Curved surface conformal antenna and assembly system and method thereof

Abstract

In the aspect of the manufacturing technology of the conformal antenna, due to the complex carrier structure form, except for higher processing difficulty, high-precision assembly among the layer structures is the key to influence the performance of the antenna. In order to meet high-precision assembly requirements of complex electronic equipment such as the curved surface conformal antenna and the like on each layer of structure, the invention provides the curved surface conformal antenna based on measured data and the assembly system and the assembly method thereof, and high-precision assembly of the curved surface conformal antenna is realized by fusing machine vision, self-adaptive pose adjustment and automatic assembly technologies. The curved surface conformal antenna is mainly composed of a radiation feed layer, a liquid cooling interconnection layer, an electric connector and an assembly layer, starting from the structural characteristics, an assembly system is built, an assembly process is formulated, the assembly process is monitored and guided in real time through visual measurement, and full-closed-loop assembly control is achieved, so that the one-time success rate of assembly is improved, and the optimal performance of the antenna is exerted.

Description

Technical Field

[0001] The present invention relates to the field of conformal antenna assembly, and in particular to a curved conformal antenna based on measured data, and an assembly system and an assembly method thereof. Background Art

[0002] Conformal antennas have become a research hotspot in the field of modern antenna communications because of their low profile, miniaturization, large aperture, and advantages such as not affecting the aerodynamic performance of the carrier, saving installation space, and reducing the radar cross section of the antenna. Like traditional antennas, conformal antennas are a complete RF system that includes not only a radiating unit, but also an electromagnetic protection (filtering) system, a feeding system, a control system, and a cooling system. They are conformal to any shape of carrier through a multi-layer structure.

[0003] In terms of manufacturing technology, due to the complexity of the carrier structure, the various layers of the conformal antenna structure not only face higher processing difficulties, but also the high-precision assembly between the various layers of the structure is the key to affecting the antenna performance. At present, the assembly of conformal antennas is mainly done by manually connecting and combining the various layers of the structure, and the assembly parameters and assembly postures are not studied and controlled, resulting in the antenna performance after one assembly not meeting the requirements. Repeated disassembly and assembly are required until the requirements are met, which seriously affects the assembly efficiency. Summary of the invention

[0004] In order to meet the high-precision assembly requirements of various layers of complex electronic equipment such as curved conformal antennas, the present invention proposes a curved conformal antenna based on measured data, and an assembly system and assembly method thereof, which realizes high-precision assembly of curved conformal antennas by integrating machine vision, adaptive posture adjustment, and automated assembly technology. The curved conformal antenna is mainly composed of a radiation feed layer, a liquid cooling interconnect layer, an electrical connector, and a component layer. Based on the above structural features, an assembly system is built, an assembly process is formulated, and the assembly process is monitored and guided in real time through visual measurement to achieve full closed-loop assembly control, thereby improving the one-time success rate of assembly and giving full play to the best performance of the antenna.

[0005] The present invention provides a curved conformal antenna, comprising four parts: a radiation feed layer (1), a liquid cooling interconnect layer (2), an electric connector (3) and an antenna assembly (4). The radiation feed layer (1), the liquid cooling interconnect layer (2) and the antenna assembly (4) are arranged in layers from top to bottom. A mounting hole is provided on the liquid cooling interconnect layer (2). One end of the electric connector (3) passes through the mounting hole of the liquid cooling interconnect layer (2) and is connected to a pad of the radiation feed layer 1. The other end of the electric connector (3) is connected to an interface of the antenna assembly (4) to achieve signal transmission.

[0006] The present invention provides an assembly system for a curved surface conformal antenna, which is used for assembling a curved surface conformal antenna.

[0007] The hardware platform of the assembly system includes a base, a six-axis robot (5), a four-axis robot (6), a radiation feed layer loading fixture (7), a liquid cooling interconnect layer loading fixture (8), an electrical connector assembly loading fixture (9), a radiation feed layer adsorption terminal (10), a binocular structured light camera (11), a screw tightening end effector (12) and an electrical connector assembly end effector (13); the six-axis robot (5) and the four-axis robot (6) are respectively installed at two ends of the base, and the feed layer loading fixture (7) and the liquid cooling interconnect layer loading fixture (8) are arranged on the same side of the four-axis robot (6). On the base, an electric connector assembly loading fixture (9), a radiation feed layer adsorption end (10), and a screw tightening end effector (12) are arranged on the base on the same side of the six-axis robot (5), a binocular structured light camera (11) is installed at the end of the mechanical arm of the four-axis robot (6), and an electric connector assembly end effector (13) is installed at the end of the mechanical arm of the six-axis robot (5); the radiation feed layer adsorption end 10, the screw tightening end effector 12, and the electric connector assembly end effector 13 can all be installed at the end of the mechanical arm of the six-axis robot (5), and can be automatically disassembled and replaced as needed.

[0008] The functional modules of the assembly system include an offline operation system, a visual measurement system, an end effector and fixture system, and a control system; the offline operation system includes a visual system calibration module, a workpiece surface detection module, an assembly hole feature extraction module, and an assembly coordinate system establishment module; the visual measurement system includes a workpiece posture calculation module and a positioning error compensation module; the end effector and fixture system includes a workpiece adsorption and grasping module, an assembly information perception module, and a workpiece positioning and clamping module; the control system includes a robot body control module, an end effector control module, a fixture motion control module, and an error compensation control module.

[0009] The following steps are used to assemble the curved conformal antenna:

[0010] Step S1: Calibrate the relevant coordinate system in the assembly system hardware platform

[0011] The visual system calibration module calibrates the flange coordinate system of the electric connector assembly end effector (13) and the six-axis robot (5) in the assembly system hardware platform, and calibrates the base coordinate system of the binocular structured light camera (11) and the four-axis robot (6);

[0012] Step S2: Loading and fastening the radiation feed layer (1) and the liquid cooling interconnect layer (2)

[0013] The radiation feed layer (1) and the liquid cooling interconnect layer (2) are respectively placed on a radiation feed layer loading fixture (7) and a liquid cooling interconnect layer loading fixture (8), and are positioned by means of limit blocks on the fixtures, and a workpiece positioning and clamping module controls the pneumatic clamping of the fixtures;

[0014] Step S3: Hold the radiation feed layer and adjust the assembly posture to assemble and fasten it with the liquid cooling interconnect layer

[0015] The radiation feed layer (1) is scanned and reconstructed by the assembly coordinate system establishment module to establish the radiation feed layer coordinate system; the liquid cooling interconnection layer (2) is positioned by the workpiece positioning clamping module and the assembly coordinate system establishment module to establish the liquid cooling interconnection layer coordinate system; the assembly posture of the radiation feed layer (1) is optimized according to the two coordinate systems and the workpiece posture calculation module; the robot body control module controls the six-axis robot (5) to carry the radiation feed layer adsorption end (10) to move above the radiation feed layer (1); the end effector control module adjusts the end posture; the workpiece adsorption and grasping module controls the radiation feed layer adsorption end (10) to absorb the radiation feed layer (1); the robot body control module controls the six-axis robot (5) to hold the radiation feed layer (1) to reach The workpiece posture calculation module calculates the positioning error of the radiation feed layer (1) at the pre-assembly position above the liquid cooling interconnection layer (2), the positioning error compensation module calculates the error compensation amount, and sends a control instruction to the error compensation control module for error compensation; the assembly positioning error is compensated cyclically until the assembly error is reduced to a specified threshold value; the six-axis robot (5) replaces the radiation feed layer adsorption end (10) with a screw tightening end effector (12), the robot body control module controls the six-axis robot (5) to assemble downward, the assembly information perception module detects the press-fitting pressure during the assembly process, and stops the press-fitting when the press-fitting pressure reaches a certain threshold value; the screw tightening end effector (12) screws the radiation feed layer (1) and the liquid cooling interconnection layer (2) according to the screw tightening parameters;

[0016] Step S4: Clamp the electrical connector and adjust the assembly posture to pass through the mounting hole and press-fit the liquid cooling interconnect layer to tighten it

[0017] The assembled radiation feed layer (1) and the liquid cooling interconnect layer (2) are moved onto an electric connector assembly loading fixture (9), positioned by a limit block on the fixture and pneumatically clamped; the end effector on the six-axis robot (5) is replaced with an electric connector assembly end effector (13); the assembled radiation feed layer (1) and the liquid cooling interconnect layer (2) are positioned by a visual system calibration module, and the normal direction of the corresponding mounting hole of each electric connector (3) is identified; the mounting hole is precisely positioned by a binocular structured light camera (11) and an assembly hole feature extraction module, and the assembly posture is adjusted; the electric connector (3) is guided to be pressed into the mounting hole of the liquid cooling interconnect layer (2) along the normal direction, so as to ensure that each electric connector (3) is installed coaxially;

[0018] Step S5, manually assembling the antenna assembly and fastening it together with screws.

[0019] The beneficial effects of the present invention are

[0020] 1. Through the fully closed-loop controlled automated assembly solution, the first-time success rate of curved conformal antenna assembly is effectively improved, avoiding damage to the antenna caused by repeated disassembly and assembly.

[0021] 2. Based on machine vision, the posture data during the assembly process is obtained, and the optimization algorithm is used to feedback and guide the robot to complete the assembly action, so that each assembly unit can be assembled in the best posture, which improves the assembly accuracy of the curved conformal antenna and ensures the best performance of the antenna. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 Schematic diagram of a curved conformal antenna.

[0023] Figure 2 A partial cutaway view of a curved conformal antenna assembly.

[0024] Figure 3 Figure 1 is a schematic diagram of the hardware platform of the assembly system.

[0025] Figure 4 It is a schematic diagram of the assembly system composition and functions.

[0026] Figure 5 Flowchart of the pose optimization algorithm for radiating feed layer assembly.

[0027] Figure 6 Flowchart of the pose error compensation algorithm for the radiating feed layer assembly.

[0028] The meanings of the accompanying drawings are: 1-radiation feed layer; 2-liquid cooling interconnection layer; 3-electric connector; 4-component layer; 5-six-axis robot; 6-four-axis robot; 7-radiation feed layer loading fixture; 8-liquid cooling interconnection layer loading fixture; 9-electric connector assembly loading fixture; 10-radiation feed layer adsorption end; 11-binocular structured light camera; 12-screw tightening end effector; 13-electric connector assembly end effector. DETAILED DESCRIPTION

[0029] The following will be combined with the attached Figure 1-6 The technical solutions in the embodiments of the present invention are described clearly and completely. 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.

[0030] See also Figure 1 and Figure 2In this embodiment, the curved conformal antenna is composed of four parts: a radiation feed layer 1, a liquid cooling interconnect layer 2, an electrical connector 3, and an antenna assembly 4. The electrical connector 3 passes through the mounting hole of the liquid cooling interconnect layer 2, and the upper and lower ends are respectively connected to the pad of the radiation feed layer 1 and the interface of the antenna assembly 4 to achieve signal transmission. Based on the above structural features, the assembly system is designed and the assembly process is formulated.

[0031] See also Figure 3 The hardware platform of the assembly system includes a base, a six-axis robot 5, a four-axis robot 6, a radiation feed layer loading fixture 7, a liquid-cooled interconnection layer loading fixture 8, an electrical connector assembly loading fixture 9, a radiation feed layer adsorption terminal 10, a binocular structured light camera 11, a screw tightening end effector 12, an electrical connector assembly end effector 13 and related accessories. The six-axis robot 5 and the four-axis robot 6 are installed at both ends of the base, the feed layer loading fixture 7 and the liquid-cooled interconnection layer loading fixture 8 are arranged on the same side of the four-axis robot 6, the electrical connector assembly loading fixture 9, the radiation feed layer adsorption terminal 10, and the screw tightening end effector 12 are arranged on the same side of the six-axis robot 5, the binocular structured light camera 11 is installed at the end of the four-axis robot 6 mechanical arm, and the electrical connector assembly end effector 13 is installed at the end of the six-axis robot 5 mechanical arm. The radiation feed layer adsorption terminal 10, the screw tightening end effector 12, and the electrical connector assembly end effector 13 can be automatically disassembled and replaced and installed at the end of the six-axis robot 5 mechanical arm as needed.

[0032] See also Figure 4 According to the functional modules, the assembly system is divided into an offline operation system, a visual measurement system, an end effector and fixture system, and a control system, which respectively realize the following functions: the offline operation system includes a visual system calibration module, a workpiece shape detection module, an assembly hole feature extraction module, and an assembly coordinate system establishment module; the visual measurement system includes a workpiece posture calculation module and a positioning error compensation module; the end effector and fixture system includes a workpiece adsorption and grasping module, an assembly information perception module, and a workpiece positioning and clamping module; the control system includes a robot body control module, an end effector control module, a fixture motion control module, and an error compensation control module.

[0033] Through the assembly system hardware platform, the assembly process includes the following steps:

[0034] Step S1: Calibrate the relevant coordinate system in the assembly system hardware platform

[0035] The visual system calibration module calibrates the electrical connector assembly end effector 13 and the flange coordinate system of the six-axis robot 5 in the assembly system hardware platform, and calibrates the base coordinate system of the binocular structured light camera 11 and the four-axis robot 6.

[0036] Step S2: Loading the radiation feed layer 1 and the liquid cooling interconnect layer 2

[0037] See also Figure 3 , place the radiation feed layer 1 and the liquid cooling interconnect layer 2 on the radiation feed layer loading fixture 7 and the liquid cooling interconnect layer loading fixture 8 respectively, position them through the limit blocks on the fixtures, and control the pneumatic clamping of the fixtures by the workpiece positioning and clamping module.

[0038] Step S3: Hold the radiation feed layer and adjust it to the best assembly posture for assembly and fastening with the liquid cooling interconnection layer

[0039] The specific process is as follows: the radiation feed layer 1 is scanned and reconstructed through the assembly coordinate system establishment module to establish the radiation feed layer coordinate system; the liquid cooling interconnect layer 2 is positioned through the workpiece positioning and clamping module and the assembly coordinate system establishment module to establish the liquid cooling interconnect layer coordinate system; see Figure 5 , the assembly posture of the radiation feed layer 1 is optimized online according to the workpiece posture calculation module in the two coordinate systems and the visual measurement system; the robot body control module controls the six-axis robot 5 to carry the radiation feed layer adsorption terminal 10 to move above the radiation feed layer 1, the end effector control module adjusts the end posture, and the workpiece adsorption and grasping module controls the radiation feed layer adsorption terminal 10 to absorb the radiation feed layer 1; see Figure 6 The robot body control module controls the six-axis robot 5 to hold the radiation feed layer 1 to the pre-assembly position above the liquid-cooled interconnect layer 2. The workpiece posture calculation module of the visual measurement system calculates the positioning error of the radiation feed layer 1. The positioning error compensation module calculates the error compensation amount and sends a control instruction to the error compensation control module for error compensation. The assembly positioning error is compensated cyclically until the assembly error is reduced to a specified threshold. The six-axis robot 5 replaces the radiation feed layer adsorption end 10 with the screw tightening end effector 12. The robot body control module controls the six-axis robot 5 to assemble downward. The assembly information perception module detects the press-fitting pressure during the assembly process, and stops the press-fitting when the press-fitting pressure reaches a certain threshold. The screw tightening end effector 12 screws the radiation feed layer 1 and the liquid-cooled interconnect layer 2 according to the screw tightening parameters.

[0040] Step S4: Clamp the electrical connector, adjust the optimal assembly posture, and press-fit through the mounting hole and the liquid cooling interconnect layer to tighten it.

[0041] Specific process: Participate Figure 3, move the assembled radiation feed layer 1 and the liquid-cooled interconnect layer 2 to the electrical connector assembly loading fixture 9, position them through the limit blocks on the fixture, and pneumatically clamp them; replace the end effector with the electrical connector assembly end effector 13; use the visual system calibration module to position the assembled radiation feed layer 1 and the liquid-cooled interconnect layer 2, and identify the normal direction of the mounting hole of each electrical connector 3; use the binocular structured light camera 11 and the assembly hole feature extraction module to accurately position the mounting hole and optimize the assembly posture, guide the electrical connector 3 to be pressed into the mounting hole of the liquid-cooled interconnect layer 2 along the normal direction, and ensure that each electrical connector 3 is installed coaxially.

[0042] Step S5, manually assembling the antenna assembly and fastening it together with screws.

[0043] The present invention is not limited to the above specific implementations, and the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made to the above implementations based on the technical essence of the present invention shall be included in the protection scope of the present invention.

Claims

1. A curved conformal antenna, characterized in that: The invention comprises four parts: a radiation feed layer (1), a liquid cooling interconnect layer (2), an electric connector (3) and an antenna assembly (4). The radiation feed layer (1), the liquid cooling interconnect layer (2) and the antenna assembly (4) are arranged in layers from top to bottom. A mounting hole is provided on the liquid cooling interconnect layer (2). One end of the electric connector (3) passes through the mounting hole of the liquid cooling interconnect layer (2) and is connected to a pad of the radiation feed layer 1. The other end of the electric connector (3) is connected to an interface of the antenna assembly (4) to achieve signal transmission.

2. An assembly system for a curved conformal antenna, used for assembling the curved conformal antenna according to claim 1, characterized in that: The hardware platform of the assembly system includes a base, a six-axis robot (5), a four-axis robot (6), a radiation feed layer loading fixture (7), a liquid cooling interconnect layer loading fixture (8), an electrical connector assembly loading fixture (9), a radiation feed layer adsorption terminal (10), a binocular structured light camera (11), a screw tightening end effector (12) and an electrical connector assembly end effector (13); the six-axis robot (5) and the four-axis robot (6) are respectively installed at two ends of the base, and the feed layer loading fixture (7) and the liquid cooling interconnect layer loading fixture (8) are arranged on the same side of the four-axis robot (6). On the base, an electric connector assembly loading fixture (9), a radiation feed layer adsorption end (10), and a screw tightening end effector (12) are arranged on the base on the same side of the six-axis robot (5), a binocular structured light camera (11) is installed at the end of the mechanical arm of the four-axis robot (6), and an electric connector assembly end effector (13) is installed at the end of the mechanical arm of the six-axis robot (5); the radiation feed layer adsorption end 10, the screw tightening end effector 12, and the electric connector assembly end effector 13 can all be installed at the end of the mechanical arm of the six-axis robot (5), and can be automatically disassembled and replaced as needed.

3. The assembly system of a curved conformal antenna according to claim 2, characterized in that: The functional modules of the assembly system include an offline operation system, a visual measurement system, an end effector and fixture system, and a control system; the offline operation system includes a visual system calibration module, a workpiece surface detection module, an assembly hole feature extraction module, and an assembly coordinate system establishment module; the visual measurement system includes a workpiece posture calculation module and a positioning error compensation module; the end effector and fixture system includes a workpiece adsorption and grasping module, an assembly information perception module, and a workpiece positioning and clamping module; the control system includes a robot body control module, an end effector control module, a fixture motion control module, and an error compensation control module.

4. The assembly system of a curved conformal antenna according to claim 3, characterized in that: The following steps are used to assemble the curved conformal antenna: Step S1: Calibrate the relevant coordinate system in the assembly system hardware platform The visual system calibration module calibrates the flange coordinate system of the electric connector assembly end effector (13) and the six-axis robot (5) in the assembly system hardware platform, and calibrates the base coordinate system of the binocular structured light camera (11) and the four-axis robot (6); Step S2: Loading and fastening the radiation feed layer (1) and the liquid cooling interconnect layer (2) The radiation feed layer (1) and the liquid cooling interconnect layer (2) are respectively placed on a radiation feed layer loading fixture (7) and a liquid cooling interconnect layer loading fixture (8), and are positioned by means of limit blocks on the fixtures, and a workpiece positioning and clamping module controls the pneumatic clamping of the fixtures; Step S3: Hold the radiation feed layer and adjust the assembly posture to assemble and fasten it with the liquid cooling interconnect layer The radiation feed layer (1) is scanned and reconstructed by the assembly coordinate system establishment module to establish the radiation feed layer coordinate system; the liquid cooling interconnection layer (2) is positioned by the workpiece positioning and clamping module and the assembly coordinate system establishment module to establish the liquid cooling interconnection layer coordinate system; the assembly posture of the radiation feed layer (1) is optimized according to the two coordinate systems and the workpiece posture calculation module; the robot body control module controls the six-axis robot (5) to carry the radiation feed layer adsorption end (10) to move above the radiation feed layer (1); the end effector control module adjusts the end posture; and the workpiece adsorption and grasping module controls the radiation feed layer adsorption end (10) to absorb the radiation feed layer (1); The robot body control module controls the six-axis robot (5) to hold the radiation feed layer (1) to the pre-assembly position above the liquid cooling interconnection layer (2); the workpiece posture calculation module calculates the positioning error of the radiation feed layer (1); the positioning error compensation module calculates the error compensation amount, and sends a control instruction to the error compensation control module to perform error compensation; the assembly positioning error is compensated cyclically until the assembly error is reduced to a specified threshold; the six-axis robot (5) replaces the radiation feed layer adsorption end (10) with a screw tightening end effector (12); the robot body control module controls the six-axis robot (5) to assemble downwardly; the assembly information perception module detects the press-fitting pressure during the assembly process, and stops the press-fitting when the press-fitting pressure reaches a certain threshold; the screw tightening end effector (12) screws the radiation feed layer (1) and the liquid cooling interconnection layer (2) according to the screw tightening parameters; Step S4: Clamp the electrical connector and adjust the assembly posture to pass through the mounting hole and press-fit the liquid cooling interconnect layer to tighten it The assembled radiation feed layer (1) and the liquid cooling interconnect layer (2) are moved onto an electric connector assembly loading fixture (9), positioned by a limit block on the fixture and pneumatically clamped; the end effector on the six-axis robot (5) is replaced with an electric connector assembly end effector (13); the assembled radiation feed layer (1) and the liquid cooling interconnect layer (2) are positioned by a visual system calibration module, and the normal direction of the corresponding mounting hole of each electric connector (3) is identified; the mounting hole is precisely positioned by a binocular structured light camera (11) and an assembly hole feature extraction module, and the assembly posture is adjusted; the electric connector (3) is guided to be pressed into the mounting hole of the liquid cooling interconnect layer (2) along the normal direction, so as to ensure that each electric connector (3) is installed coaxially; Step S5, manually assembling the antenna assembly and fastening it together with screws.

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