Antenna oscillator and manufacturing process

Abstract

The invention relates to the technical field of antenna oscillator manufacturing, in particular to an antenna oscillator and a manufacturing process thereof, and the manufacturing process sequentially comprises the steps of part machining, neatening, spot welding, inspection and cleaning before welding, pre-vacuumizing atmosphere protection furnace aluminum brazing, bench work, inspection and surface treatment and air tightness inspection. According to the invention, air tightness detection is carried out through the specially arranged detection hole, the structure and function of the antenna oscillator can be protected from being influenced, a convenient-to-operate and efficient detection mode is provided, and the quality and performance of the antenna oscillator are ensured, so that potential faults and maintenance cost are reduced in practical application, and the working efficiency is improved. The size precision and form and location tolerance of welded parts are inspected by using the tool, so that the accuracy and the consistency of products are ensured, redundant objects or unqualified products caused by machining errors are reduced, the quality of the products is further effectively controlled, qualified products are screened through strict detection standards, and the percent of pass of the whole products is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of antenna vibrator manufacturing, and in particular to an antenna vibrator and a manufacturing process. Background Art

[0002] Antenna elements are the basic parts of antennas. They usually refer to the specific parts of the antenna that are responsible for receiving or transmitting electromagnetic waves. In different antenna designs, the elements can have different shapes and structures, such as half-wave elements, quarter-wave elements, etc. The design of antenna elements directly affects the performance of the antenna, including frequency response, gain, directivity, etc. For example, in the classic half-wave element antenna, the length of the element is about half of the working wavelength. This design enables the antenna to effectively receive or transmit electromagnetic waves. Antenna elements play an important role in wireless communications, broadcasting, radar and other fields.

[0003] As a key component in the antenna system, the performance of the bracket directly affects the overall performance of the antenna system. The current production process needs to effectively control the excess material and airtightness problems in the production process while ensuring high precision and quality. In the existing manufacturing process, it is difficult to control the excess material on the antenna parts and the airtightness after welding. The excess material will cause the impedance mismatch of the antenna, thereby affecting the transmission efficiency and quality of the signal. The airtightness problem will cause changes in the material or structure inside the antenna, which will affect the stability of signal transmission. Summary of the invention

[0004] The purpose of the present invention is to provide an antenna element and a manufacturing process to solve the technical problems raised in the above background technology.

[0005] To achieve the above object, the present invention provides the following technical solutions.

[0006] An antenna vibrator comprises a base, a pair of first vibrator outer conductors, a pair of second vibrator outer conductors and four vibrator blades; the two first vibrator outer conductors and the two second vibrator outer conductors are welded and fixed on the base in an array around the base axis, and both extend vertically; the vibrator blades are welded and fixed on the outer walls of the first vibrator outer conductor and the second vibrator outer conductor near the top through connecting welding blocks; the two second vibrator outer conductors are fixedly welded with sealing welding blocks, and the two sealing welding blocks are provided with blind holes; when performing air tightness testing, the blind holes are tapped into threaded holes for sealing and connecting air tightness testing equipment.

[0007] The antenna vibrator provided by the present invention is provided with a blind hole on the sealing welding block, and the hole is tapped into a threaded hole during the detection process. An airtightness detection device, such as an airtightness detector, can be connected to the antenna vibrator, thereby ensuring that a detailed airtightness test can be performed on the inside of the antenna and the sealing performance of the antenna during use is ensured. When detecting the airtightness, damage or modification to other parts of the antenna vibrator can be avoided. The airtightness inspection is performed through a specially arranged detection hole, which can protect the structure and function of the antenna vibrator from being affected, and provides a method that is easy to operate and efficient to detect, thereby ensuring the quality and performance of the antenna vibrator, thereby reducing potential failures and maintenance costs in actual applications.

[0008] The present invention provides an antenna vibrator manufacturing process, which specifically includes the following process steps:

[0009] S1, parts processing: manufacture the various parts of the antenna vibrator according to the design, drawings and process requirements;

[0010] S2, complete set: according to production requirements, prepare the required parts, tooling and solder before assembly;

[0011] S3, spot welding: The parts are pre-positioned with high precision by using a pulse argon arc spot welding machine through the spot welding fixture, and the solder wire is arranged;

[0012] S4, inspection and cleaning before welding: check whether the size of the pre-positioned workpiece meets the technical requirements, and remove oil and oxide scale from the parts to be welded;

[0013] S5, pre-vacuum atmosphere protection furnace aluminum brazing: use the antenna vibrator tooling to perform furnace brazing of the antenna vibrator in the pre-vacuum atmosphere protection furnace;

[0014] S6, fitter: tapping threaded holes on the plugging welding block inside the outer conductor of the second vibrator;

[0015] Among them, in order to avoid the influence of pre-welding cleaning and welding process on the screw hole accuracy, the process plan is to drill out the sealing welding block of the outer conductor of the second vibrator before welding, and then tap the installation thread as required after welding to ensure the screw hole accuracy requirements;

[0016] S7, inspection and surface treatment: Use tooling to inspect the dimensional accuracy and geometric tolerance requirements of the welded parts, and perform conductive oxidation and paint treatment on the workpiece surface;

[0017] Among them, please note that the parts that do not need to be sprayed with paint need to be protected;

[0018] S8, airtightness test: perform airtightness test on the brazing seam of the outer conductor of the second oscillator.

[0019] Preferably, the parts processing includes processing a base, processing a first vibrator outer conductor, processing a second vibrator outer conductor, processing a connecting welding block, processing a vibrator blade, and processing a sealing welding block;

[0020] The processing of the base is specifically as follows: according to the design requirements, a sheet material with a material grade of 3A21 is selected, annealing treatment is first performed, and then the boss, sealing groove and outer shape are milled in the machining center according to the drawing, and then the threaded bottom hole is drilled to remove the machining burrs. Among them, the aperture of the base that matches the first vibrator outer conductor and the second vibrator outer conductor is matched according to the actual outer circle of the tube to ensure that the first vibrator outer conductor and the second vibrator outer conductor and the single-side matching clearance of the hole is 0.05-0.10mm;

[0021] The processing of the first vibrator outer conductor is as follows: according to the design requirements, select the bar material with the material grade of 3A21, lathe the shape according to the drawing, lathe the two ends to ensure the total length, remove the head and tail of the material, and ensure the accuracy of the feed hole is Φ10+0.08 0, the roughness of the drawn tube is Ra1.6, and the outer diameter of the conductor is Φ13-0.03 -0.08;

[0022] The processing of the outer conductor of the second vibrator is as follows: according to the design requirements, select the tube material with the material grade of 3A21, turn the total length according to the drawing, remove the head and tail of the tube, and ensure the accuracy of the feed hole is Φ10+0.08 0, the roughness of the drawn tube is Ra1.6, and the outer diameter of the conductor is Φ13-0.03 -0.08;

[0023] The specific steps of processing the connecting welding block are as follows: according to the design requirements, select the plate material with the material grade of 3A21, mill the clamping width, mill the thickness and welding bevel according to the drawing, cut the single piece shape, remove the processing burrs, and grind the cutting surface with a grinding wheel;

[0024] The specific steps of processing the vibrator blades are as follows: according to the design requirements, select the sheet material with the material grade of 3A21, punch the blades into shape according to the attached figure, and use the CNC machining center to mill out the end welding arc surface to ensure that the welding surface is processed by cutting, and all the edges of the outer shape are chamfered C0.5. The process requires visible chamfers and no visible scratches on the surface;

[0025] The specific steps of processing the sealing welding block are as follows: forming the welding block by a lathe, processing only blind holes for the threaded structure, and tapping the threads after welding.

[0026] Preferably, in S3, the outer conductor of the second vibrator with a plugging welding block welded inside is first spot-welded on the base, and the outer circle processed after welding is the same as the drawn profile;

[0027] After S4 cleaning, the workpiece surface needs to be dried.

[0028] Preferably, in S3, the connection welding block and the vibrator blade are positioned by a spot welding fixture to ensure that the blade angle accuracy is 45°±15°;

[0029] In addition, each part is assembled and spot welded according to the drawing, and then placed in the welding tooling and the tooling together with the tooling are placed in the hanger to ensure the correctness of each dimension of the workpiece during the welding process;

[0030] After each spot welding process, an inspection process is set up to confirm the spot welded workpiece.

[0031] Preferably, in S5: the arrangement length of the solder is required to be consistent with the length of the weld, the welding forms a continuous fillet, and the appearance inspection requires the weld fillet to be transitional, full and continuous;

[0032] Use non-corrosive flux during welding, and brush off the flux after welding according to typical process requirements;

[0033] It is carried out according to the typical process of aluminum brazing in a pre-vacuum atmosphere protection furnace.

[0034] Preferably, in S8, after the workpiece is conductively oxidized, the fitter taps the blind hole of the sealing welding block to drill through the screw hole, tightens the thread seal of the airtightness detection instrument on the gap, then inflates to 0.2MPa and maintains the pressure for five minutes to perform weld airtightness detection.

[0035] Preferably, in all processes before the paint treatment in S7, the blind holes on the plugging welding blocks need to be sealed to prevent excess matter from entering the blind cavity;

[0036] After the air tightness test and inflation in S8, it is necessary to use compressed air to blow away the remaining water stains on the workpiece and tooling before removing the inflation tooling.

[0037] Preferably, after the air tightness test is completed and before packaging, an M2.5 screw needs to be screwed into the screw hole formed by blind hole tapping on the sealing welding block for protection;

[0038] During the parts production turnover process, plastic turnover boxes are required for transit protection. The welded parts need to be packaged in customized cartons with cardboard partitions in the middle, and the workpieces are placed vertically for protection.

[0039] Compared with the prior art, the beneficial effects of the present invention are as follows.

[0040] 1. The antenna vibrator provided by the present invention is provided with a blind hole on the sealing welding block, and is tapped into a threaded hole during the detection process. An airtightness detection instrument, such as an airtightness detector, can be connected to the antenna vibrator, thereby ensuring a detailed airtightness test on the inside of the antenna and ensuring the sealing performance of the antenna during use. When detecting the airtightness, damage or modification to other parts of the antenna vibrator can be avoided. The airtightness check is performed through the specially arranged detection hole, which can protect the structure and function of the antenna vibrator from being affected, and provides a method that is easy to operate and efficient to detect, thereby ensuring the quality and performance of the antenna vibrator, thereby reducing potential failures and maintenance costs in actual applications.

[0041] 2. The spot welding process of the present invention ensures the accuracy of the position of parts through high-precision pre-positioning, reduces the unnecessary materials that may be generated during the assembly process, such as misalignment, gaps, etc., which helps to improve the overall quality and performance of the product. The parts to be welded are degreased and descaled. This step effectively removes oil and oxides on the surface of the parts, reduces impurities that may be introduced during the welding process, thereby improving the welding quality and the purity of the product. The dimensional accuracy and form and position tolerance of the parts after welding are inspected using tooling, which ensures the accuracy and consistency of the product, reduces unnecessary materials or defective products caused by processing errors, and thus effectively controls the quality of the product.

[0042] 3. The present invention performs brazing of the antenna vibrator in a pre-vacuum atmosphere protection furnace. This environment can effectively prevent oxidation and pollution during the welding process, ensure the quality and airtightness of the weld. The furnace brazing technology can provide a more uniform and stable welding temperature compared to the traditional welding method, thereby reducing welding defects and further improving the airtightness of the weld. In order to avoid the influence of the welding process on the accuracy of the threaded hole, the process scheme performs the tapping of the threaded hole after welding, which can ensure the accuracy of the threaded hole and provide good sealing performance in subsequent airtightness testing and use.

[0043] 4. The present invention specifically performs an airtightness test on the brazing seam of the second vibrator outer conductor in S8. This step is a key step in ensuring the airtightness of the product. Qualified products are screened through strict testing standards, thereby improving the overall product qualification rate. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] Figure 1 This is one of the three-dimensional schematic diagrams of the overall structure of the antenna vibrator provided by the present invention;

[0045] Figure 2 The second three-dimensional schematic diagram of the overall structure of the antenna vibrator provided by the present invention;

[0046] Figure 3 The present invention provides a flowchart of the manufacturing process of the antenna element.

[0047] In the figure: 1, base; 2, first vibrator outer conductor; 3, second vibrator outer conductor; 4, connecting welding block; 5, vibrator blade; 6, sealing welding block; 7, blind hole. DETAILED DESCRIPTION

[0048] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0049] See also Figure 1 and Figure 2 The present invention provides an antenna vibrator, comprising a base 1, a pair of first vibrator outer conductors 2, a pair of second vibrator outer conductors 3 and four vibrator blades 5; the two first vibrator outer conductors 2 and the two second vibrator outer conductors 3 are welded and fixed on the base 1 in an array around the axis of the base 1, and both extend vertically; the vibrator blades 5 are welded and fixed on the outer walls of the first vibrator outer conductor 2 and the second vibrator outer conductor 3 near the top through a connecting welding block 4; the two second vibrator outer conductors 3 are fixedly welded with a sealing welding block 6, and the two sealing welding blocks 6 are provided with a blind hole 7; when testing the air tightness, the blind hole 7 is tapped into a threaded hole for sealing and connecting the air tightness testing instrument.

[0050] By setting a blind hole 7 on the sealing welding block 6 and tapping it into a threaded hole during the detection process, an airtightness detection device, such as an airtightness detector, can be connected to the antenna vibrator, ensuring that a detailed airtightness test can be performed on the inside of the antenna and the sealing performance of the antenna during use. When detecting the airtightness, damage or modification to other parts of the antenna vibrator can be avoided. By performing an airtightness check through a specially set detection hole, the structure and function of the antenna vibrator can be protected from being affected, and a method that is easy to operate and efficient to detect is provided, thereby ensuring the quality and performance of the antenna vibrator, thereby reducing potential failures and maintenance costs in actual applications.

[0051] See also Figure 1-Figure 3 , the present invention provides an antenna vibrator manufacturing process, which specifically includes the following process steps;

[0052] S1, parts processing: manufacture the various parts of the antenna vibrator according to the design, drawings and process requirements;

[0053] S2, complete set: prepare the required parts, tooling and solder before assembly according to production requirements;

[0054] S3, spot welding: The parts are pre-positioned with high precision by using a pulse argon arc spot welding machine through the spot welding fixture, and the solder wire is arranged;

[0055] S4, inspection and cleaning before welding: check whether the size of the pre-positioned workpiece meets the technical requirements, and remove oil and oxide scale from the parts to be welded;

[0056] S5, pre-vacuum atmosphere protection furnace aluminum brazing: use the antenna vibrator tooling to perform furnace brazing of the antenna vibrator in the pre-vacuum atmosphere protection furnace;

[0057] S6, fitter: tapping a threaded hole on the plugging welding block 6 in the outer conductor 3 of the second vibrator;

[0058] Among them, in order to avoid the influence of pre-welding cleaning and welding process on the screw hole accuracy, the process scheme is to drill out the plugging welding block 6 of the outer conductor 3 of the second vibrator before welding, and then tap the installation thread as required after welding to ensure the screw hole accuracy requirements;

[0059] S7, inspection and surface treatment: Use tooling to inspect the dimensional accuracy and geometric tolerance requirements of the welded parts, and perform conductive oxidation and paint treatment on the workpiece surface;

[0060] Among them, please note that the parts that do not need to be sprayed with paint need to be protected;

[0061] S8, airtightness test: perform an airtightness test on the soldering seam of the second vibrator outer conductor 3.

[0062] The spot welding process in S3 ensures the accuracy of part position through high-precision pre-positioning, reduces the unnecessary materials that may be generated during the assembly process, such as misalignment and gaps, which helps to improve the overall quality and performance of the product. In S4, the parts to be welded are degreased and descaled. This step effectively removes oil and oxides on the surface of the parts and reduces impurities that may be introduced during the welding process, thereby improving the welding quality and the purity of the product. In S7, the dimensional accuracy and form and position tolerances of the parts after welding are inspected using tooling, ensuring the accuracy and consistency of the product, reducing unnecessary materials or defective products caused by processing errors, and thus effectively controlling the quality of the product.

[0063] In addition, in S5, the antenna vibrator is brazed in a pre-vacuum atmosphere protection furnace. This environment can effectively prevent oxidation and contamination during the welding process, ensuring the quality and airtightness of the weld. The furnace brazing technology can provide a more uniform and stable welding temperature compared to traditional welding methods, thereby reducing welding defects and further improving the airtightness of the weld. In order to avoid the influence of the welding process on the accuracy of the threaded holes, the process scheme performs tapping of the threaded holes after welding, which can ensure the accuracy of the threaded holes and provide good sealing performance in subsequent airtightness testing and use. S8 specifically performs an airtightness test on the brazing seam of the outer conductor 3 of the second vibrator. This step is a key link in ensuring the airtightness of the product. Qualified products are screened through strict testing standards, thereby improving the overall product pass rate.

[0064] Specifically, the parts processing includes processing the base 1, processing the first vibrator outer conductor 2, processing the second vibrator outer conductor 3, processing the connecting welding block 4, processing the vibrator blade 5 and processing the plugging welding block 6;

[0065] The processing of the base 1 is specifically as follows: according to the design requirements, a sheet material with a material grade of 3A21 is selected, and annealing treatment is first performed, and then the boss, sealing groove and outer shape are milled in the machining center according to the drawing, and then the threaded bottom hole is drilled to remove the machining burrs. Among them, the aperture of the base 1 that matches the first vibrator outer conductor 2 and the second vibrator outer conductor 3 is matched according to the actual outer circle of the tube, ensuring that the first vibrator outer conductor 2 and the second vibrator outer conductor 3 and the single-side matching clearance of the hole is 0.05-0.10mm;

[0066] 3A21 is a material commonly used in aluminum alloy structures. It has good mechanical properties and corrosion resistance. It is suitable for manufacturing components such as antenna oscillators that require good conductivity and stability. Annealing treatment can eliminate stress inside the material, improve the material's processability and mechanical properties, and make the aluminum alloy more stable in subsequent processing, reducing the risk of deformation and cracks. Milling operations in the machining center can ensure that the geometry and dimensional accuracy of the components meet the design requirements. This precise machining helps to ensure the correct fit and assembly accuracy between the various components. Drilling and tapping operations ensure that the assembly position of the components is accurate, and bolts or other fasteners can be effectively installed to enhance the stability of the structure.

[0067] The apertures on the base 1 and the outer conductors of the first and second oscillators 2 and 3 are matched according to the actual outer circle of the tube, maintaining a single-sided fitting clearance of 0.05-0.10 mm. The precise fitting clearance ensures the close fit of the components during assembly, reduces the shaking and gaps between the components, thereby improving the stability and reliability of the antenna, effectively reducing the stress concentration caused by vibration or thermal expansion during use, and reducing the fatigue and damage risks of components. Especially where sealing is required, controlling the fitting clearance can help achieve better sealing effects and prevent the external environment from affecting the interior of the antenna, such as moisture or dust from entering.

[0068] The burr removal step after processing helps to ensure the smooth surface of the component, avoid damage to other components or assembly difficulties caused by burrs, and at the same time improve the appearance quality and safety of the component.

[0069] The processing of the first vibrator outer conductor 2 is specifically as follows: according to the design requirements, select a bar material with a material grade of 3A21, lathe the shape according to the drawing, lathe the two ends to ensure the total length, remove the head and tail of the material, and ensure that the accuracy of the feed hole is Φ10+0.08 0, the roughness of the drawn tube is Ra1.6, and the outer diameter of the conductor is Φ13-0.03 -0.08;

[0070] The processing of the second vibrator outer conductor 3 is as follows: according to the design requirements, select the tube material with the material grade of 3A21, turn the total length according to the drawing, remove the head and tail of the tube, and ensure the accuracy of the feed hole is Φ10+0.08 0, the roughness of the drawn tube is Ra1.6, and the outer diameter of the conductor is Φ13-0.03 -0.08;

[0071] By lathe processing the shape and total length, it can be ensured that the appearance of the conductor components meets the design requirements and is maintained within the specified tolerance range, thereby improving the accuracy and consistency of the processing. The precision of the feed hole is Φ10+0.080. Such tolerance control helps to ensure the reliability of the feed connection and avoids connection problems caused by inappropriate apertures. The roughness of the drawn tube is Ra1.6, which ensures a smooth inner surface, helps to reduce resistance and interference in signal transmission, and improves the performance of the conductor. The outer diameter of the conductor is Φ13-0.03-0.08, which can ensure that the outer diameter of the conductor meets the design requirements, which is crucial for the matching and assembly of components.

[0072] These processing requirements improve the performance and reliability of the first dipole outer conductor 2 and the second dipole outer conductor 3 by ensuring precise material processing and dimensional control, thereby having a positive impact on the quality and function of the overall antenna dipole.

[0073] The processing of the connecting welding block 4 is specifically as follows: according to the design requirements, select the plate material with the material grade of 3A21, mill the clamping width, mill the thickness and welding bevel according to the drawing, cut the single piece shape, remove the processing burrs, and grind the cutting surface with a grinding wheel;

[0074] The processing of the vibrator blade 5 is specifically as follows: according to the design requirements, a sheet material with a material grade of 3A21 is selected, the blade is punched into shape according to the attached figure, and the end welding arc surface is milled out by a CNC machining center to ensure that the welding surface is processed by cutting, and all the edges of the outer shape are chamfered C0.5. The process requires visible chamfers and no visible scratches on the surface;

[0075] The operations of milling the clamping width, thickness and welding bevel ensure that the geometric shape and size of the welding block meet the design requirements, improve the matching accuracy and firmness of the welding joint, cut the single-piece shape and remove processing burrs to ensure the neat appearance of the welding block, while avoiding the defects in the processing process affecting the use and reducing assembly problems. The grinding wheel grinding the cutting surface improves the surface quality of the welding block, making it more suitable for welding, reducing welding defects caused by surface roughness, and ensuring the uniformity and strength of the welding.

[0076] The specific processing of the plugging welding block 6 is as follows: forming the block by a lathe, processing only the blind hole 7 of the threaded structure, and tapping the thread after welding;

[0077] By only processing the blind hole 7 before welding, deformation or damage to the threaded structure caused by high temperature during welding is avoided, and the stability and structural integrity of the welding area are ensured. Tapping is performed after welding is completed, and the quality and size of the thread can be accurately controlled, avoiding the influence of the welding process on the accuracy of the threaded hole, thereby ensuring the matching accuracy and functionality of the thread. This process simplifies the processing steps before welding and reduces interference with the welding process. At the same time, tapping after welding can better ensure the quality of the threaded hole, improve the processing efficiency and reliability of the finished product.

[0078] Specifically, in S3, the second vibrator outer conductor 3 with the plugging welding block 6 welded inside is first spot-welded on the base 1, which can ensure the stability and positioning accuracy of the conductor, provide a solid foundation for subsequent processing, and the outer circle processed after welding is the same as the drawn profile, which helps to ensure the precise fit between the components and reduce the fit error caused by welding deformation, thereby improving the overall assembly accuracy and functionality of the component;

[0079] After S4 cleaning, the workpiece surface needs to be dried. The drying treatment after cleaning can completely remove the residual moisture on the surface, prevent corrosion caused by moisture or affect the subsequent coating, adhesive or welding quality, thereby protecting the long-term stability and durability of the workpiece.

[0080] Finishing, cleaning and drying after welding make the assembly of the workpiece smoother, reduce assembly problems caused by surface unevenness or residues, and improve the reliability of the whole machine. Thorough cleaning and drying can prevent moisture and contaminants from being retained on the surface of the workpiece, thereby reducing possible corrosion risks and extending the service life of the components.

[0081] Specifically, in S3, the connection welding block 4 and the vibrator blade 5 are positioned by a spot welding fixture to ensure that the blade angle accuracy is 45°±15°, thereby ensuring the performance and stability of the vibrator during operation;

[0082] In addition, each part is assembled and spot welded according to the drawing, and then placed in the welding tooling and placed in the hanger together with the tooling to ensure the correctness of each dimension of the workpiece during the welding process. Each part is assembled and spot welded according to the drawing, making the overall assembly process more systematic and standardized, reducing errors caused by improper operation of personnel, and improving the consistency and reliability of the final product;

[0083] After each spot welding process, an inspection process is set up to confirm the spot welded workpiece, which can timely discover and correct problems that may occur in the welding process, ensure the welding quality of each process, and reduce the risk of later maintenance and rework. Through precise tooling positioning and regular inspection, rework caused by welding quality problems can be reduced, improving overall production efficiency and reducing production costs.

[0084] Specifically, in S5: the arrangement length of the brazing filler metal is required to be consistent with the length of the weld, so that the brazing filler metal is evenly distributed during the welding process, thereby forming a weld with high strength and good sealing performance, reducing welding defects caused by insufficient brazing filler metal, and forming a continuous fillet during welding. The appearance inspection requires that the weld fillet has a transition, fullness and continuity, which not only improves the aesthetics of the weld, but also reduces stress concentration to a certain extent, and improves the flexibility and durability of the welded structure;

[0085] Use non-corrosive flux during welding. Selecting non-corrosive flux can effectively reduce chemical reactions during welding, avoid corrosion of metal substrates by flux residues, and ensure long-term performance and reliability of welded joints. Brush off the flux according to typical process requirements after welding to further ensure the cleanliness of the weld surface, prevent residues from affecting subsequent processing or use, and maintain consistency in welding quality.

[0086] The typical process of aluminum brazing in a pre-vacuum atmosphere protection furnace is followed to ensure the controllability and consistency of the welding process, and to improve the scientificity and reliability of the welding process. Through the above strict control and specifications, the mechanical strength and durability of the weld can be significantly improved, thereby extending the service life of the structure.

[0087] Specifically, in S8, after the workpiece is conductively oxidized, the fitter taps the blind hole 7 of the plugging welding block 6 to drill through the screw hole, and tightens the thread seal of the airtightness detection device on the gap, which can effectively fix the airtightness detection device on the workpiece to ensure that the gas will not leak during the detection process, so as to accurately detect the airtightness of the weld. Then, the air is inflated to 0.2MPa and the pressure is maintained for five minutes to perform the weld airtightness detection, which can simulate the airtightness requirements of the workpiece in actual use and detect whether there is leakage in the weld. This detection method can detect minor defects in the weld, such as pores or incomplete penetration, to ensure that the weld can remain airtight under actual working conditions.

[0088] Through airtightness testing, defects that may occur in the welding process can be discovered and repaired early, preventing unqualified workpieces from entering the next process or being put into use, ensuring the reliability and performance of the final product. This airtightness testing method complies with conventional quality control standards, ensuring that the welding process and the final product meet design requirements and industry standards, and improving the overall product quality assurance level.

[0089] Specifically, in all the processes before the paint treatment in S7, the blind hole 7 on the plugging welding block 6 needs to be sealed to prevent excess matter from entering the blind cavity, keep the blind cavity clean, avoid contamination and damage to the internal structure, and also reduce the additional cleaning work that may be required later, thereby improving production efficiency and the simplicity of workpiece processing;

[0090] After the air tightness test in S8, it is necessary to use compressed air to blow away the residual water stains on the workpiece and tooling before removing the inflation tooling, which effectively removes the possible moisture and prevents the residual moisture from having a negative impact on the subsequent processing and use of the workpiece, such as corrosion or affecting the adhesion of the coating. Blowing away the residual water stains in time can reduce the corrosion or other pollution problems caused by moisture on the surface of the tooling and workpiece, and extend the service life of the tooling and workpiece.

[0091] Specifically, after the air-tightness test is completed and before packaging, an M2.5 screw needs to be screwed into the screw hole formed by tapping the blind hole 7 on the sealing welding block 6 for protection. This can not only effectively prevent the entry of debris and increase the structural stability, but also reduce the potential leakage risk, enhance the reliability of the product, improve the packaging and transportation efficiency, and at the same time enhance the customer's trust and satisfaction with the product.

[0092] In the manufacturing process provided by the present invention, the main processing equipment is summarized as follows.

[0093] Serial number name model quantity Verification 1 Pre-vacuum gas atmosphere protection welding furnace 1 qualified 2 Pulse argon arc spot welding machine 2 qualified 3 Machining Center CV-600 2 qualified 4 Vertical machining center MV-800 1 qualified 5 Vertical machining center DV-800 4 qualified 6 Vertical machining center CV-600 2 qualified 7 Drill Press Z4006 2 qualified 8 Table tapping machine SWJ-6B 1 qualified 9 Fiber laser marking machine YL-FB-M20A 1 qualified

[0094] In the manufacturing process provided by the present invention, the main processing tools are summarized as follows.

[0095] Serial number name model quantity Verification 1 External conductor furnace welding tool Z6-002 2 qualified 2 Spot welding tooling Z6-003 2 qualified 3 Furnace welding equipment Z6-004 81 qualified 4 Blade spot welding tooling Z6-005 2 qualified 5 Engraving tooling Z6-006 1 qualified 6 Inflatable work clothes Z6-007 20 qualified 7 Furnace welding hanging basket Homemade work clothes 4 qualified

[0096] In the manufacturing process provided by the present invention, when inspecting the workpiece, the main measuring equipment used is summarized in the following table.

[0097] Serial number name model quantity Verification 1 Height gauge HT-26-4 1 qualified 2 Angle comparison board Homemade work clothes 2 qualified 3 Caliper with dial 0-200 HT-25-71 1 qualified 4 Go / No-go Gauge for Inner Hole of Outer Conductor Homemade work clothes 1 qualified

[0098] In addition, during the production turnover of parts, plastic turnover boxes are required for transit protection. The welded parts need to be packaged in customized cartons with cardboard partitions in the middle. The workpieces are placed vertically for protection. When the product is delivered, a special plastic box is required with the screw holes placed downward to ensure that no foreign matter enters the workpiece. By using plastic turnover boxes and customized cartons for effective protection and packaging, not only the quality and safety of the workpieces during the production turnover and delivery process are ensured, but also management efficiency can be improved, costs can be reduced, and customer satisfaction and brand image can be enhanced.

[0099] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations falling within the meaning and scope of the equivalent elements of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

Claims

1. An antenna vibrator, characterized in that: It comprises a base (1), a pair of first vibrator outer conductors (2), a pair of second vibrator outer conductors (3) and four vibrator blades (5); The two first vibrator outer conductors (2) and the two second vibrator outer conductors (3) are welded and fixed on the base (1) in an array around the axis of the base (1), and both extend vertically; The vibrator blades (5) are welded and fixed to the outer walls of the first vibrator outer conductor (2) and the second vibrator outer conductor (3) near the top ends via connecting welding blocks (4); A plugging welding block (6) is fixedly welded inside the two second vibrator outer conductors (3), and a blind hole (7) is provided on the two plugging welding blocks (6); During air tightness testing, the blind hole (7) is tapped into a threaded hole for sealing and connecting an air tightness testing device.

2. A manufacturing process for an antenna vibrator, based on the antenna vibrator according to claim 1, characterized in that: The specific process steps include: S1, parts processing: manufacture the various parts of the antenna vibrator according to the design, drawings and process requirements; S2, complete set: prepare the required parts, tooling and solder before assembly according to production requirements; S3, spot welding: The parts are pre-positioned with high precision by using a pulse argon arc spot welding machine through the spot welding fixture, and the solder wire is arranged; S4, inspection and cleaning before welding: check whether the size of the pre-positioned workpiece meets the technical requirements, and remove oil and oxide scale from the parts to be welded; S5, pre-vacuum atmosphere protection furnace aluminum brazing: use the antenna vibrator tooling to perform furnace brazing of the antenna vibrator in the pre-vacuum atmosphere protection furnace; S6, fitter: tapping a threaded hole on the sealing welding block (6) inside the second vibrator outer conductor (3); In order to avoid the influence of cleaning before welding and welding process on the screw hole precision, the process scheme is that before welding, the second vibrator outer conductor (3) only drills out the blocking welding block (6), and then taps the installation thread as required after welding to ensure the screw hole precision requirement; S7, inspection and surface treatment: Use tooling to inspect the dimensional accuracy and geometric tolerance requirements of the welded parts, and perform conductive oxidation and paint treatment on the workpiece surface; Among them, please note that the parts that do not need to be sprayed with paint need to be protected; S8, airtightness test: perform an airtightness test on the soldering seam of the second vibrator outer conductor (3).

3. The antenna vibrator manufacturing process according to claim 2, characterized in that: The parts processing includes processing the base (1), processing the first vibrator outer conductor (2), processing the second vibrator outer conductor (3), processing the connecting welding block (4), processing the vibrator blade (5) and processing the sealing welding block (6); The processing of the base (1) is specifically as follows: according to the design requirements, a sheet material with a material grade of 3A21 is selected, and annealing treatment is first performed, and then the boss, sealing groove and outer shape are milled in a machining center according to the drawing, and then the threaded bottom hole is drilled to remove the processing burrs, wherein the hole diameter on the base (1) that matches the first vibrator outer conductor (2) and the second vibrator outer conductor (3) is matched according to the actual outer circle of the tube, ensuring that the first vibrator outer conductor (2) and the second vibrator outer conductor (3) have a single-side matching clearance of 0.05-0.10mm with the hole; Processing the first vibrator outer conductor (2) specifically includes: selecting a bar material with a material grade of 3A21 according to design requirements, lathing the bar material according to the drawing, lathe processing the two ends to ensure the total length, removing the head and tail of the bar material, and ensuring the accuracy of the feed hole is Φ10+0.080, the roughness of the inner part of the drawn tube is Ra1.6, and the outer diameter of the conductor is Φ13-0.03-0.08; Processing the second vibrator outer conductor (3) specifically includes: selecting a tube material with a material grade of 3A21 according to design requirements, turning the total length according to the drawing, removing the head and tail of the tube material, and ensuring that the accuracy of the feed hole is Φ10+0.080, the roughness of the drawn tube is Ra1.6, and the outer diameter of the conductor is Φ13-0.03-0.08; Processing the connecting welding block (4) specifically includes: selecting a sheet material with a material grade of 3A21 according to design requirements, milling the clamping width, milling the thickness and welding bevel according to the drawing, cutting the single piece shape, removing the processing burrs, and grinding the cut surface with a grinding wheel; The processing of the vibrator blade (5) is specifically as follows: according to the design requirements, a sheet material with a material grade of 3A21 is selected, the blade is punched into shape according to the attached figure, and the end welding arc surface is milled out by a CNC machining center, ensuring that the welding surface is processed by cutting, and all the edges of the outer shape are chamfered C0.

5. The process requires visible chamfers, and no visible scratches on the surface; The sealing welding block (6) is specifically processed by using a lathe to form the block, and the threaded structure is processed by only processing the blind hole (7), and then tapping the block after welding.

4. The antenna vibrator manufacturing process according to claim 2, characterized in that: In S3, the second vibrator outer conductor (3) with the sealing welding block (6) welded inside is first spot-welded on the base (1), and the outer circle processed after welding is the same as the drawn profile; After S4 cleaning, the workpiece surface needs to be dried.

5. The antenna vibrator manufacturing process according to claim 2, characterized in that: In S3, the connection welding block (4) and the vibrator blade (5) are positioned by a spot welding fixture to ensure that the blade angle accuracy is 45°±15°; In addition, each part is assembled and spot welded according to the drawing, and then placed in the welding tooling and the tooling together with the tooling are placed in the hanger to ensure the correctness of each dimension of the workpiece during the welding process; After each spot welding process, an inspection process is set up to confirm the spot welded workpiece.

6. The antenna vibrator manufacturing process according to claim 2, characterized in that: In S5: The length of the brazing filler metal is required to be consistent with the length of the weld, and the weld forms a continuous fillet. The appearance inspection requires that the weld fillet is transitional, full and continuous; Use non-corrosive flux during welding, and brush off the flux after welding according to typical process requirements; It is carried out according to the typical process of aluminum brazing in a pre-vacuum atmosphere protection furnace.

7. The antenna vibrator manufacturing process according to claim 2, characterized in that: In S8, after the workpiece is conductively oxidized, the fitter taps the blind hole (7) of the sealing welding block (6) to drill through the screw hole, tightens the thread seal of the airtightness detection tool on the gap, then inflates to 0.2MPa and maintains the pressure for five minutes to perform weld airtightness detection.

8. The antenna vibrator manufacturing process according to claim 2, characterized in that: In all the processes before the paint treatment in S7, the blind hole (7) on the plugging welding block (6) needs to be sealed to prevent excess matter from entering the blind cavity; After the air tightness test and inflation in S8, it is necessary to use compressed air to blow away the remaining water stains on the workpiece and tooling before removing the inflation tooling.

9. The antenna vibrator manufacturing process according to claim 2, characterized in that: After the airtightness test is completed and before packaging, an M2.5 screw needs to be screwed into the screw hole formed by tapping the blind hole (7) on the sealing welding block (6) for protection; During the parts production turnover process, plastic turnover boxes are required for transit protection. The welded parts need to be packaged in customized cartons with cardboard partitions in the middle, and the workpieces are placed vertically for protection.

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