An X-band dual-polarized stacked waveguide manufacturing process

Abstract

The application relates to a kind of X-band dual-polarization stacked waveguide manufacturing methods, the application is mainly in fixed tooling, using T-type positioning device realizes the positioning installation of narrow edge waveguide and wide edge ridge waveguide, structural glue is daubed in the mutual adhesion surface between wide edge ridge waveguide and narrow edge waveguide, after the solidification of structural glue, the wide edge ridge waveguide and narrow edge waveguide of adhesive solidification and structural glue form waveguide subarray, the waveguide subarray after having been adhered and solidified is taken off from fixed tooling;The waveguide subarray can be combined to form waveguide subarray, and X-band dual-polarization stacked waveguide is formed.The beneficial effects achieved by the application are that the manufacturing method can realize high-precision and high-efficiency waveguide manufacturing.

Description

Technical Field

[0001] This invention relates to the field of adhesive strip installation technology, and in particular to a fabrication process for an X-band dual-polarization superimposed waveguide. Background Technology

[0002] like Figure 1 As shown, a certain X-waveguide dual-polarized common-aperture antenna uses a 16mm × 8.3mm wide-side ridge waveguide and a 25.4mm × 7.5mm narrow-side waveguide stacked to achieve horizontal and vertical polarization of the waveguide slot antenna. Both the 16mm × 8.3mm wide-side ridge waveguide and the 25.4mm × 7.5mm narrow-side waveguide are made of aluminum profiles.

[0003] Existing X-band dual-polarized common-aperture antennas employ a piecewise screw-connection assembly process. The 16 mm × 8.3 mm wide-side ridge waveguide is directly screwed to the antenna frame, while the 25.4 mm × 7.5 mm narrow-side waveguide requires a transition post welded before screwing to the frame. This existing technology suffers from drawbacks such as significant welding deformation, high cost, low installation efficiency, and excessively poor antenna profile accuracy after installation. Achieving high-precision installation of the dual-polarized superimposed waveguide is the main challenge. Therefore, a fabrication process for X-band dual-polarized superimposed waveguides is proposed. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a high-efficiency fabrication process for X-band dual-polarized superimposed waveguides. It solves the problems of large welding deformation, high cost, low installation efficiency, and excessively poor antenna profile accuracy after installation inherent in existing technologies.

[0005] The objective of this invention is achieved through the following technical solution: A method for fabricating an X-band dual-polarized superimposed waveguide, comprising: Step 1: Obtain the fixing fixture, which includes a base plate, a secondary plate, and a clamping device; Step 2: Install and fix the waveguide positioning block to one end of the secondary plate; Step 3: Install the narrow-side waveguide in the positioning mounting slot on the secondary flat plate. The end face of the narrow-side waveguide along its length is positioned and installed using waveguide positioning blocks. Step 4: Obtain the T-shaped positioning device, which includes a height equalization block, a mounting plate, and a T-shaped component; Step 5: Place the wide-side ridge waveguide parallel to the narrow-side waveguide and the positioning mounting slot, and place the wide-side ridge waveguides alternately on two adjacent narrow-side waveguides; Step 6: Insert the lower part of the T-shaped component into the middle of two adjacent wide-side ridge waveguides and fix them in place; Step 7: Use the clamping device to clamp the wide-side ridge waveguide and the narrow-side waveguide, so that the narrow-side waveguide fits against the lower wall of the positioning and mounting groove, and the wide-side ridge waveguide fits against the narrow-side waveguide; Step 8: Apply structural adhesive to the mating surfaces between the T-shaped component, the wide-side ridge waveguide, and the narrow-side waveguide; Step 9: After the structural adhesive has cured, bond the cured wide-side ridge waveguide, narrow-side waveguide and structural adhesive to form a waveguide subarray, and remove the bonded and cured waveguide subarray from the fixture.

[0006] Furthermore, in step three, the gap between the mating surfaces of the narrow-side waveguide and the waveguide positioning block is less than or equal to 0.2 mm; Furthermore, in step five, the gap between the mating surfaces of the wide-edge ridge waveguide and the waveguide positioning block is less than or equal to 0.2 mm.

[0007] Furthermore, step six includes: the wide-edge ridge waveguide and the T-shaped positioning device are fitted with a gap of 0.2 mm.

[0008] Furthermore, step seven includes: the gap between the narrow-side waveguide and the secondary plate is less than or equal to 0.3 mm, and the gap between the wide-side ridge waveguide and the narrow-side waveguide is less than or equal to 0.3 mm.

[0009] Furthermore, the fixing fixture includes a base plate, a secondary plate, and a clamping device; The substrate is rectangular, with a secondary plate mounted in the middle of the substrate and guide grooves on both sides of the substrate. The clamping device includes a positioning column, a rotating column, and a clamping arm; one end of the clamping arm is mounted on the positioning column by a screw, and the other end is hinged to the rotating column by a rotating shaft; The positioning post is installed on one side of the substrate along the guide groove on the substrate; the rotating post is installed on the other side of the substrate in the guide groove, and the top of the rotating post is provided with a rotating shaft.

[0010] Furthermore, the secondary plate is provided with multiple positioning mounting slots, which are arranged sequentially in the transverse direction. The gap between two adjacent positioning mounting slots is 0.2mm, the accuracy error of the spacing between two adjacent positioning mounting slots is ±0.02mm, and the straightness of each positioning mounting slot is 0.1mm.

[0011] Furthermore, the T-shaped positioning device includes a height equalization block, a mounting plate, and a T-shaped component; The contour blocks are symmetrically installed on both sides of the substrate, and the lower end of the contour blocks is provided with two symmetrical connecting ears; the two ends of the mounting plate are fixed on the two symmetrical contour blocks, the lower surface of the mounting plate is fixed to the smooth surface of the T-shaped piece, and the lower end of the T-shaped piece is inserted into the adjacent wide-side ridge waveguide.

[0012] Furthermore, a method for fabricating an X-band dual-polarization superimposed waveguide also includes: bonding multiple waveguide subarrays together to form an integrated frame structure, thereby obtaining a waveguide array.

[0013] The present invention has the following advantages: (1) The assembly efficiency and assembly accuracy can be improved by using the integrated bonding molding of waveguide subarrays; (2) The radar antenna system formed by the integrated assembly of waveguide subarrays has improved its electrical energy parameters such as beam pointing and sidelobe level. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of a dual-polarized common-aperture antenna for an X-waveguide. Figure 2 This is a schematic diagram of the waveguide positioning block. Figure 3 A schematic diagram of the waveguide subarray fabricated according to the present invention; Figure 4 This is a schematic diagram of the clamping device. Figure 5 This is a schematic diagram of the T-shaped positioning device; In the figure: 1-fixed fixture; 2-T-shaped positioning device; 3-narrow-side waveguide; 4-wide-side ridge waveguide; 5-waveguide positioning block; 6-clamping block; 11-substrate; 12-secondary plate; 13-clamping device; 21-level block; 22-mounting plate; 23-T-shaped part; 131-positioning post; 132-rotating post; 133-clamping arm. Detailed Implementation

[0015] The present invention will be further described below with reference to the accompanying drawings, but the scope of protection of the present invention is not limited to the following description.

[0016] It should be noted that the orientation or positional relationship indicated by terms such as "left" and "right" is based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of the invention is usually placed during use, or the orientation or positional relationship in which those skilled in the art would conventionally understand it. Such terms are only for the convenience of describing the invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention.

[0017] It should be noted that, unless otherwise specified, the embodiments and features and technical solutions in the present invention can be combined with each other.

[0018] like Figures 3-5 As shown, this embodiment proposes a method for fabricating an X-band dual-polarized superimposed waveguide, comprising: Step 1: Obtain the fixing fixture 1, which includes a base plate 11, a secondary plate 12, and a clamping device 13; Step 2: Install and fix the waveguide positioning block 5 to one end of the secondary plate 12; Step 3: Install the narrow-side waveguide 3 in the positioning and mounting slot on the secondary flat plate 12. The end face of the narrow-side waveguide 3 in the length direction is positioned and installed by the waveguide positioning block 5. Step 4: Obtain the T-shaped positioning device 2, which includes a height equalization block 21, a mounting plate 22, and a T-shaped component 23; Step 5: Place the wide-side ridge waveguide 4 parallel above the narrow-side waveguide 3 and the positioning mounting slot, and place the wide-side ridge waveguide 4 alternately on two adjacent narrow-side waveguides 3; Step 6: Insert the lower part of the T-shaped piece 23 into the middle of two adjacent wide-side ridge waveguides 4 and fix them in place; Step 7: Use the clamping device 13 to clamp the wide-side ridge waveguide 4 and the narrow-side waveguide 3, so that the narrow-side waveguide 3 is in contact with the lower wall of the positioning and mounting groove, and the wide-side ridge waveguide 4 is in contact with the narrow-side waveguide 3. Step 8: Apply structural adhesive to the mating surfaces between the T-shaped component 23, the wide-side ridge waveguide 4, and the narrow-side waveguide 3; Step 9: After the structural adhesive has cured, bond the cured wide-side ridge waveguide 4, narrow-side waveguide 3 and structural adhesive to form a waveguide subarray, and remove the bonded and cured waveguide subarray from the fixture.

[0019] Specifically, such as Figure 3 As shown, the X-waveguide dual-polarization superimposed waveguide forms a waveguide subarray by bonding eight 16 mm × 8.5 mm × 1 mm wide-side ridge waveguides 4 and eight 25.4 mm × 7.5 mm × 1.27 mm narrow-side waveguides 3 onto a fixed fixture 1. The fixed fixture 1 is provided with multiple T-shaped positioning devices 2 at unequal intervals. The T-shaped positioning devices 2 are used to position and install the wide-side ridge waveguides 4 and narrow-side waveguides 3. At the same time, a clamping device 13 is provided before and after each T-shaped positioning device 2 on the fixed fixture 1 to assist in fixing and clamping the wide-side ridge waveguides 4 and narrow-side waveguides 3.

[0020] In step three, the narrow-side waveguide 3 is installed in the positioning and mounting slot on the secondary flat plate 12, and the end faces of multiple narrow-side waveguides 3 along the length direction are positioned and installed by the waveguide positioning block 5. like Figure 3 As shown, the narrow-side waveguide 3 is positioned and installed by the waveguide positioning block 5, which is horizontally fixed on the secondary plate 12. The waveguide positioning block 5 completes the positioning and installation of the narrow-side waveguide 3 by manually adjusting the position of the narrow-side waveguide 3, ensuring that the top end face of the narrow-side waveguide 3 is flush with the top end face on this side. The narrow-side waveguide 3 is required to fit with the waveguide positioning block 5, and the gap between the fitting surfaces is less than or equal to 0.2mm.

[0021] Step five also includes positioning and installing the wide-ridge waveguide 4 using waveguide positioning block 5: the waveguide positioning block 5 is inserted perpendicularly to the surface of the secondary plate 12, and the wide-ridge waveguide 4 is positioned along its length by the waveguide positioning block 5. The positioning and installation of the wide-ridge waveguide 4 is completed by manually adjusting the position of the wide-ridge waveguide 4. The waveguide positioning block 5 ensures that the top end face of the wide-ridge waveguide 4 is flush with the surface of the wide-ridge waveguide 4, and the gap between the mating surfaces of the wide-ridge waveguide 4 and the waveguide positioning block 5 is less than or equal to 0.2 mm.

[0022] Step 6: Insert the lower part of the T-shaped piece 23 into the middle of two adjacent wide-side ridge waveguides 4; the gap between the wide-side ridge waveguide 4 and the lower part of the T-shaped piece 23 is 0.2mm, which facilitates waveguide positioning and bonding.

[0023] Step seven includes: the gap between the narrow-side waveguide 3 and the secondary plate 12 is less than or equal to 0.3 mm, and the gap between the wide-side ridge waveguide 4 and the narrow-side waveguide 3 is less than or equal to 0.3 mm; A clamping block 6 is placed between the clamping device 13 and the wide-side ridge waveguide 4. The clamping block 6 is pressed down by the bolt in the middle of the clamping device 13. The clamping block 6 transmits pressure to the wide-side ridge waveguide 4 and the narrow-side ridge waveguide 3, so that the wide-side ridge waveguide 4 and the narrow-side waveguide 3 are pressed together. The narrow-side waveguide 3 is attached to the lower wall of the positioning and mounting groove. It is required that the gap between the narrow-side waveguide 3 and the secondary plate 12 is less than or equal to 0.3mm, and the gap between the wide-side ridge waveguide 4 and the narrow-side waveguide 3 is less than or equal to 0.3mm, to ensure the flatness of the wide-side ridge waveguide 4 and the narrow-side ridge waveguide 3 after bonding.

[0024] like Figure 3 As shown, the fixing fixture 1 includes a base plate 11, a secondary plate 12, and a clamping device 13; The substrate 11 is rectangular, and a secondary plate 12 is mounted in the middle of the substrate 11. Guide grooves are provided on both sides of the substrate 11. like Figure 4 As shown, the clamping device 13 includes a positioning post 131, a rotating post 132, and a clamping arm 133; one end of the clamping arm 133 is mounted on the positioning post 131 by screws, and the other end is hinged to the rotating post 132 by a rotating shaft; The positioning post 131 is installed on one side of the substrate 11 along the guide groove on the substrate 11. The bottom of the positioning post 131 is inserted into the guide groove. The bottom of the positioning post 131 is provided with symmetrical lugs. The lugs are provided with threaded holes. Screws pass through the threaded holes to fix the positioning post 131 on the substrate 11. The top of the positioning post 131 is provided with threaded holes. The rotating post 132 is installed on the other side of the substrate 11 in the guide groove relative to the positioning post 131. The bottom of the rotating post 132 is inserted into the guide groove. The bottom of the rotating post 132 is provided with symmetrical lugs. The lugs are provided with threaded holes. Screws pass through the threaded holes to fix the positioning post 131 on the substrate 11. The bottom two sides are fixed to the substrate 11 by screws. The top of the rotating post 132 is provided with a rotating shaft. In some specific embodiments, the secondary plate 12 is set to 3m×1.5m, and multiple positioning mounting slots are provided on the secondary plate 12 arranged sequentially in the transverse direction. The positioning mounting slots are used to install the narrow-side waveguide 3 and the wide-side ridge waveguide 4. The gap between two adjacent positioning mounting slots is 0.2mm, the spacing accuracy error between two adjacent positioning mounting slots is ±0.02mm, and the straightness is 0.1mm.

[0025] Fixture 1 is used to assist in the positioning and installation of the wide-side ridge waveguide 4 and the narrow-side waveguide 3.

[0026] like Figure 5 As shown, the T-shaped positioning device 2 includes a height equalization block 21, a mounting plate 22, and a T-shaped component 23; The contour blocks 21 are symmetrically mounted on the guide grooves on both sides of the substrate 11. The lower end of the contour blocks 21 is provided with two symmetrical connecting ears. Screws pass through the connecting ears to fix the contour blocks 21 on the substrate 11. The contour blocks are used to control the height of the narrow-side waveguide 3 and the wide-side ridge waveguide 4 after they are stacked. The mounting plate 22 is fixed at both ends on the two symmetrical contour blocks 21. The lower surface of the mounting plate 22 is fixed to the smooth surface of the T-shaped piece 23. The lower end of the T-shaped piece 23 is inserted into the adjacent wide-side ridge waveguide 4.

[0027] A method for fabricating X-band dual-polarized superimposed waveguides further includes: bonding multiple waveguide subarrays together to form an integrated frame structure to create a waveguide array. Existing technology uses 64 wide-side ridge waveguides 4 (16 mm × 8.3 mm × 1 mm) and 64 narrow-side waveguides 3 (25.4 mm × 7.5 mm × 1.27 mm) individually screwed onto a frame. This invention optimizes and improves the structure by using 8 waveguide subarrays fixed to the frame via screwing. The original single narrow-side waveguide 3 experienced welding deformation exceeding 1 mm, requiring a shim adjustment assembly process to ensure antenna array surface accuracy. This assembly process suffers from low efficiency and poor surface accuracy. After using integrated bonding of the waveguide subarrays, the surface accuracy of the waveguide subarray can be controlled to an RMS of less than or equal to 0.1 mm. The direct assembly process of waveguide subarrays was adopted to replace the assembly process with shims, thereby achieving an antenna array surface accuracy RMS of less than or equal to 0.2mm. The assembly efficiency was improved by nearly 10 times, and the surface accuracy was improved from the original RMS greater than or equal to 0.5mm to RMS less than or equal to 0.2mm.

[0028] The above embodiments only illustrate preferred implementation methods, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of this invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this invention, and these all fall within the protection scope of this invention.

Claims

1. A method for fabricating an X-band dual-polarized superimposed waveguide, characterized in that: include: Step 1: Obtain the fixing fixture (1), which includes a base plate (11), a secondary plate (12), and a clamping device (13). Step 2: Install and fix the waveguide positioning block (5) to one end of the secondary plate (12); Step 3: Install the narrow-side waveguide (3) in the positioning mounting slot on the secondary plate (12). The end face of the narrow-side waveguide (3) in the length direction is positioned and installed by the waveguide positioning block (5). The narrow-side waveguide (3) is in contact with the waveguide positioning block (5), and the gap between the contact surfaces is less than or equal to 0.2 mm. The gap between the narrow-side waveguide (3) and the secondary plate (12) is less than or equal to 0.3 mm. Step 4: Obtain the T-shaped positioning device (2), which includes a height block (21), a mounting plate (22), and a T-shaped component (23). Step 5: Place the wide-side ridge waveguide (4) parallel above the narrow-side waveguide (3) and the positioning mounting slot, and place the wide-side ridge waveguide (4) alternately on two adjacent narrow-side waveguides; Step 6: Insert the lower part of the T-shaped piece (23) into the middle of two adjacent wide-side ridge waveguides (4) and fix them together; the gap between the wide-side ridge waveguide (4) and the lower part of the T-shaped piece (23) is 0.2mm; Step 7: Use the clamping device (13) to clamp the wide-side ridge waveguide (4) and the narrow-side waveguide (3) so that the narrow-side waveguide (3) is in contact with the lower wall of the positioning mounting groove, and the wide-side ridge waveguide (4) is in contact with the narrow-side waveguide (3); wherein the gap between the wide-side ridge waveguide (4) and the narrow-side waveguide (3) is less than or equal to 0.3mm; Step 8: Apply structural adhesive to the mating surfaces between the T-shaped component (23), the wide-side ridge waveguide (4), and the narrow-side waveguide (3); Step 9: After the structural adhesive has cured, bond the cured wide-side ridge waveguide (4), narrow-side waveguide (3) and structural adhesive to form a waveguide subarray, and remove the bonded and cured waveguide subarray from the fixture (1).

2. The method for fabricating an X-band dual-polarized superimposed waveguide according to claim 1, characterized in that: Step five also includes: Position and install the wide-side ridge waveguide (4) using the waveguide positioning block (5): A waveguide positioning block (5) is inserted perpendicular to the surface of the secondary plate (12). The waveguide positioning block (5) positions the wide-side ridge waveguide (4) along its length. The gap between the mating surfaces of the wide-side ridge waveguide (4) and the waveguide positioning block (5) is less than or equal to 0.2 mm.

3. The method for fabricating an X-band dual-polarized superimposed waveguide according to claim 2, characterized in that: The substrate (11) is rectangular, with a secondary plate (12) installed in the middle of the substrate, and guide grooves provided on both sides of the substrate (11). The clamping device (13) includes a positioning column (131), a rotating column (132), and a clamping arm (133); one end of the clamping arm (133) is mounted on the positioning column (131) by screws, and the other end is hinged to the rotating column (132) by a rotating shaft; The positioning post (131) is installed on one side of the substrate (11) along the guide groove on the substrate (11); the rotating post (132) is installed on the other side of the substrate (11) relative to the positioning post (131), and the top of the rotating post (132) is provided with a rotating shaft.

4. The method for fabricating an X-band dual-polarized superimposed waveguide according to claim 3, characterized in that: The secondary plate (12) is provided with multiple positioning mounting slots, which are arranged sequentially in the horizontal direction. The gap between two adjacent positioning mounting slots is 0.2mm, the accuracy error of the distance between two adjacent positioning mounting slots is ±0.02mm, and the straightness of each positioning mounting slot is 0.1mm.

5. The method for fabricating an X-band dual-polarized superimposed waveguide according to claim 1, characterized in that: The contour blocks (21) are symmetrically installed on both sides of the substrate (11). The lower end of the contour blocks (21) is provided with two symmetrical connecting ears. The two ends of the mounting plate (22) are fixed on the two symmetrical contour blocks (21). The lower surface of the mounting plate (22) is fixed to the smooth surface of the T-shaped piece (23). The lower end of the T-shaped piece (23) is inserted into the adjacent wide-side ridge waveguide (4).

6. The method for fabricating an X-band dual-polarized superimposed waveguide according to claim 1, characterized in that, Also includes: Multiple waveguide subarrays are bonded together to form an integrated frame structure, thus obtaining a waveguide array.

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