A stress absorption device and assembly method based on a flangeless waveguide

Abstract

This invention relates to a stress-absorbing device and assembly method based on a flangeless waveguide, comprising an I-beam bracket, waveguide clips, screws, spring washers, flat washers, and rubber pads. The rubber pads, serving as stress-absorbing materials, have a slanted opening on their long end face, allowing them to fit over the outer surface of the waveguide. Waveguide clips press against the rubber pads and have through holes. The I-beam bracket has threaded through holes on its wall surface. Screws, fitted with spring washers and flat washers, pass through the through holes in the waveguide clips and connect to the threaded through holes in the I-beam bracket wall. Tightening the screws secures the waveguide clips, rubber pads, and waveguide. Loosening the screws adjusts the relative position of the rubber pads, releasing assembly stress. This invention eliminates assembly stress generated during the assembly of flangeless waveguide components without affecting the assembly efficiency and reliability of other individual devices in the spacecraft, reducing the risk of failure due to assembly stress in flangeless waveguides.

Description

Technical Field

[0001] This invention belongs to the field of spacecraft payload technology, and relates to a stress absorption device and assembly method based on a flangeless waveguide. Background Technology

[0002] With the development of aerospace technology and the continuous research and development of high-throughput satellite models, in order to load more payloads inside the cabin, the spatial layout of waveguide components will present a multi-beam, dense arrangement, and the application of flangeless waveguides will become more and more widespread. Flangless waveguides are fixed by means of brackets and clamps to tighten and hold the waveguide components, and are generally made of hard aluminum material.

[0003] During the assembly process, waveguide components in spacecraft generate assembly stress, which directly acts on the waveguide. Since the waveguide is made of hard aluminum alloy and has a wall thickness of about 1 mm, long-term exposure to assembly stress will cause deformation and failure of the waveguide, affecting the electrical performance of the waveguide components and thus impacting the stability and reliability of the spacecraft throughout its entire lifecycle.

[0004] Due to the gradual accumulation of design tolerances and assembly errors, waveguides, supports, and clamps inevitably experience assembly stresses of varying degrees when assembled together. Although there is extensive experience with mounting flangeless waveguide components onto satellites, the assembly stress problem in flangeless waveguides cannot be completely eliminated. The presence of stress directly leads to varying degrees of deformation in the waveguide and persists throughout the spacecraft's lifecycle. Current methods for relieving assembly stress in flangeless waveguides are relatively limited, typically involving adjusting the installation position of individual components, the relative installation positions of supports and clamps, and using nylon tape to fill the gap between the clamps and the waveguide to adjust installation deviations.

[0005] Currently, the use of nylon tape filling in waveguide assembly with brackets and clamps suffers from low assembly efficiency, high skill requirements, and difficulty in implementation during assembly operations for models with densely packed waveguide components. To improve assembly efficiency and meet the increasing demands of model assembly tasks while ensuring product performance and reliability, a new device for stress relief or absorption in flangeless waveguide assembly is needed. This device would eliminate the assembly stress generated during the assembly of flangeless waveguides, ensuring high reliability for model tasks. Summary of the Invention

[0006] The technical problem solved by this invention is to overcome the shortcomings of the prior art and propose a stress absorption device and assembly method based on a flangeless waveguide. This method aims to eliminate or reduce the assembly stress generated during the assembly of flangeless waveguide components without affecting the assembly efficiency and reliability of other individual equipment in the spacecraft, thereby reducing the risk of failure of the flangeless waveguide due to assembly stress.

[0007] The solution of the present invention is: a stress absorption device based on a flangeless waveguide, comprising an I-shaped bracket, a waveguide clip, screws, spring washers, flat washers, and rubber pads;

[0008] The rubber pad, used as a stress-absorbing material, has a truncated oblique opening on one end face for fitting onto a predetermined position on the outer surface of the waveguide. The waveguide clip presses against the rubber pad and the I-shaped bracket along the direction perpendicular to the waveguide axis. The part of the waveguide clip that presses against the I-shaped bracket has a through hole, and the wall of the I-shaped bracket is designed with threaded through holes. Screws equipped with spring washers and flat washers pass through the through holes of the waveguide clip and connect with the threaded through holes on the wall of the I-shaped bracket. Tightening the screws secures the waveguide clip, the rubber pad, and the waveguide, and the end face of the waveguide clip with the oblique opening contacts the end face of the rubber pad.

[0009] Furthermore, spring washers and flat washers are inserted into the screws one after the other.

[0010] Furthermore, the rubber pad has a rectangular cavity structure with dimensions designed according to the outer contour of the waveguide; its largest end face has an oblique opening, and the rubber pad is fitted onto the outer surface of the waveguide through the oblique opening, and after being fitted, it restores its initial structure through its own elasticity.

[0011] Furthermore, the thickness of the rubber pad is set according to the gap between the waveguide clip and the waveguide, so that the waveguide clip, rubber pad and waveguide are fastened together after the screw is tightened.

[0012] Furthermore, depending on the waveguide mounting method, waveguide clips include H-plane waveguide clips and E-plane waveguide clips.

[0013] Furthermore, the wall surface of the I-shaped bracket supports the simultaneous installation of multiple waveguides.

[0014] Furthermore, the bottom of the I-shaped bracket is provided with light holes on both sides for screwing the second screw to the mounting surface of the external equipment. The diameter of the second screw is 0.5 to 0.8 mm smaller than the diameter of the light hole.

[0015] Furthermore, a method for assembling a stress absorption device based on a flangeless waveguide is provided, comprising the following steps:

[0016] The I-shaped bracket is installed and fixed onto the external mounting plate;

[0017] Place the rubber pad onto the waveguide, and adjust the relative position of the rubber pad according to the actual position of the waveguide and the I-shaped bracket.

[0018] Select waveguide clips according to the waveguide mounting method;

[0019] Press the waveguide clip onto the rubber pad, ensuring that the distance between the two ends of the waveguide clip and the two ends of the rubber pad are equal.

[0020] After the screw is inserted into the spring washer and the flat washer, it passes through the through hole on the waveguide clip and the threaded through hole on the wall of the I-shaped bracket. Tighten the screw until the spring washer is flattened.

[0021] Inspect the waveguide assembly. If the assembly stress is too high, causing the waveguide to deform, or if there are deviations in assembly accuracy and the screws cannot be connected, loosen the screws, adjust the relative position of the rubber pads, release the assembly stress, and ensure assembly accuracy.

[0022] Furthermore, if the assembly stress is found to be too high, causing waveguide deformation, it can be adjusted in the following ways:

[0023] Loosen the second screw and fine-tune the relative position of the I-shaped bracket on the external mounting plate within the range of the difference between the diameter of the second screw and the diameter of the optical aperture, thereby achieving fine-tuning of the distance between the waveguide and the I-shaped bracket and eliminating the design tolerance between the two; then tighten the second screw.

[0024] The advantages of this invention compared to the prior art are:

[0025] (1) Without affecting the assembly efficiency and reliability of other individual equipment in the spacecraft, this invention utilizes a rubber pad with a special structural shape as a stress absorption device for flangeless waveguide assembly, thereby eliminating or reducing the assembly stress generated during the assembly of flangeless waveguide components and reducing the risk of failure of flangeless waveguides due to assembly stress.

[0026] (2) The device of the present invention is easy to assemble and adjust. When it is found that the assembly stress is too large, causing the waveguide to deform or the assembly accuracy is deviated and the screws cannot be connected, the assembly stress can be released and the assembly accuracy can be ensured by loosening the screws and adjusting the relative position of the rubber pad, or by using the margin between the diameter of the second screw and the diameter of the optical hole to finely adjust the relative position of the I-shaped bracket on the spacecraft cabin plate. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the overall assembly structure of the waveguide stress absorption device according to an embodiment of the present invention;

[0028] Figure 2 This is a schematic diagram of the rubber pad structure according to an embodiment of the present invention;

[0029] Figure 3 This is a schematic diagram of an I-shaped support structure. Detailed Implementation

[0030] The invention will now be further described with reference to the accompanying drawings.

[0031] This invention utilizes a specially designed rubber pad fitted onto a flangeless waveguide as an assembly stress-absorbing material. The selected rubber material meets the requirements of spacecraft operating conditions. The specific implementation is as follows:

[0032] like Figure 1 As shown, the stress absorption device based on a flangeless waveguide proposed in this invention includes an I-shaped bracket 2, a waveguide clip 3, a screw 4, a spring washer 5, a flat washer 6, and a rubber pad 7.

[0033] The rubber pad 7 is fitted onto the waveguide 1. The end face of the rubber pad 7 with the largest area has a cut-off oblique opening, which makes it easier for the rubber pad to be fitted onto the preset position on the outer surface of the waveguide 1 more quickly and efficiently.

[0034] Waveguide clip 3 presses against rubber pad 7 and I-beam bracket 2 along the direction perpendicular to the axis of waveguide 1. A through hole is provided at the point where waveguide clip 3 presses against I-beam bracket 2, and threaded through holes are designed on the wall surface of I-beam bracket 2. Spring washers 5 and flat washers 6 are inserted into screws 4 one after the other. The screws 4, equipped with spring washers 5 and flat washers 6, pass through the through hole of waveguide clip 3 and connect to the threaded through hole line on the wall surface of I-beam bracket 2. Tightening screws 4 secures waveguide clip 3, rubber pad 7, and waveguide 1 together, and the end face of waveguide clip 3 with an oblique opening contacts the rubber pad 7.

[0035] like Figure 2 As shown, in this embodiment, the rubber pad 7 is a cuboid cavity structure, and its dimensions are designed according to the outer contour of the waveguide 1. The slope of the oblique opening on its end face is as large as possible to increase the contact area between the oblique opening and the waveguide clip 3; the rubber pad 7 is fitted onto the outer surface of the waveguide 1 through the oblique opening, and after being fitted, it restores its initial structure through its own elasticity.

[0036] The thickness of the rubber pad 7 is set according to the gap between the waveguide clip 3 and the waveguide 1, so as to achieve a tight connection between the waveguide clip 3, the rubber pad 7, and the waveguide 1 after the screw 4 is tightened.

[0037] Preferably, depending on the installation method of the waveguide assembly, the waveguide clip 3 can be designed as an H-plane waveguide clip, an E-plane waveguide clip, etc.

[0038] like Figure 1 As shown, multiple waveguides 1 can be installed on the wall of the I-shaped bracket 2 at the same time.

[0039] Preferably, the bottom sides of the I-shaped bracket 2 are provided with light holes for screwing the second screw to the mounting surface of the external equipment; the diameter of the second screw is 0.5 to 0.8 mm smaller than the diameter of the light hole. In this embodiment, the second screw is φ4 mm and the light hole is φ4.5 mm.

[0040] The assembly method of the flangeless waveguide stress absorption device of the present invention includes the following steps:

[0041] 110. Select a suitable I-beam bracket 2 according to the structural shape of the waveguide assembly layout, and install the I-beam bracket 2 onto the spacecraft cabin plate through the optical hole and the second screw.

[0042] 120. Place the rubber pad 7 onto the waveguide 1, and adjust the relative position of the rubber pad 7 according to the actual position of the waveguide 1 and the I-shaped bracket 2.

[0043] 130. Select either H-plane waveguide clips or E-plane waveguide clips according to the installation method of the waveguide assembly;

[0044] 140. Press the waveguide clip 3 onto the rubber pad 7, and ensure that the edge distance between the two ends of the waveguide clip 3 and the two ends of the rubber pad 7 is equal.

[0045] 150. Screw 4 is inserted into spring washer 5 and flat washer 6 in succession, and then passes through the through hole on waveguide clip 3 and the threaded through hole on I-shaped bracket 2. Tighten screw 4 until spring washer 5 is flattened.

[0046] 160. Check the assembly of waveguide 1. If the assembly stress is too large, causing the waveguide 1 to deform or the assembly accuracy is off, and the screws 4 cannot be connected, loosen the screws 4, adjust the relative position of the rubber pads 7, release the assembly stress, and ensure the assembly accuracy.

[0047] In addition, if the assembly stress is found to be too large and causes deformation of waveguide 1, it can be adjusted in the following ways:

[0048] Loosen the second screw and fine-tune the relative position of the I-shaped bracket 2 on the spacecraft cabin plate within the range of the difference between the diameter of the second screw and the diameter of the optical aperture, thereby realizing the fine adjustment of the distance between the waveguide 1 and the I-shaped bracket 2 and eliminating the design tolerance between the two; then tighten the second screw.

[0049] This invention replaces the current method of using nylon tape to fill the waveguide with an innovative rubber pad structure to protect it from assembly stress deformation and failure. Compared to the nylon tape filling method, the rubber pad with an oblique opening structure can more effectively eliminate or reduce assembly stress. If the stress is too high during assembly or there is an assembly deviation between the screw hole and the screw, the assembly stress can be released and the assembly accuracy can be ensured by loosening the connecting screw and moving the position of the rubber pad. This achieves the goal of stress-free assembly of waveguide components and reduces the risk of failure of spacecraft waveguide components due to assembly stress.

[0050] Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make possible changes and modifications to the technical solutions of the present invention by utilizing the methods and techniques disclosed above without departing from the spirit and scope of the present invention. Therefore, any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solutions of the present invention shall fall within the protection scope of the technical solutions of the present invention.

Claims

1. A stress absorption device based on a flangeless waveguide, characterized in that, Includes I-shaped bracket (2), waveguide clip (3), screw (4), spring washer (5), flat washer (6), and rubber pad (7); The rubber pad (7) is used as a stress-absorbing material for assembly. One end face is provided with a truncated oblique opening for fitting onto the preset position on the outer surface of the waveguide (1). The waveguide clip (3) is pressed on the rubber pad (7) and the I-shaped bracket (2) along the direction perpendicular to the axis of the waveguide (1). The part of the waveguide clip (3) pressed on the I-shaped bracket (2) is provided with a through hole. The wall surface of the I-shaped bracket (2) is designed with a threaded through hole. The screw (4) equipped with spring washer (5) and flat washer (6) passes through the through hole of the waveguide clip (3) and connects with the threaded through hole line on the wall surface of the I-shaped bracket (2). Tightening the screw (4) makes the waveguide clip (3), the rubber pad (7) and the waveguide (1) secure together, and the end face of the waveguide clip (3) and the rubber pad (7) with the oblique opening is in contact. The rubber pad (7) is a rectangular cavity structure, and its size is designed according to the outer contour of the waveguide (1). The end face with the largest area is provided with an oblique opening. The rubber pad (7) is fitted onto the outer surface of the waveguide (1) through the oblique opening. After being fitted, it restores its initial structure through its own elasticity. The thickness of the rubber pad (7) is set according to the gap between the waveguide clip (3) and the waveguide (1) to achieve the tight fastening between the waveguide clip (3), the rubber pad (7), and the waveguide (1) after the screw (4) is tightened. The assembly process of the stress-absorbing device is as follows: Install and fix the I-shaped bracket (2) onto the external mounting plate; The rubber pad (7) is fitted onto the waveguide (1), and the relative position of the rubber pad (7) is adjusted according to the actual position of the waveguide (1) and the I-shaped bracket (2); Select waveguide clip (3) according to the installation form of waveguide (1); Press the waveguide clip (3) onto the rubber pad (7) and ensure that the distance between the two ends of the waveguide clip (3) and the two ends of the rubber pad (7) is equal; The screw (4) is inserted into the spring washer (5) and the flat washer (6) in succession, and then passes through the through hole on the waveguide clip (3) and the threaded through hole on the wall of the I-shaped bracket (2). Tighten the screw (4) until the spring washer (5) is flattened. Check the assembly of waveguide (1). If the assembly stress is too large and causes the waveguide (1) to deform or the assembly accuracy is off and the screws (4) cannot be connected, loosen the screws (4), adjust the relative position of the rubber pads (7), release the assembly stress, and ensure the assembly accuracy.

2. The stress absorption device based on a flangeless waveguide according to claim 1, characterized in that, The spring washer (5) and the flat washer (6) are inserted into the screw (4) one after the other.

3. The stress absorption device based on a flangeless waveguide according to claim 1, characterized in that, According to the installation form of the waveguide (1), the waveguide clip (3) includes the H-plane waveguide clip and the E-plane waveguide clip.

4. The stress absorption device based on a flangeless waveguide according to claim 1, characterized in that, The wall of the I-shaped bracket (2) supports the simultaneous installation of multiple waveguides (1).

5. A stress absorption device based on a flangeless waveguide according to claim 1, characterized in that, The bottom sides of the I-shaped bracket (2) are provided with light holes for screwing the second screw to the mounting surface of the external equipment. The diameter of the second screw is 0.5~0.8mm smaller than the diameter of the light hole.

6. A stress absorption device based on a flangeless waveguide according to claim 5, characterized in that, If the assembly stress is found to be too large, causing deformation of the waveguide (1), it can be adjusted in the following ways: Loosen the second screw and fine-tune the relative position of the I-shaped bracket (2) on the external mounting plate within the range of the difference between the diameter of the second screw and the diameter of the optical aperture, thereby realizing the fine adjustment of the distance between the waveguide (1) and the I-shaped bracket (2) and eliminating the design tolerance between the two; then tighten the second screw.

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