A discrete support skin forming mold and method of use

Abstract

This invention discloses a discrete support skin forming mold and its usage method, belonging to the field of curved sheet metal forming technology. It includes a base, a discrete support device, and a positioning device; the base has multiple support holes for mounting the discrete support device; the discrete support device includes a sleeve and a support column; the upper end of the support column is hemispherical, and the lower part of the support column has an external thread structure; the inner wall of the sleeve has an internal thread structure; the sleeve is fitted onto the lower part of the support column and threadedly connected to it; the top of the sleeve has an integrated sleeve flange; the sleeve is located in the support hole, and the sleeve flange is positioned at the edge of the top of the support hole. This invention achieves flexible manufacturing of curved skin to a certain extent, breaking the correspondence between the panel and the mold, and realizing the purpose of producing multiple panels with one mold. It is particularly suitable for the production of large-aperture reflector antennas in single sets or small batches, as well as the production of other large-area, multi-variety panel products.

Description

Technical Field

[0001] This invention relates to the field of curved sheet metal forming technology, specifically to a discrete support skin forming mold and its usage method. Background Technology

[0002] The demands of radio astronomy observation and deep space exploration have driven the rapid development of large-aperture reflector antenna technology, contributing to many significant scientific explorations and discoveries. The reflector surface of large-aperture reflector antennas primarily utilizes a skin-back-rib structure. This structure is formed by bending a thin sheet of skin according to a specific curvature, then bending and attaching the back ribs to the back of the skin, and finally fixing them together using riveting or adhesive methods.

[0003] Due to the large aperture size and numerous segmented design, the curvature of each individual reflective panel is relatively small, making it difficult to bend and shape the skin using plastic forming methods. The industry primarily employs precision panel forming technology and manufacturing methods based on the principles of "enveloping molds, skin slits, stress release, and vacuum negative pressure." In this process, the curved surface shaping of the skin relies on molds. In traditional production methods, the forming molds for the skin are machined as a single unit, meaning the mold has a continuous, rigid working surface, resulting in high processing costs. Each type of panel requires the manufacture of a mold with a specific curved surface and dimensions. For large-aperture antennas, the variety of panel types necessitates the manufacture of many different molds, leading to significant production, storage, and management costs. This is especially true for many single-unit or small-batch large-aperture antennas, where the one-time mold cost constitutes a large proportion of the overall project cost. Furthermore, the continuous rigidity of the integrated mold presents difficulties in correcting the curved surface shape, hindering improved manufacturing precision and rapid manufacturing. Summary of the Invention

[0004] To address the problems existing in the aforementioned background technology, this invention proposes a discrete support skin forming mold and its usage method. It achieves flexible manufacturing of curved skin to a certain extent, breaking the correspondence between the panel and the mold, and enabling the production of multiple panels from a single mold. It is particularly suitable for the production of large-aperture reflector antennas in single-unit or small-batch production, as well as the production of other large-area, multi-variety panel products.

[0005] The technical solution of this invention is implemented as follows:

[0006] A discrete support skin forming mold includes a base, a discrete support device, a positioning device, and a positioning rod; the base is provided with a plurality of support holes for mounting the discrete support device.

[0007] The discrete support device includes a sheath and a support column; the upper end of the support column is hemispherical, and the lower part of the support column has an external thread structure, while the inner wall of the sheath has an internal thread structure; the sheath is fitted onto the lower part of the support column and is threadedly connected to it; the top of the sheath is provided with an integral sheath flange; the sheath is located in a support hole, and the sheath flange is mounted on the edge of the top of the support hole; the support columns of multiple discrete support devices are used to support the skin to be shaped;

[0008] The skin to be shaped has a positioning hole, and the discrete support device located directly below the positioning hole is a positioning device; the top of the support column of the positioning device has a central hole extending along the central axis of the support column; the positioning rod passes through the positioning hole on the skin to be shaped and is fixed in the central hole.

[0009] Furthermore, the substrate is a planar structure or a curved structure; the support holes are arranged in a rectangular array on the substrate, each support hole has an independent identification number, and there is a clear positional relationship between each hole.

[0010] Furthermore, the axis of the sheath flange coincides with the axis of the sheath, and the upper surface of the sheath flange has uniformly circumferential graduations.

[0011] A method for using a discrete support skin forming mold, wherein the specific steps are as follows:

[0012] Step 1: Determine the location:

[0013] Before molding, based on the size and shape characteristics of the skin and the distribution of positioning devices on the mold, determine the coverage area of ​​the skin on the mold, the positioning position on the mold, and the positioning position of the skin to be molded. This step can be completed using 3D modeling software.

[0014] Step 2: Install the positioning device

[0015] Install positioning devices at the positioning positions on the mold; install discrete support devices at other support hole positions within the skin coverage area on the mold; machine positioning holes at the positioning positions on the skin, which can be completed in one operation during the cutting process of the skin shape;

[0016] Step 3: Adjusting the formed curved surface

[0017] The height of the support column is adjusted by the relative rotational movement of the support column and the sleeve, so that the upper end of each discrete support column forms a predetermined curved surface shape; the precise adjustment can be completed with the help of the scale on the sleeve flange.

[0018] Step 4: Confirmation of the formed curved surface

[0019] After the support columns are adjusted, remove the positioning rods, put the measuring sleeves on all the support columns covered by the skin, attach the measuring target to the upper surface of the measuring sleeves, and use digital close-range photogrammetry equipment or other high-precision measuring equipment to quickly collect and calculate the real-time shape of the surface to confirm that the surface adjustment is in place or to guide the adjustment work.

[0020] Step 5: Skin positioning

[0021] Remove all measuring sleeves; insert positioning rods into the support rods of the mold positioning device; spread the skin with precisely cut outline and positioning holes onto the support column of the mold, so that the positioning rods of the positioning device are inserted into the corresponding positioning holes on the skin, thereby achieving the positioning of the skin and the mold.

[0022] Step 6: Skin Forming

[0023] Vacuum negative pressure, sandbags, or other uniformly distributed pressure methods are used to ensure a tight and reliable fit between the skin and the upper surfaces of each support column of the mold, thereby achieving the shaping of the curved skin.

[0024] Furthermore, the measuring sleeve has a cylindrical structure with a boss at the top and a cylindrical hole extending along the central axis of the measuring sleeve at the bottom; the inner diameter of the cylindrical hole is the same as the outer diameter of the support column; the central axis of the cylindrical hole coincides with the central axis of the boss; and a measuring target is attached to the upper surface of the boss.

[0025] Compared with the prior art, the present invention has the following advantages:

[0026] 1. This invention achieves different surface configurations on a single mold by individually adjusting a certain number of discrete support structures and adjusting the relative positions of the dot matrix. It enables flexible manufacturing of different skin parts with precise positioning and shaping, with good operability and strong versatility.

[0027] 2. This invention achieves the effect of replacing multiple molds with one mold, which is particularly suitable for small-batch, multi-type panel production tasks, and greatly reduces the manufacturing, storage and management costs of molds.

[0028] 3. This invention facilitates the adjustment of mold surface shape and precision, eliminates the mold repair step, shortens the production cycle, and reduces production costs. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the structure of an embodiment of the present invention.

[0030] Figure 2 This is a schematic diagram of the usage structure of an embodiment of the present invention.

[0031] Figure 3 This is a schematic diagram of the discrete support device according to an embodiment of the present invention.

[0032] Figure 4 This is an exploded view of the positioning device according to an embodiment of the present invention.

[0033] Figure 5 This is a schematic diagram of the positioning device according to an embodiment of the present invention.

[0034] Figure 6 This is a schematic diagram of the structure of the skin to be shaped according to an embodiment of the present invention.

[0035] Figure 7 This is a cross-sectional view of the measuring sleeve according to an embodiment of the present invention.

[0036] 1: Matrix; 2: Discrete support device; 3: Positioning device; 4: Skin;

[0037] 2.1: Sheath; 2.2: Support column;

[0038] 3.2: Perforated support column; 3.3: Positioning rod;

[0039] 4.1: Slit structure; 4.2: Positioning holes; Detailed Implementation

[0040] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0041] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings of the embodiments will be briefly described below. The following detailed descriptions are merely illustrative of different aspects of the present invention and should not be construed as limiting the scope of the invention. Obviously, the drawings described below are only some embodiments of the invention; those skilled in the art can obtain other drawings based on these drawings without creative effort.

[0042] Reference Figures 1 to 7 A discrete support skin forming mold mainly includes a base 1, a discrete support device 2, a positioning device 3, and a measuring sleeve. The base 1 is a 2.5m × 2m flat steel plate with a thickness of 50mm. The steel plate has evenly spaced arrayed support holes, each 60mm in diameter and 80mm apart. This ensures a clear positional relationship between the center points of each support hole.

[0043] The discrete support device 2 comprises two parts: a sheath 2.1 and a support column 2.2. The sheath 2.1 has an internal thread structure, and the upper surface of the sheath flange of the sheath 2.1 is provided with radially spaced, equally spaced graduation lines. The upper end of the support column 2.2 is a hemispherical shape with a diameter of 50mm, and the lower half is machined with external threads. The internal thread of the sheath and the external thread of the support column mate, and the thread is a fine-pitch trapezoidal thread. The graduation lines guide the adjustment of the support column; the operator can easily determine the number of rotations of the support column by referring to the graduation lines, and thus accurately calculate the vertical adjustment distance of the support column through the thread pitch.

[0044] The positioning device 3 includes a sheath 2.1, a perforated support column 3.2, and a positioning rod 3.3. The only difference between the perforated support column 3.2 and the support column 2.2 is that the top of the perforated support column 3.2 has a central deep hole with a diameter of 10 mm. The positioning rod also has a diameter of 10 mm.

[0045] The sheath 2.1 is fixedly connected to the hole on the base 1; the support column 2.2 is fitted and connected to the sheath 2.1, and can move up and down along its axis. The diameter of the cylindrical hole inside the measuring sleeve is 50mm, which can precisely fit with the upper end of the support column. The upper end has a circular boss with an outer diameter of 15mm, and is concentric with the inner hole. The distance between the top surface of the boss and the top surface of the inner cylindrical hole is 10mm. A reflective measuring target of glass microspheres is attached to the upper surface of the boss.

[0046] To achieve precise positioning and shaping of the skin, the main operating methods for using molds are as follows:

[0047] 1. Determine the surface shape and positioning of the mold through theoretical models and data calculations.

[0048] Based on the model of the skin and the specifications of the mold, the curved shape of the mold is determined, which in turn determines the relative height position of each support column in the mold in theory, and a suitable position is selected as the positioning position; the flat unfolded material is calculated and cut according to the data of the formed skin, including the size of the positioning hole, which also needs to be processed in one go.

[0049] In this embodiment, eight positioning positions near the corners of the skin are determined based on the shape characteristics of the skin. These eight positions correspond to eight positions on the mold and are used to install positioning devices.

[0050] 2. Adjust the discrete surfaces of the mold

[0051] Adjust the relative height of the hemispherical apexes of the support columns in each discrete support device on the mold, so that the hemispherical apexes of a certain number of discrete support columns can fit the qualified curved surface shape required for skin forming. After the adjustment is completed, put all support columns on the measuring sleeve, and collect data at the center of the boss using digital close-up method. Calculate the accuracy of the generated curved surface and readjust it until the curved surface fitted by the top of the discrete support columns meets the requirements.

[0052] Select the 8 positioning positions determined in step 1, and replace the installed discrete support device with the positioning device. This can be done by simply replacing the support column with a perforated support column and inserting a positioning rod into its center hole.

[0053] 3. Position the skin and complete precise surface shaping.

[0054] The flat skin is attached to the support pillar of the mold, and the positioning holes of the skin are fitted onto the positioning rods. The cooperation between the positioning rods and the positioning holes achieves precise positioning of the skin. Then, by using sandbags or vacuum negative pressure, the skin is evenly and completely attached to the support pillar, achieving precise shaping of the skin.

[0055] In summary, this invention provides a technical solution for a discrete support skin forming mold, suitable for the precise positioning and surface forming of large-area, low-curvature rigid skins. This solution utilizes the multi-point forming principle to provide a split mold for multi-point support of discontinuous surfaces. The mold achieves high-precision discrete forming of curved surfaces through numerous regularly arranged discrete support devices in a dot matrix format. Combining the theoretical model and the specific dimensional characteristics of the actual object, appropriate positioning positions are selected, and precise positioning of the skin and mold is achieved through positioning rods and positioning holes. Compared to traditional integrated molds for continuous rigid surfaces, this technical solution achieves flexible manufacturing of curved skins to a certain extent, breaking the correspondence between the panel and the mold, and enabling the production of multiple panels from a single mold. It is particularly suitable for the production of large-aperture reflector antennas in single-unit or small-batch production, as well as the production of other large-area, multi-variety panel products.

[0056] This technical solution can greatly reduce the types and quantities of molds, significantly reduce mold production and storage costs, and shorten the mold repair and trial cycle, which is of positive significance.

[0057] It should be understood that the above description of the specific embodiments of this patent is merely an exemplary description provided to facilitate understanding of the patent solution by those skilled in the art, and does not imply that the scope of protection of this patent is limited to these specific examples. Those skilled in the art can obtain more specific embodiments without any creative effort by combining technical features, replacing some technical features, adding more technical features, etc., of the various examples listed in this patent, provided that they have a full understanding of the technical solution of this patent. All of these specific embodiments are within the scope of the claims of this patent, and therefore, these new specific embodiments should also be within the scope of protection of this patent.

[0058] Furthermore, for the purpose of simplifying the description, this patent may not list some common specific implementation schemes that can be naturally conceived by a person skilled in the art after understanding the technical solution of this patent. Obviously, these schemes should also be included within the scope of protection of this patent.

Claims

1. A discrete support skin form mold characterized by, It includes a measuring sleeve, a base, a discrete support device, a positioning device, and a positioning rod; the base is provided with multiple support holes for mounting the discrete support device. The discrete support device includes a sheath and a support column; the upper end of the support column is hemispherical, and the lower part of the support column has an external thread structure, while the inner wall of the sheath has an internal thread structure; the sheath is fitted onto the lower part of the support column and is threadedly connected to it; the top of the sheath is provided with an integral sheath flange; the sheath is located in a support hole, and the sheath flange is mounted on the edge of the top of the support hole; the support columns of multiple discrete support devices are used to support the skin to be shaped; The skin to be shaped has positioning holes, and the discrete support device located directly below the positioning holes is a positioning device; the top of the support column of the positioning device has a central hole extending along the central axis of the support column; the positioning rod passes through the positioning holes on the skin to be shaped and is fixed in the central hole. The substrate is a planar or curved structure; the support holes are arranged in a rectangular array on the substrate, each support hole has an independent identification number, and there is a clear positional relationship between each hole; The axis of the sheath flange coincides with the axis of the sheath, and the upper surface of the sheath flange has a uniform circumferential scale. The measuring sleeve has a cylindrical structure with a boss at the top and a cylindrical hole at the bottom extending along the central axis of the measuring sleeve. The inner diameter of the cylindrical hole is the same as the outer diameter of the support column. The central axis of the cylindrical hole coincides with the central axis of the boss. A measuring target is attached to the upper surface of the boss.

2. A method of using a discrete support skin forming mold, for using the discrete support skin forming mold as described in claim 1, characterized in that, The specific steps are as follows: Step 1: Determine the location: Before molding, based on the size and shape characteristics of the skin and the distribution of the positioning devices on the mold, determine the coverage area of ​​the skin on the mold, the positioning position on the mold, and the positioning position of the skin to be molded. This step can be completed using 3D modeling software. Step 2: Install the positioning device: Install positioning devices at the positioning positions on the mold; install discrete support devices at other support hole positions within the skin coverage area on the mold; machine positioning holes at the positioning positions on the skin, which can be completed in one operation during the cutting process of the skin shape; Step 3: Adjusting the formed curved surface: The height of the support column is adjusted by the relative rotational movement of the support column and the sleeve, so that the upper end of each discrete support column forms a predetermined curved surface shape; the precise adjustment can be completed with the help of the scale on the sleeve flange. Step 4: Confirm the formed curved surface: After the support columns are adjusted, remove the positioning rods, put the measuring sleeves on all the support columns covered by the skin, attach the measuring target to the upper surface of the measuring sleeves, and use digital close-range photogrammetry equipment or other high-precision measuring equipment to quickly collect and calculate the real-time shape of the surface to confirm that the surface adjustment is in place or to guide the adjustment work. Step 5: Skin positioning: Remove all measuring sleeves; insert positioning rods into the support rods of the mold positioning device; spread the skin with precisely cut outline and positioning holes onto the support column of the mold, so that the positioning rods of the positioning device are inserted into the corresponding positioning holes on the skin, thereby achieving the positioning of the skin and the mold. Step 6: Skin forming: Vacuum negative pressure, sandbags, or other uniformly distributed pressure methods are used to ensure a tight and reliable fit between the skin and the upper surfaces of each support column of the mold, thereby achieving the shaping of the curved skin.

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