A forming tool and method for a satellite-borne high-power radio frequency cable assembly

Abstract

The present invention discloses a shaping tool for a satellite-borne high-power radio frequency cable assembly, including a bending die and a sampling dimensional shaping tool. In the sampling dimensional shaping tool, the connector assembly provides a first threaded interface that is the same as the threaded interface of a real radio frequency connector, and the double-female assembly provides a second threaded interface that is the same as the threaded interface of a real double-female connector; a binding bracket is used to bind and fix the middle section between the two ends of the cable. The present invention also discloses a shaping method for a satellite-borne high-power radio frequency cable assembly, using a bending die to obtain a formed cable; fixing the cable assembly in a sampling dimensional shaping tool; packaging the cable assembly and the sampling dimensional shaping tool as a whole, and then storing or transporting them; in the satellite assembly stage, each formed cable is sequentially taken out of the sampling dimensional shaping tool one by one and transplanted to the corresponding position of the satellite cabin board. The present invention can ensure the three-dimensional forming accuracy and dimensional accuracy of the cable, and greatly save production costs.

Description

Technical Field

[0001] The invention relates to a shaping tool and method for a satellite-borne high-power radio frequency cable assembly, belonging to the technical field of spacecraft manufacturing. Background Art

[0002] In the current manufacturing of large-scale satellites, in order to achieve high-power transmission of satellite systems, it is often necessary to select RF cable components with a transmission power of kilowatts. Among them, the best is the SFC-50-11-52 cable, which has excellent performance in high-power and low-loss transmission and has become the only choice for high-power transmission of certain types of satellite systems. The inner conductor 8 of the SFC-50-11-52 cable is a 3.9mm diameter silver-plated copper single wire, the insulating medium layer 9 is made of F-6 type polytetrafluoroethylene, and the outer conductor 10 is a 0.3mm thick pure copper strip rolled into a corrugated tube. The final cable has an outer diameter of 11.3mm. The structural diagram is shown in the figure below. Figure 1 The large physical size of the cable makes it very easy to wrinkle the outer conductor copper bellows during the three-dimensional molding process (such as Figure 2 as shown), cracking (as shown Figure 3 As shown in the figure), even the inner and outer conductors are misaligned during the bending process, which brings the risk of micro-discharge, thereby reducing the reliability of the product. The production yield is less than 20%, and the molding accuracy is not high. The shape cannot be maintained during the circulation of each link, and the cable rebounds and deforms (such as Figure 4 As shown in the figure), deformation due to touch. The deformation will not only change the key technical indicators of the cable such as loss, standing wave, phase consistency, etc., but also make it unable to match the assembly status of the satellite during the assembly stage. The above problems are technical difficulties that need to be solved urgently during the development stage of the satellite. Summary of the invention

[0003] The purpose of the present invention is to overcome the above-mentioned defects and provide a dimensional shaping tool and method for satellite-borne high-power radio frequency cable assemblies, which solves the technical problems that the outer conductor copper bellows of kilowatt-level high-power copper bellows radio frequency cables is prone to wrinkling, cracking, and low yield, as well as deformation during the development, packaging, and transportation processes that cannot match the satellite's assembly state. The present invention can ensure the three-dimensional forming accuracy and dimensional accuracy of the cable, greatly saving production costs.

[0004] In order to achieve the above-mentioned object of the invention, the present invention provides the following technical solutions:

[0005] A forming tool for a satellite-borne high-power radio frequency cable assembly, comprising a bending die and a sampling tool;

[0006] The bending mold is a semicircular structure, and a semicircular groove is provided on the surface of the semicircular structure. The radius of the semicircular groove is equal to the predetermined bending radius of the cable to be formed. The cable to be formed is bent by the semicircular groove to obtain a formed cable; the cable assembly includes ≥1 formed cable;

[0007] The sampling dimension forming tooling includes a base plate, and a connector assembly, a double-female assembly and a binding bracket fixed on the base plate; the connector assembly provides a first threaded interface that is the same as the real RF connector threaded interface on the satellite cabin board, and the double-female assembly provides a second threaded interface that is the same as the real double-female connector threaded interface on the satellite cabin board, and the first threaded interface and the second threaded interface are respectively connected to the two ends of the same formed cable; the binding bracket includes a third bracket installed on the base plate and an anti-static sponge sleeved on the third bracket, and a plurality of binding brackets are used to bind and fix the middle section between the two ends of the formed cable.

[0008] Furthermore, the connector assembly includes a first bracket and an RF connector structure fixed on the first bracket, the dual-female assembly includes a second bracket and a dual-female connector structure fixed on the second bracket, the first bracket and the second bracket are fixed on the base plate, the RF connector structure includes an RF connector structure shell, the RF connector structure shell is provided with a first threaded interface, the dual-female connector structure includes a dual-female connector structure shell, the dual-female connector structure shell is provided with a second threaded interface; the shape of the RF connector structure and the first threaded interface are the same as the shape and threaded interface of the real RF connector, and the shape of the dual-female connector structure and the second threaded interface are the same as the shape and threaded interface of the real dual-female connector.

[0009] Furthermore, the RF connector structure only includes the RF connector structure shell, the RF connector structure shell is a hollow structure, and no insulating medium and conductor pins are arranged inside the RF connector structure shell; the double-female connector structure only includes the double-female connector structure shell, the double-female connector structure shell is a hollow structure, and no insulating medium and conductor pins are arranged inside the double-female connector structure shell;

[0010] The number of RF connector structural parts and double-female connector structural parts is the same as the number of real RF connectors and real double-female connectors on the satellite cabin board, and the positions of the RF connector structural parts and double-female connector structural parts relative to the base plate are the same as the positions of the real RF connectors and real double-female connectors relative to the satellite cabin board.

[0011] Furthermore, at least one binding point is respectively arranged in the straight area in front of and behind the bending area of ​​the formed cable, and each binding point is bound to a binding bracket; the spacing between several binding brackets used for binding and fixing the same formed cable is 200 to 400 mm.

[0012] Furthermore, the surface of the bottom plate used to fix the connector assembly, the double female assembly and the tying bracket is taken as the front side, the four corners of the front side of the bottom plate are provided with a lifting ring mechanical interface, and the four corners of the back side of the bottom plate are provided with a universal wheel device and a spring shock absorbing device;

[0013] The bottom plate is also provided with a mechanical interface for docking with the packaging box.

[0014] A method for forming a satellite-borne high-power radio frequency cable assembly, comprising:

[0015] Determine the predetermined bending radius of the cable to be formed according to the effective layout space of the satellite cabin panel;

[0016] Using the bending die, the cable to be formed is bent according to a predetermined bending radius to obtain a formed cable, and ≥1 formed cables constitute a cable assembly;

[0017] Fixing the cable assembly in a sampling dimensional tool; the sampling dimensional tool is the sampling dimensional tool mentioned above;

[0018] The cable assembly and sampling dimensional tooling are packaged as a whole for storage or transportation;

[0019] During the satellite assembly phase, each formed cable is taken out from the sampling dimensional tooling one by one and transplanted to the corresponding position of the satellite cabin panel.

[0020] Furthermore, the method for determining the predetermined bending radius of the cable to be formed according to the effective layout space of the satellite cabin board is:

[0021] When the effective layout space is ≥130 mm, the predetermined bending radius of the cable to be formed is determined to be R120 mm;

[0022] When 110mm≤effective layout space<130mm, the predetermined bending radius of the cable to be formed is determined as R100mm;

[0023] When 90 mm ≤ effective layout space < 110 mm, the predetermined bending radius of the cable to be formed is determined to be R80 mm.

[0024] Furthermore, the forming method of the satellite-borne high-power radio frequency cable assembly also includes:

[0025] Before bending the cable to be formed according to the predetermined bending radius, perform the following steps using the metal round tube:

[0026] Using a bending die, the metal round tube is bent according to a predetermined bending radius to obtain a formed round tube, and ≥ 1 formed round tubes constitute a round tube assembly;

[0027] Fix each formed round tube in the round tube assembly in the sampling dimensional shaping tool at the same position as each formed cable in the cable assembly, adjust the position of the formed round tube to meet the preset standard, and then remove the round tube assembly; the sampling dimensional shaping tool is the sampling dimensional shaping tool in the forming dimensional shaping tool according to any one of claims 1 to 6;

[0028] The material of the metal round tube is the same as that of the outer conductor of the cable, and the outer diameter of the metal round tube is the same as that of the cable.

[0029] Furthermore, the preset standard is:

[0030] The gap between the binding point of the round tube after forming and the anti-static sponge in the binding bracket is -0.5mm to +0.5mm, and the coaxiality between the two ends of the same round tube after forming and the first threaded interface and the second threaded interface is within Φ0.5mm;

[0031] When fixing the cable assembly in the sampling dimension tooling, replace the molded round tube one by one for each molded cable, and fine-tune the position of each molded cable so that the gap between the binding point of the molded cable and the anti-static sponge in the binding bracket is -0.5mm~+0.5mm, and the coaxiality between the two ends of the same molded cable and the first threaded interface and the second threaded interface is within Φ0.5mm.

[0032] Furthermore, the specific method of using a bending die to bend the cable to be formed according to a predetermined bending radius to obtain the formed cable is as follows:

[0033] Before bending the cable to be formed, the position of the binding bracket is set according to the three-dimensional design drawing of the cable, so that when the cable is fixed in the sampling dimensional tooling, at least one binding point is set in the straight area in front of and behind the cable bending area, and each binding point is bound to a binding bracket; the spacing between several binding brackets used to bind and fix the same formed cable is 200 to 400 mm;

[0034] Assume that the bending area of ​​a cable to be formed is n, n≥1. First, after forming the first bending area using a bending mold, place the cable to be formed in a sampling dimension forming tooling to determine whether the gap between the binding points set in the straight areas in front and behind the first bending area and the anti-static sponge in the binding bracket meets the requirement of -0.5mm~+0.5mm. If so, continue to use the bending mold to form the next bending area. If not, use the bending mold to adjust the first bending area until the gap between it and the anti-static sponge meets the requirement, and repeat the above steps to form the second to n bending areas.

[0035] Compared with the prior art, the present invention has at least one of the following beneficial effects:

[0036] (1) The present invention creatively proposes a set of sampling and profiling tooling, which accurately simulates the relevant interface state when the satellite cabin board and the cable are connected, so that the cable has an accurate spatial reference environment during the sampling and profiling process;

[0037] (2) The present invention utilizes a binding bracket to achieve cable binding and fixation, and can be flexibly adjusted according to the different three-dimensional shapes of the cables;

[0038] (3) The bending mold of the present invention has a simple structure, is easy to operate, and is suitable for forming cables with various bending radii;

[0039] (4) In the shaping method of the present invention, the requirements between the layout space and the cable bending radius are fully balanced, and the optimal design method of the cable bending radius is provided, which effectively reduces the risk of wrinkles and cracks in the cable forming process, and increases the product yield from less than 20% to more than 95%, and the product reliability is also greatly improved;

[0040] (5) In the forming method of the present invention, a metal tube with the same outer diameter as the cable is selected for three-dimensional bending forming. After the correction and adjustment are completed, the cable is used for one-time replication forming, thereby avoiding damage to the cable caused by multiple adjustments and corrections, and effectively reducing costs;

[0041] (6) In the shaping method of the present invention, the finally formed copper corrugated tube cable is always fixed on the sampling shaping tooling during the subsequent circulation process, which can not only reduce the packaging and maintenance costs, but also ensure that the shaping accuracy of the cable does not change over a long period of time. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 This is the structural diagram of the SFC-50-11-52 cable;

[0043] Figure 2 This is the copper skin wrinkle diagram of the cable outer conductor;

[0044] Figure 3 This is the cracking diagram of the copper skin of the cable outer conductor;

[0045] Figure 4 These are photos of the springback deformation during the cable manufacturing process, where (a) is a photo of the springback deformation in one state, and (b) is a photo of the springback deformation in another state;

[0046] Figure 5 Schematic diagram of the three-dimensional simulation design of the cable of the present invention; wherein (a) is a stereogram, (b) is a front view, and (c) is a side view;

[0047] Figure 6 Schematic diagram of the bending mold processing of the present invention; wherein (a) is a front view, (b) is a side view, (c) is a stereogram, and (d) is a top view;

[0048] Figure 7 This is a schematic diagram of the sampling dimensional tooling of the present invention;

[0049] In the figure, 1-base plate, 2-simulation partition, 3-connector assembly, 4-double-female assembly, 5-binding bracket, 6-antistatic sponge, 7-cable assembly, 8-inner conductor, 9-insulating medium layer, 10-outer conductor. DETAILED DESCRIPTION

[0050] The following detailed description of the present invention will make the features and advantages of the present invention more clear and explicit.

[0051] The word "exemplary" is used exclusively herein to mean "serving as an example, embodiment, or illustration." Any embodiment described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments. Although various aspects of the embodiments are shown in the drawings, the drawings are not necessarily drawn to scale unless otherwise noted.

[0052] In view of the superior performance of SFC-50-11-52 copper bellows radio frequency cable in high-power and low-loss transmission, it is the preferred product for the design of high-power systems of spacecraft. However, the cost of this type of cable is high, so it is particularly important to clear the technical barriers and cost control in the development process of the cable. The technical barriers mainly include: on the one hand, the outer conductor copper bellows of the kilowatt-level high-power copper bellows radio frequency cable is prone to wrinkling and cracking, and the yield rate is low; on the other hand, the deformation during the development, packaging, and transportation process makes the key technical indicators of the cable assembly, such as loss, standing wave, and phase consistency, unstable or even deteriorated, and the deformation makes it impossible to match the technical status of the final assembly, and the correction will bring new wrinkles and cracking risks, which reduces the reliability of the cable assembly. The present invention is not only of great significance to the application of the radio frequency cable, but also has the value of popularization and application in the development of all semi-rigid aerospace products with high precision and high reliability requirements.

[0053] Through theoretical analysis and experimental verification, it is determined that the reason for the wrinkles of the copper skin of the cable outer conductor is that the bending radius is too small and the force is uneven during the bending process; the reason for the cracking is that the reverse bending of the cable causes stress concentration at the convex and concave joints of the corrugation. The larger the bending radius of the cable, the smaller the risk of wrinkles and cracks. However, if the bending radius is too large, it cannot meet the layout space requirements of the satellite. Therefore, when performing the three-dimensional model simulation design of the cable, it is necessary to fully balance the requirements between the layout space and the bending radius of the cable. When the effective layout space of the cable is greater than or equal to 130mm, the bending radius parameter of R120mm is selected. When its effective layout space is greater than or equal to 110mm and less than 130mm, the bending radius parameter of R100mm is selected. When its effective layout space is greater than or equal to 90mm and less than 110mm, the bending radius parameter of R80mm is selected. When its effective layout space is less than 90mm, the layout position of the satellite payload equipment needs to be optimized to provide sufficient space environment for cable extension, thereby reducing the risk of wrinkles and cracks during cable forming. In the present invention, the effective space refers to a one-dimensional space, namely, the extension direction of the cable segment.

[0054] The present invention is based on optimizing the forming parameters and designing a bending die that matches the optimized parameters, which effectively avoids the risk of wrinkles, cracks, and misalignment of the inner and outer conductors caused by uneven local force on the cable during the bending process, and increases the product yield from less than 20% to more than 95%, and the reliability of aerospace products is also greatly improved. If the parameters of the bending die are adaptively modified, this method can be used for the three-dimensional forming of other semi-rigid pipes and cable products.

[0055] The traditional sampling method of copper corrugated tube cable has low accuracy, and problems such as rebound deformation and touch deformation are inevitable in the development process, making the key technical indicators of the cable assembly such as loss, standing wave, and phase consistency unstable or even deteriorating. Deformation will also cause different degrees of deviation in the mechanical interface between the cable and the satellite when it is installed in the cabin, and re-calibration will bring new wrinkles and cracking risks. The present invention designs a sampling dimensional tooling that is completely consistent with the cabin interface, so that the product is always kept in the same state as the satellite mechanical interface during the development process after sampling, so as to ensure the three-dimensional molding accuracy of the cable, and fully ensure the stability of the key technical indicators such as standing wave, loss, and phase consistency of the cable assembly and the three-dimensional molding accuracy.

[0056] Because the SFC-50-11-52 cable cannot be accurately formed in one time during the manual bending process, it needs to be adjusted and corrected many times to reach the installation requirements, but multiple adjustments will cause the cable to wrinkle and crack. In the adjustment link, the risk of cracking of the outer conductor copper skin during reverse bending is the highest (the so-called reverse bending, that is, after the first bending and forming at the same position of the cable, it is bent in the opposite direction at the same position). The present invention uses a semi-rigid metal round tube with the same outer diameter as the cable to replace the formal cable for bending and forming. The semi-rigid metal round tube can be bent repeatedly without damage. Finally, the shape of the semi-rigid metal tube can be copied with the formal cable to eliminate the above risks and greatly save production costs. Specifically, the preset three-dimensional size cannot be achieved by manual bending with molds and tooling once, and 3 to 5 adjustments are required to achieve it. The formal cable will inevitably be damaged 3 to 5 times, so it is pre-formed with a metal round tube. Although the formal copy is also manually bent, it can be successfully copied once.

[0057] The traditional packaging of semi-rigid cables (copper corrugated tube cables are a type of semi-rigid cables) is to put each cable into a packaging box separately, and fill it with anti-static sponge for protection. For semi-rigid cables with large sizes and complex shapes, the adaptability of ordinary packaging boxes is extremely low. A certain model has as many as 40 sets of cable assemblies, and most of the cable space dimensions exceed 3 meters. According to the previous method of packaging each cable assembly separately, 40 large packaging boxes of 3.5m*2.5m*0.5m are required. The customization and maintenance costs of large quantities of packaging boxes are high, the storage space requirements are large, and the reuse rate is low, resulting in a huge waste of resources. The present invention uses the sampling dimensional tooling system as a transfer system. The two cabin plates of a certain satellite each correspond to a set of sampling dimensional tooling. Only two 4m*2.5m*0.55m packaging boxes are needed to solve the packaging and transportation needs of 40 sets of cable assemblies.

[0058] The following is combined with Figures 5 to 7 The specific implementation mode of the present invention is described. In a preferred implementation mode of the present invention, the steps of the shaping method of the satellite-borne high-power radio frequency cable assembly are as follows:

[0059] (1) Refer to the preferred values ​​of bending radius (R120, R100, R80) obtained from the cable bending test to perform three-dimensional cable design, and fully balance the contradiction between layout space and bending radius. When the effective layout space of the cable is greater than or equal to 130 mm, select the bending radius value of R120 mm. When its effective layout space is greater than or equal to 110 mm and less than 130 mm, select the bending radius value of R100 mm. When its effective layout space is greater than or equal to 90 mm and less than 110 mm, select the bending radius value of R80 mm. When its effective layout space is less than 90 mm, it is necessary to optimize the layout position of the satellite payload equipment to provide sufficient space environment for cable extension. The schematic diagram of cable three-dimensional simulation design is shown in the figure. Figure 5 .

[0060] (2) Design and manufacture bending molds of three specifications: R120, R100, and R80. The tooling material is high-stability, non-adhesive, and highly lubricating polytetrafluoroethylene; design semicircular pancake molds with a thickness of 20 mm according to the bending radius value, and set a Φ12.5 mm semicircular groove along the circumference at the geometric center of the thickness (the groove diameter is slightly larger than the cable diameter to facilitate the cable body to enter and exit the groove); the bending mold is designed to be hollow, so that the operator can easily pass his fingers through the mold and hold the string position to perform the operation; the small round hole on the mold can be used as a hole for the mold hanging rope (handheld tools or molds need to be hung on the operator's neck or wrist with a hanging rope during use to prevent them from falling and damaging aerospace products). Detailed information about the mold is as follows: Figure 6As shown. When bending the cable, first put the straight section of the mold into the palm of your left hand, and hold the straight section of the mold from the outside to the inside through the hollow semicircular hole with your index finger, middle finger, ring finger and little finger, and then put the unformed cable body into the groove. Fix one end of the cable with your left thumb, and support the cable with your right hand to gradually and evenly apply force along the circumference of the mold to make the cable enter the groove to achieve the purpose of bending. In this process, the cable body is evenly stressed, avoiding the risk of wrinkles and cracks. For different bending radius parameters on the cable design model, the molds with corresponding bending radius values ​​should be used to implement the operation.

[0061] (3) Combined with the 3D design information of all cables of this type on a certain panel of the satellite, a set of tooling simulation system is designed and manufactured to sample cables and be used for dimensional analysis in the later circulation process. The design information is as follows: Figure 7 The sampling dimensional tooling includes a base plate 1, a connector component 3, a double-female component 4 and a tying bracket 5 fixed on the base plate 1, and may also include a simulated partition 2; the simulated partition 2, the connector component 3, the double-female component 4 and the tying bracket 5 are assembled according to the design requirements.

[0062] Among them, each connector component 3 includes an RF connector structure and an L-shaped bracket (first bracket), which is a local simplified solution of the load device connected to one end of each cable. The RF connector structure is a hollow part with the same appearance size and external thread interface as the real RF connector. The hollow part without the internal insulating medium and other structures can not only eliminate the hidden danger of damage to the conductor inside the cable connector caused by repeated plugging of the connector male and female heads during cable installation, but also reduce production costs and shorten processing cycles; the L-shaped bracket is installed with the RF connector structure on one side and fixed to the bottom plate 1 on the other side to ensure that the three-dimensional position of the RF connector structure is exactly the same as its position on the real cabin plate, and the bracket cannot hinder the three-dimensional direction of the cable in space.

[0063] The dual-female component 4 includes a second bracket and several dual-female connector (a dual-female connector is a radio frequency connector with female ends) structural parts in similar positions. The number and three-dimensional positions of the dual-female connector structural parts are exactly the same as their states on the cabin plate. The simplification principles of the second bracket and the dual-female connector structural parts are consistent with the simplification principles of the connector component 3.

[0064] Binding bracket 5, this type of binding bracket only simulates the outer contour of the cabin bracket and the interface of the mounting ear piece, and the other details are simplified. Binding bracket 5 is set on the straight sections before and after the cable bending area, ensuring that there is a bracket binding 5 and limit on each extension section, and the bracket spacing is controlled at 200mm-400mm.

[0065] Simulated baffle 2 is a simplified structural cabin plate originally used for installing payload equipment and fixing cables on the satellite. Here, only the actual position and size of the U-shaped groove through which some SFC-50-11-52 cables pass need to be simulated, and the rest of the irrelevant information is simplified. A 5mm thick antistatic sponge 6 is mounted on the support cylinder (the third support) to simulate the effect of nylon tape (when formally tying the threaded cable, a 2-3mm thick nylon tape will be wrapped around the contact area between the support and the cable as a buffer when the support and the cable are in hard contact). The mounting process is efficient and simple, low-cost, and easy to move up and down.

[0066] Base plate 1, all connector components 3, double female components 4, tying brackets 5 and simulated partitions 2 related to cable sampling are set on the base plate 1. A lifting ring mechanical interface is designed at each of the four corners on the front of the base plate 1 for engineering hoisting. A set of universal wheel devices and a set of spring shock absorbers are set at each of the four corners on the back of the tooling base plate 1 to meet the needs of ground transportation and shock absorption protection inside the factory. A mechanical interface for docking with the packaging box is set on the base plate 1, and the rest can be simplified.

[0067] (4) A semi-rigid metal tube (flexible metal tube) with the same outer diameter as the SFC-50-11-52 cable is used to replace the cable for sampling and molding on the tooling. When sampling, a base plate 1 is used as a unit. According to the arrangement order of all the three-dimensional design models of such cables in the unit, the semi-rigid metal tube is simulated one by one from bottom to top and from inside to outside. The thickness of the semi-rigid metal tube does not need to be the same as the thickness of the outer conductor of the cable. Each bending area is formed by selecting a corresponding bending mold according to the design parameters. After simulating all the cables on the base plate 1, the simulated cable (i.e., metal tube) is adjusted and corrected again so that the binding point position of each metal tube is evenly fitted with the anti-static sponge, the gap is controlled within plus or minus 0.5mm, and the coaxiality with the connector structure is controlled within Φ0.5mm. The significance of this step is to use the formed metal tube as a reference. The higher the reference accuracy, the more accurate the cable will be when copying. The smaller the adjustment amount in the last copy of the formal cable, the better.

[0068] (5) Use SFC-50-11-52 cable to copy the simulated cable. During the copying process, strictly use the bending mold to form it, and replace the simulated cables on the tooling one by one to prevent the cable from rebounding and deforming in a free state for a long time. After the replacement is completed, perform a one-time fine-tuning correction to ensure that the gap between the cable binding point and the anti-static sponge is controlled within plus or minus 0.5 mm, and the coaxiality with the connector structure is controlled within Φ0.5 mm. Finally, tie and fix the formal cable to complete the fixation and shaping of the cable assembly 7.

[0069] (6) In the subsequent development and transportation of the cable, except for the need to operate each cable component individually, the cable components are kept in a state of maintenance and protection on the tooling system for the rest of the time until the satellite assembly stage, when the cables are transplanted onto the satellite one by one in the order required by the process.

[0070] (7) Before the cable assembly is packaged and transported, the packaging box is configured according to the size of the simulated tooling system, and the mechanical interface inside the packaging box is ensured to match the mechanical interface set on the simulated tooling base plate. The cable is hoisted into the packaging box along with the tooling system as a whole, and the fasteners between the sampling dimensional tooling and the packaging box are connected to ensure that the cable assembly is always in a dimensional and protected state during transportation and storage.

[0071] The present invention has been described in detail above in conjunction with specific implementations and exemplary examples, but these descriptions cannot be understood as limiting the present invention. Those skilled in the art understand that, without departing from the spirit and scope of the present invention, a variety of equivalent substitutions, modifications or improvements may be made to the technical solution of the present invention and its implementation methods, all of which fall within the scope of the present invention. The scope of protection of the present invention shall be subject to the attached claims.

[0072] The contents not described in detail in the specification of the present invention belong to the common knowledge of those skilled in the art.

Claims

1. A forming tool for a satellite-borne high-power radio frequency cable assembly, characterized in that: Including bending die and sampling dimension tooling; The bending mold is a semicircular structure, and a semicircular groove is provided on the surface of the semicircular structure. The radius of the semicircular groove is equal to the predetermined bending radius of the cable to be formed. The cable to be formed is bent by the semicircular groove to obtain a formed cable; the cable assembly includes ≥1 formed cables; the cable to be formed is a copper corrugated tube radio frequency cable; The sampling dimensional tooling comprises a base plate (1), and a connector assembly (3), a double-female assembly (4) and a tying bracket (5) fixed on the base plate (1); the connector assembly (3) provides a first threaded interface that is identical to a threaded interface of a real radio frequency connector on a satellite cabin board, the double-female assembly (4) provides a second threaded interface that is identical to a threaded interface of a real double-female connector on a satellite cabin board, the first threaded interface and the second threaded interface are respectively connected to two ends of a same formed cable; the tying bracket (5) comprises a third bracket mounted on the base plate (1) and an antistatic sponge (6) sleeved on the third bracket, and a plurality of tying brackets (5) are used to tie and fix the middle section between the two ends of the formed cable; At least one binding point is respectively arranged in the straight line area in front of and behind the bending area of ​​the formed cable, and each binding point is bound to a binding bracket (5); the spacing between the plurality of binding brackets (5) used for binding and fixing the same formed cable is 200-400 mm; The forming method of the satellite-borne high-power radio frequency cable assembly comprises: Determine the predetermined bending radius of the cable to be formed according to the effective layout space of the satellite cabin panel; Set the position of the binding bracket according to the three-dimensional design graphics of the cable; Using a bending die, the cable to be formed is bent according to a predetermined bending radius to obtain a formed cable, and ≥1 formed cables constitute a cable assembly; Fix the cable assembly in the sampling dimension tooling; The cable assembly and sampling dimensional tooling are packaged as a whole for storage or transportation; During the satellite assembly phase, each formed cable is taken out from the sampling dimensional tooling one by one and transplanted to the corresponding position of the satellite cabin board; The method for determining the predetermined bending radius of the cable to be formed according to the effective layout space of the satellite cabin board is: When the effective layout space is ≥130 mm, the predetermined bending radius of the cable to be formed is determined to be R120 mm; When 110mm≤effective layout space<130mm, the predetermined bending radius of the cable to be formed is determined as R100mm; When 90mm≤effective layout space<110mm, the predetermined bending radius of the cable to be formed is determined to be R80mm; Before bending the cable to be formed according to the predetermined bending radius, perform the following steps using the metal round tube: Using a bending die, the metal round tube is bent according to a predetermined bending radius to obtain a formed round tube, and ≥ 1 formed round tubes constitute a round tube assembly; Fix each formed round tube in the round tube assembly in the same position as each formed cable in the cable assembly in the sampling dimension tooling, adjust the position of the formed round tube to meet the preset standard, and then remove the round tube assembly; The material of the metal round tube is the same as that of the outer conductor of the cable, and the outer diameter of the metal round tube is the same as that of the cable.

2. The forming tool for a satellite-borne high-power radio frequency cable assembly according to claim 1, characterized in that: The connector component (3) comprises a first bracket and a radio frequency connector structure fixed on the first bracket, and the double-female component (4) comprises a second bracket and a double-female connector structure fixed on the second bracket. The first bracket and the second bracket are fixed on the bottom plate (1). The radio frequency connector structure is a radio frequency connector structure shell, and the radio frequency connector structure shell is provided with a first threaded interface. The double-female connector structure is a double-female connector structure shell, and the double-female connector structure shell is provided with a second threaded interface. The shape and the first threaded interface of the radio frequency connector structure are the same as the shape and the threaded interface of a real radio frequency connector, and the shape and the second threaded interface of the double-female connector structure are the same as the shape and the threaded interface of a real double-female connector.

3. The forming tool for a satellite-borne high-power radio frequency cable assembly according to claim 2, characterized in that: The shell of the RF connector structural part is a hollow structure, and the shell of the double-female connector structural part is a hollow structure; The number of the RF connector structure and the dual-female connector structure is the same as the number of the real RF connector and the real dual-female connector on the satellite cabin board, and the position of the RF connector structure and the dual-female connector structure relative to the bottom plate (1) is the same as the position of the real RF connector and the real dual-female connector relative to the satellite cabin board.

4. The forming tool for a satellite-borne high-power radio frequency cable assembly according to claim 1, characterized in that: The surface of the bottom plate (1) used for fixing the connector assembly (3), the double female assembly (4) and the lashing bracket (5) is the front side, the four corners of the front side of the bottom plate (1) are provided with lifting ring mechanical interfaces, and the four corners of the back side of the bottom plate (1) are provided with universal wheel devices and spring shock absorbing devices; The bottom plate (1) is also provided with a mechanical interface for docking with the packaging box.

5. The forming tool for a satellite-borne high-power radio frequency cable assembly according to claim 1, characterized in that: The preset standards are: The gap between the binding point of the formed round tube and the antistatic sponge (6) in the binding bracket (5) is -0.5 mm to +0.5 mm, and the coaxiality between the two ends of the same formed round tube and the first threaded interface and the second threaded interface is within Φ0.5 mm; When the cable assembly is fixed in the sampling dimension tooling, each formed cable is replaced with the formed round tube one by one, and the position of each formed cable is fine-tuned so that the gap between the binding point position of the formed cable and the antistatic sponge (6) in the binding bracket (5) is -0.5mm~+0.5mm, and the coaxiality between the two ends of the same formed cable and the first threaded interface and the second threaded interface is within Φ0.5mm.

6. The forming tool for a satellite-borne high-power radio frequency cable assembly according to claim 1, characterized in that: The specific method of bending the cable to be formed according to a predetermined bending radius by using a bending die to obtain the formed cable is as follows: Before bending the cable to be formed, the position of the binding bracket is set according to the three-dimensional design pattern of the cable, so that when the cable is fixed in the sampling dimensional tooling, at least one binding point is respectively set in the straight line area in front of and behind the bending area of ​​the cable, and each binding point is bound to a binding bracket (5); the spacing between the plurality of binding brackets (5) used for binding and fixing the same formed cable is 200-400 mm; Assume that the bending area of ​​a cable to be formed is n, n≥1. First, after forming the first bending area using a bending mold, place the cable to be formed in a sampling dimension forming tooling to determine whether the gap between the binding points set in the straight areas in front and behind the first bending area and the anti-static sponge in the binding bracket meets the requirement of -0.5mm~+0.5mm. If so, continue to use the bending mold to form the next bending area. If not, use the bending mold to adjust the first bending area until the gap between it and the anti-static sponge meets the requirement, and repeat the above steps to form the second to n bending areas.

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