is provided with a clamping mechanism on the outside. The clamping mechanism includes multiple linear motors (843) and multiple clamping blocks (844). The multiple clamping blocks (844) are arranged circumferentially along the conical section (842). The multiple linear motors (843) are used to realize the sliding control of the multiple clamping blocks (844) along the generatrix direction of the conical section (842).

10. A gradient curing bonding method for a reflector, characterized in that: The reflector gradient curing and bonding device according to any one of claims 1 to 9 comprises the following steps: First, the bonding surfaces of the reflector (100) and the reflector frame (200) are pretreated. After pretreatment, the dispensing mode is determined based on the difference in thermal expansion coefficients between the reflector (100) material and the reflector frame (200) material, and the adhesive mechanism (8) is started to perform dispensing. Then, the positioning clamping mechanism (6) is started to perform the positioning calibration operation of the reflector (100). Finally, the composite temperature control component (72) is started to perform the step curing program. During the bonding process, the mirror surface deformation of the reflector (100) is monitored in real time by the laser interferometer (3). When the position and angle changes of the reflector (100) exceed the safety threshold, the force-thermal coupling control module (7) is automatically triggered.

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