5G base station antenna housing manufacturing method and system

Abstract

The invention relates to the technical field of wireless communication, in particular to a 5G base station antenna housing manufacturing method and system, and the method comprises the following steps: selecting an electromagnetic shielding material matched with a 5G antenna housing based on the electromagnetic wave absorptivity, carrying out the material performance test, adjusting the material components according to the test result, optimizing the conductive path of the material, and evaluating the shielding effect. And obtaining the selected shielding material specification. According to the invention, by optimizing materials, electromagnetic performance and structural design, the performance of the 5G base station antenna housing is improved, shielding material components are selected and adjusted, a conductive path is optimized, the electromagnetic shielding performance is improved, a microstructure is designed and optimized, the electromagnetic wave reflection and absorption performance is enhanced, radiation leakage is reduced, and the signal transmission stability is improved; the stability and mechanical strength are improved through structural analysis and adjustment, the material distribution is optimized to reduce the weight, the actual performance of the radome is verified through an environment matching test, the shielding effectiveness and reliability are enhanced, and technical support is provided for 5G base station deployment.

Description

Technical Field

[0001] The present invention relates to the field of wireless communication technologies, and in particular to a method and system for manufacturing a 5G base station antenna cover. Background Art

[0002] The field of wireless communication technology involves various technologies that use electromagnetic waves to transmit information, including radio, microwave, fiber optic communication and other technical means. The application range of this field is wide, from traditional broadcasting and television to mobile communications (such as 2G, 3G, 4G, 5G), as well as satellite communications, Wi-Fi, Bluetooth and other short-distance communication technologies, all of which belong to the category of wireless communication technology. The core of wireless communication technology is to ensure efficient and stable signal transmission, amplification, and reception through equipment and methods such as antennas, waveguides, and signal processing technologies. With the emergence of new generation communication technologies such as 5G, the field of wireless communication technology continues to develop in the direction of higher speed, lower latency, and more access devices, covering wireless networks, mobile terminals, base station equipment and other aspects.

[0003] Among them, the 5G base station antenna cover manufacturing method refers to the design and processing method for the antenna cover when manufacturing a 5G base station. As a part of the base station antenna system, the antenna cover undertakes the dual tasks of signal transmission and environmental protection. By optimizing the material and structure of the antenna cover, the antenna performance is improved to ensure that the base station can stably transmit and receive signals. Its main purpose is to provide 5G base stations with efficient electromagnetic wave transmission media and environmental protection, support high-speed, large-capacity wireless communication needs, and is one of the key technologies in the construction of 5G communication networks.

[0004] The existing technology has problems such as insufficient electromagnetic shielding performance, poor structural matching, and low environmental stability in the manufacture of 5G base station antenna covers. The existing technology's selection of materials is mostly guided by a single performance, and the electromagnetic shielding effectiveness in complex multi-band environments is not fully considered, resulting in insufficient signal interference suppression capabilities, which can easily cause communication interruptions. The design of the antenna cover microstructure fails to effectively balance signal transmittance and radiation leakage control. The selection and optimization of the microstructure form have limitations, resulting in unstable signal transmission, which is particularly evident in high-density base station deployment environments. The existing antenna cover structure is prone to loss or deformation under climate change and long-term mechanical vibration. There is a lack of effective design and verification of environmental matching capabilities, which affects the overall operating efficiency of 5G base stations and limits the further improvement of 5G base station antenna covers in terms of efficient communication and environmental matching capabilities, which is not conducive to supporting large-scale 5G communication networks with higher demands. Summary of the invention

[0005] The purpose of the present invention is to solve the shortcomings existing in the prior art and to propose a 5G base station antenna cover manufacturing method and system.

[0006] In order to achieve the above object, the present invention adopts the following technical solution: a method for manufacturing a 5G base station antenna cover, comprising the following steps:

[0007] S1: Select electromagnetic shielding materials that match the 5G antenna cover based on the electromagnetic wave absorption rate, conduct material performance tests, adjust the material composition according to the test results, optimize the conductive path of the material, evaluate the shielding effect, and obtain the selected shielding material specifications;

[0008] S2: Based on the selected shielding material specifications, design the physical microstructure of the radome, select the type of the microstructure, perform structural simulation to estimate the reflection and absorption performance of electromagnetic waves, obtain microstructure performance analysis data, perform signal interference suppression analysis and processing, adjust the size and shape of the microstructure, and obtain a microstructure optimization design solution;

[0009] S3: Based on the microstructure optimization design scheme, the overall structural stability and mechanical strength of the radome are analyzed, structural stress analysis data are obtained, and matching analysis of the structure and materials is performed. According to the analysis results, the design parameters are adjusted, the structural layout and material distribution of the radome are determined, and the design scheme of the radome structure and materials is obtained;

[0010] S4: According to the design of the antenna cover structure and materials, produce antenna cover samples, perform material processing and assembly, conduct environmental matching test on the samples in a simulated 5G environment, record the test data, analyze the shielding effect and environmental matching capability of the antenna cover, and obtain the antenna cover performance verification result.

[0011] As a further solution of the present invention, the step of obtaining the selected shielding material specification is specifically as follows:

[0012] S111: Select electromagnetic shielding materials that match the 5G antenna cover based on electromagnetic wave absorption rate, conduct initial performance tests, measure electromagnetic wave absorption rate, conductivity and material thickness, record key performance indicators, and generate preliminary test results for shielding materials;

[0013] S112: According to the preliminary test results of the shielding material, the composition of the electromagnetic shielding material is adjusted, the conductive path is optimized by simulating the electromagnetic field distribution, and a secondary performance test is performed to obtain optimized test data;

[0014] S113: Analyze the optimized test data using the formula:

[0015]

[0016] Calculate the adjusted mean deviation, evaluate the shielding effectiveness, and generate the selected shielding material specifications;

[0017] Where S represents the adjusted mean deviation, Pi represents the electromagnetic wave absorption rate of the i-th optimization test, T represents the target absorption rate threshold, and w i is the weight factor and n represents the total number of tests.

[0018] As a further solution of the present invention, the step of acquiring the microstructure performance analysis data is specifically as follows:

[0019] S211: Based on the selected shielding material specifications, a draft design of various microstructures is performed, including honeycomb, porous and layered structures, and three-dimensional modeling is performed to obtain a preliminary design model of the microstructure;

[0020] S212: applying the preliminary design model of the microstructure to the electromagnetic characteristics analysis process, setting the corresponding electromagnetic wave frequency and boundary conditions, analyzing the reflection and absorption performance of each microstructure, and obtaining electromagnetic wave performance data;

[0021] S213: Analyze the electromagnetic wave performance data to evaluate the performance of the microstructure using the formula:

[0022]

[0023] Calculate the performance deviation of each microstructure and obtain microstructure performance analysis data;

[0024] Among them, w k is the weight of frequency k, D k is the target absorption or reflectivity, S k is the simulated absorption or reflectivity, K represents the number of frequency points analyzed, and R represents the performance deviation value of the microstructure.

[0025] As a further solution of the present invention, the steps of obtaining the microstructure optimization design solution are specifically as follows:

[0026] S221: According to the microstructure performance analysis data, adjusting the size and shape parameters of the data, setting upper and lower limits of the parameters and controlling the variation range, and obtaining adjusted microstructure parameter data;

[0027] S222: applying a signal interference suppression process according to the adjusted microstructure parameter data, optimizing data filtering and signals, adjusting filtering thresholds and enhancing signals, and obtaining signal processing data;

[0028] S223: Utilizing the signal processing data, optimizing the shape and size of the microstructure, comparing the performance of each design solution, adjusting the design parameters according to the performance evaluation results, testing the parameters and matching the optimal design, and obtaining the microstructure optimization design solution.

[0029] As a further solution of the present invention, the step of acquiring the structural stress analysis data is specifically as follows:

[0030] S311: Based on the microstructure optimization design scheme, meshing is performed, the geometric model is decomposed, the model is divided into a plurality of small units, and the size and distribution of the units are adjusted according to the shape and size of the differentiated area, and a meshing result is generated;

[0031] S312: Based on the meshing result, boundary conditions and load conditions are applied to the structure, fixed constraints are set at the support position of the structure, and external force loads in the real-time working environment are applied to the surface of the radome, including gravity, airflow, and temperature changes, to establish boundary conditions and load application results;

[0032] S313: Based on the boundary conditions and load application results, analyze the stress and strain of the antenna cover under differentiated loads, evaluate the stress and deformation of each grid unit, output the stress value and deformation data of each point, and obtain structural stress analysis data.

[0033] As a further solution of the present invention, the steps for obtaining the design solution of the antenna cover structure and material are specifically as follows:

[0034] S321: extracting the stress distribution of the radome under the differentiated load according to the structural stress analysis data, analyzing the relationship between the stress value and the critical value of the material strength, performing a comparison between the stress and the material strength, judging the matching of the materials, selecting a matching material area, and generating material matching analysis data;

[0035] S322: Based on the material matching analysis data, perform a structural optimization analysis to analyze the influence of the differentiated material distribution on the radome structure, optimize the geometric shape and thickness distribution of the radome, and obtain adjusted structural parameter data;

[0036] S323: Based on the adjusted structural parameter data and material matching analysis data, the structure and material evaluation is performed using the formula:

[0037]

[0038] Calculate the matching index of the radome design and generate the design scheme of the radome structure and materials;

[0039] Among them, C represents the matching index of the radome design, w1 and w2 represent the weight coefficients of material matching and structural optimization respectively, X1 represents the material matching index, X2 represents the structural optimization index, X3 represents the load distribution stability, and X4 represents the stress deformation.

[0040] As a further solution of the present invention, the steps for obtaining the antenna cover performance verification result are specifically as follows:

[0041] S411: Based on the design scheme of the radome structure and materials, perform material processing and assembly, combine the structure and selected materials in the design scheme, process the radome sample, and perform assembly operations to form a radome sample to be tested;

[0042] S412: According to the antenna cover sample to be tested, a 5G environment simulation test is performed on the antenna cover sample, the test conditions are set and meet the real-time 5G environment parameters, and each performance of the sample in the simulated environment is tested, including signal attenuation, shielding effect and anti-interference ability, using the formula:

[0043]

[0044] Obtain the shielding effectiveness data of the radome;

[0045] Among them, P shield Indicates the percentage of shielding effect improvement, S after To simulate the shielding effect after environmental testing, S before is the shielding effect during the preliminary test, λ1, λ2, λ3 are weight coefficients, ΔT is the temperature difference before and after the test, ΔF is the frequency change value under the test conditions, and D temp is the temperature difference of the radome sample;

[0046] S413: Combine the shielding effect data of the radome with the experimental threshold, perform data analysis, and evaluate the performance of the radome. If the shielding performance does not reach the standard threshold, return to the design plan for optimization and retesting. If it meets the standard, determine the performance and obtain the radome performance verification result.

[0047] A 5G base station radome manufacturing system, the 5G base station radome manufacturing system is used to execute the above-mentioned 5G base station radome manufacturing method, the system comprising:

[0048] The material formula development module selects electromagnetic shielding materials that match the 5G antenna cover based on the electromagnetic wave absorption rate, fine-tunes the conductivity characteristics of the material components according to the test results, evaluates the shielding effect of differentiated formulas, and obtains the optimized material formula;

[0049] The microstructure design and simulation module uses the optimized material formula to design the microstructure of the radome, simulates the electromagnetic wave reflection and absorption performance, adjusts the microstructure parameters according to the performance feedback, and establishes a microstructure design plan;

[0050] The structure and material integration module analyzes the structural stability and mechanical strength based on the microstructure design scheme, adjusts the antenna cover design parameters, optimizes the material distribution, and forms a structure and material design scheme;

[0051] The radome sample production module performs sample production according to the design scheme of the structure and materials, including material processing and assembly, performs preliminary functional testing, and obtains the completed radome sample;

[0052] The performance testing and evaluation module performs performance testing on the completed antenna cover sample in a simulated 5G environment, evaluates the shielding effect and environmental matching, and obtains the antenna cover performance verification result.

[0053] Compared with the prior art, the advantages and positive effects of the present invention are:

[0054] In the present invention, the performance of the 5G base station antenna cover is comprehensively improved through optimization of materials, electromagnetic properties, structural design and other aspects. By selecting shielding materials based on the electromagnetic wave absorption rate and adjusting their components, optimizing the conductive path and evaluating the shielding effect, the electromagnetic shielding performance of the material in the complex 5G frequency band is improved, and the problem of insufficient signal interference suppression capability is solved. By designing and optimizing the microstructure shape and size of the antenna cover, the reflection and absorption performance of electromagnetic waves is enhanced, radiation leakage is reduced, and the stability of signal transmission is significantly improved. The analysis and design adjustment of the overall structural stability and mechanical strength enable the antenna cover to maintain long-term reliable operation in high-frequency vibration environments and climate changes. At the same time, the material distribution is optimized to reduce the weight burden. By conducting comprehensive environmental matching tests in a simulated 5G environment, the performance of the antenna cover under actual working conditions is verified, so that the shielding effectiveness and environmental matching capability are guaranteed, so that the 5G base station antenna cover obtains significant gains in signal transmission efficiency and reliability, providing solid technical support for large-scale 5G base station deployment. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] Figure 1 It is a schematic diagram of the workflow of the present invention;

[0056] Figure 2 A flow chart of the shielding material specifications selected in the present invention;

[0057] Figure 3 A flow chart of microstructure performance analysis data in the present invention;

[0058] Figure 4 A flow chart of the microstructure optimization design scheme in the present invention;

[0059] Figure 5 It is a flow chart of structural stress analysis data in the present invention;

[0060] Figure 6 A flow chart of the design scheme of the antenna cover structure and materials in the present invention;

[0061] Figure 7 It is a flow chart of the performance verification results of the radome in the present invention. DETAILED DESCRIPTION

[0062] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0063] In the description of the present invention, it should be understood that the terms "length", "width", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, in the description of the present invention, "multiple" means two or more, unless otherwise clearly and specifically defined.

[0064] Embodiment 1

[0065] See also Figure 1 The present invention provides a technical solution: a method for manufacturing a 5G base station antenna cover, comprising the following steps:

[0066] S1: Select electromagnetic shielding materials that match the 5G antenna cover based on the electromagnetic wave absorption rate, conduct material performance tests, adjust the material composition according to the test results, optimize the conductive path of the material, evaluate the shielding effect, and obtain the selected shielding material specifications;

[0067] S2: Based on the selected shielding material specifications, design the physical microstructure of the radome, select the type of microstructure, perform structural simulation to estimate the reflection and absorption performance of electromagnetic waves, obtain microstructure performance analysis data, perform signal interference suppression analysis and processing, adjust the size and shape of the microstructure, and obtain the microstructure optimization design scheme;

[0068] S3: Based on the microstructure optimization design scheme, the overall structural stability and mechanical strength of the radome are analyzed, the structural stress analysis data are obtained, the matching analysis of the structure and materials is performed, the design parameters are adjusted according to the analysis results, the structural layout and material distribution of the radome are determined, and the design scheme of the radome structure and materials is obtained;

[0069] S4: According to the design plan of the radome structure and materials, produce radome samples, perform material processing and assembly, conduct environmental matching tests on the samples in a simulated 5G environment, record the test data, analyze the shielding effect and environmental matching capability of the radome, and obtain the radome performance verification results.

[0070] The selected shielding material specifications include shielding material type, conductivity index, and electromagnetic wave absorption efficiency. The microstructure performance analysis data include reflection performance parameters, absorption performance parameters, and scattering intensity parameters. The microstructure optimization design scheme includes optimized microstructure shape, microstructure size parameters, and arrangement design. The structural stress analysis data includes structural stability assessment, stress distribution characteristics, and deformation behavior parameters. The design scheme of the radome structure and material includes material configuration layout, structural geometric design parameters, and load-bearing capacity assessment. The radome performance verification results include shielding effectiveness assessment, signal transmission interference suppression capability, and environmental matching test data.

[0071] See also Figure 2 , the specific steps for obtaining the selected shielding material specifications are:

[0072] S111: Select electromagnetic shielding materials that match the 5G antenna cover based on electromagnetic wave absorption rate, conduct initial performance tests, measure electromagnetic wave absorption rate, conductivity and material thickness, record key performance indicators, and generate preliminary test results for shielding materials;

[0073] In a laboratory environment, the selected electromagnetic shielding materials for 5G antenna covers are subjected to an initial comprehensive performance test. A multi-band electromagnetic wave signal generator is used to emit electromagnetic waves of different wavelengths and measure the electromagnetic wave absorption rate of the material. A high-precision network analyzer is used to collect reflection loss and transmission loss to ensure that the shielding effectiveness data of the material in different frequency bands can be obtained. The collected reflection signal and transmission signal are then subjected to spectrum analysis using Fourier transform to extract the specific values ​​of each frequency band. After the absorption rate test is completed, a four-point probe test is performed on the surface conductivity of the material to obtain the average value of the surface resistance of the material. Combined with the thickness of the material, the theoretical value of the shielding effectiveness of the material is calculated using the conductive path model. An electromagnetic interference simulator is used to simulate the actual interference intensity and the shielding effect of the material in a 5G signal environment, and the shielding effectiveness value in an actual signal environment is recorded. The deviation between the theoretical value and the actual test value is comprehensively analyzed to generate preliminary test results for the shielding material.

[0074] S112: According to the preliminary test results of the shielding material, the composition of the electromagnetic shielding material is adjusted, the conductive path is optimized by simulating the electromagnetic field distribution, and a secondary performance test is performed to obtain optimized test data;

[0075] According to the electromagnetic shielding performance parameters of the material recorded in the preliminary test results of the shielding material, the material composition is precisely adjusted. By selecting the changes in the composition ratio of metal powder, conductive polymer and insulating matrix, the density and distribution structure of the conductive path formed in the mixed state are adjusted. Subsequently, the finite element simulation method is used to establish a three-dimensional conductive path model, and the influence of the conductive path on the shielding effectiveness is analyzed. After adjusting the composition ratio, the material is evenly mixed and compression molded to ensure that the optimized conductive path forms a continuous network structure. After the material composition adjustment is completed, the electromagnetic wave shielding performance of the optimized material is measured by performing multi-band absorptivity, transmittance and reflectivity tests, and the performance of each frequency band is recorded. At the same time, the absorptivity, surface conductivity and conductive path distribution parameters of the material before and after improvement are recorded. Combined with the test records and simulation calculation data, the optimized test data is obtained.

[0076] S113: Analyze the optimized test data using the formula:

[0077]

[0078] Calculate the adjusted mean deviation, evaluate the shielding effectiveness, and generate the selected shielding material specifications;

[0079] Where S represents the adjusted mean deviation, P i represents the electromagnetic wave absorption rate of the i-th optimization test, T represents the target absorption rate threshold, and w i is the weight factor, n represents the total number of tests;

[0080] The benefit of the formula is that it introduces the weight parameter w i , weighted average of shielding effectiveness in different frequency bands is performed to avoid the situation where direct averaging masks insufficient performance in key frequency bands. At the same time, the cumulative effect of performance deviation is accurately reflected through absolute value calculation, effectively improving the accuracy and operability of performance evaluation;

[0081] P i is the electromagnetic wave absorption rate of the i-th test, obtained through the multi-band signal testing equipment, and the absorption rates of the five frequency bands are set to 0.75, 0.8, 0.83, 0.78, and 0.81 respectively; T is the target absorption rate threshold, which is set to 0.82;

[0082] w i is the weight parameter, reflecting the importance of each frequency band, and is set to 1.1, 1.0, 0.9, 1.2, and 0.8 respectively;

[0083] n=5 is the number of test frequency bands;

[0084] Calculate the absolute value of deviation of each frequency band |P i-T|, get [0.07, 0.02, 0.01, 0.04, 0.01];

[0085] Multiply each deviation by the weight parameter to get [0.077, 0.02, 0.009, 0.048, 0.008];

[0086] Calculate S by summing and dividing by the number of test bands:

[0087]

[0088] The result shows that the deviation between the actual material performance and the target performance is 0.0324, indicating that the shielding effectiveness of the optimized material is close to the target value and meets the expected requirements, generating the selected shielding material specifications.

[0089] See also Figure 3 , the specific steps for obtaining microstructure performance analysis data are:

[0090] S211: Based on the selected shielding material specifications, draft designs of various microstructures are carried out, including honeycomb, porous and layered structures, and three-dimensional modeling is performed to obtain a preliminary design model of the microstructure;

[0091] Based on the selected shielding material specifications, preliminary drafts of various microstructures are designed. The microstructure schemes used for the antenna cover are successively refined into three basic design schemes: honeycomb, porous and layered. The microstructure design process is gradually completed through 3D modeling tools, including the hexagonal arrangement structure of the honeycomb units, the aperture size and distribution position of the porous type, and the thickness and spacing parameters of the layered structure. The geometric model generated in the design process is optimized in size and shape, and the boundary adjustment method is used to determine the complete geometric shape of each microstructure. Finally, three microstructure design models are output to generate a preliminary design model of the microstructure.

[0092] S212: applying the preliminary design model of the microstructure to the electromagnetic characteristics analysis process, setting the corresponding electromagnetic wave frequency and boundary conditions, analyzing the reflection and absorption performance of each microstructure, and obtaining electromagnetic wave performance data;

[0093] The preliminary design models of the microstructures are imported into the electromagnetic simulation environment one by one, and the simulation parameters are set, including the electromagnetic wave frequency range, incident angle, and material boundary conditions. The density of the simulation grid and the boundary characteristics of the microstructure are gradually adjusted to ensure that the geometric accuracy of each microstructure in the simulation environment meets the input requirements. The reflection and absorption rate of the honeycomb, porous, and layered microstructure models are simulated respectively, and the reflection and absorption characteristics of each microstructure in each frequency band are recorded. The reflection and absorption performance lists are compiled according to the simulation output data, and finally the electromagnetic wave performance data is output.

[0094] S213: Analyze the electromagnetic wave performance data and evaluate the performance of the microstructure using the formula:

[0095]

[0096] Calculate the performance deviation of each microstructure and obtain microstructure performance analysis data;

[0097] Among them, w k is the weight of frequency k, D k is the target absorption or reflectivity, S k is the absorption or reflectivity obtained by simulation, K represents the number of frequency points analyzed, and R represents the performance deviation value of the microstructure;

[0098] The formula is useful in that by introducing the frequency weight w k Adjust the importance of different frequency bands in the evaluation and use the target value D k and the simulation value S k The square of the deviation expresses the performance consistency, which helps to optimize the comprehensive performance evaluation of the microstructure;

[0099] w k represents the weight of frequency k, which is allocated according to the importance of the frequency band in practical applications;

[0100] D k is the target absorption or reflectivity of the frequency band, which is provided by the design requirements;

[0101] S k It is the absorption or reflectivity of the frequency band obtained by simulation, which is directly output by the simulation system;

[0102] K is the total number of frequency bands, for example, K = 3 represents three main communication frequency bands;

[0103] Calculate the deviation (D) of each frequency band k -S k ), set D1=0.9, D2=0.8, D3=0.85, corresponding to S1=0.88, S2=0.78, S3=0.82, and get the deviation [0.02, 0.02, 0.03];

[0104] Calculate the square of the deviation and multiply it by the corresponding weight w k , set w1=1.0, w2=1.2, w3=0.9, and get the weighted square deviation [0.0004, 0.00048, 0.00081];

[0105] Calculate the weighted sum of squares of deviations, and we get R = 0.0004 + 0.00048 + 0.00081 = 0.00169;

[0106] The results show that the calculated comprehensive deviation R = 0.00169 represents the average deviation between the simulation performance of the current microstructure and the target performance. The microstructure performance analysis data can be further obtained by adjusting the microstructure parameters to optimize the design.

[0107] See also Figure 4 , the specific steps for obtaining the microstructure optimization design solution are:

[0108] S221: According to the microstructure performance analysis data, the size and shape parameters of the data are adjusted, the upper and lower limits of the parameters are set and the variation range is controlled, and the adjusted microstructure parameter data is obtained;

[0109] To adjust the size and shape parameters of the data, each microstructure parameter in the data set needs to be classified and marked, and the data range is limited to the upper and lower limits of the parameter settings through the screening function. Adjustment operations are performed according to the setting rules of the variation range, including trimming of data points that exceed the range and linear interpolation of missing data to ensure data integrity and availability. In the process of data adjustment, a fixed-ratio scaling strategy is adopted for the size parameters, such as determining the adjustment ratio based on the median within the initial size range, while the shape parameters correct irregular features through discrete point fitting curves, and further adjust them to be close to the standardized curve. The adjusted data needs to go through the error checking process, and use repeated sampling to verify whether the distribution law of the data meets the established standards. At the same time, the statistical characteristics of the changes before and after the adjustment are recorded for reference in subsequent optimization design. The adjusted microstructure parameter data is obtained.

[0110] S222: applying a signal interference suppression process according to the adjusted microstructure parameter data, optimizing data filtering and signals, adjusting filtering thresholds and enhancing signals, and obtaining signal processing data;

[0111] The filtering effect of the data is optimized in sections by introducing a layer-by-layer noise reduction method. First, the upper and lower threshold ranges of the filter are determined to exclude data from non-target signal parts. In the specific implementation, a suitable segmentation interval is selected by calculating the change amplitude and fluctuation frequency of the adjusted parameter data. The data is grouped and low-pass filtered one by one to eliminate high-frequency interference signals and further enhance the effective part of the signal. When enhancing the signal, the gain function is used to correct the target frequency band to ensure that the amplification rate of the effective signal can meet the original data analysis requirements. After processing, the signal quality is checked to detect whether the filtered data meets the uniformity and stability requirements. At the same time, the change comparison results of the signal strength before and after processing are recorded to obtain the signal processing data.

[0112] S223: Optimize the shape and size of the microstructure using signal processing data, compare the performance of each design scheme, adjust the design parameters according to the performance evaluation results, test the parameters and match the optimal design, and obtain the microstructure optimization design scheme;

[0113] It is necessary to gradually analyze the data performance under different design schemes, make subtle adjustments to the microstructure size of each scheme, and gradually match the shape parameters to ensure that the performance indicators of each parameter combination are optimal. During execution, first extract the key values ​​of various performances through signal processing data, such as shape rigidity, dimensional stability, etc., and record the performance of each scheme. Then, combined with the performance evaluation results, the weights of various parameters are normalized and calculated, and the parameter combination with better performance is selected for in-depth testing. During the testing phase, the selected combination needs to be tested for small-range fluctuations to ensure the stability and repeatability of its optimization direction. According to the best performing parameter design in multiple rounds of testing, a microstructure optimization design scheme is formed, and the optimization path is recorded to provide support for subsequent research.

[0114] See also Figure 5 , the specific steps for obtaining structural stress analysis data are:

[0115] S311: Based on the microstructure optimization design scheme, meshing is performed. By decomposing the geometric model, the model is divided into multiple small units, and the size and distribution of the units are adjusted according to the shape and size of the differentiated area to generate the meshing result;

[0116] In the process of meshing, firstly, according to the overall shape of the geometric model, an appropriate partitioning method is selected to decompose the model in three dimensions. Taking a typical radome as an example, if the model includes complex curved surfaces and polygonal structures, a step-by-step refinement strategy is adopted to improve the calculation accuracy by using finer mesh units at the support position of the radome and in areas where large deformation may occur. For example, in the edge area of ​​the radome, the size of the mesh unit is 10mm, while in the central area it can be set to 20mm. The geometric features of the model are analyzed locally, and the size and distribution of the unit are dynamically adjusted according to the stress conditions and deformation characteristics of each area to ensure that the partitioning results can reflect the physical characteristics of the structure. The model is meshed by using finite element software, and the mesh quality is checked to ensure that each unit meets the good shape standard and avoid the generation of deformed units, thereby improving the accuracy and stability of subsequent calculations.

[0117] S312: Based on the meshing results, boundary conditions and load conditions are applied to the structure, fixed constraints are set at the support positions of the structure, and external force loads in the real-time working environment are applied to the surface of the radome, including gravity, airflow, and temperature changes, to establish boundary conditions and load application results;

[0118] When applying boundary conditions and loads to the structure, first set fixed constraints on the support points according to the design requirements and the actual working environment. For example, at the bottom support position of the radome, constraints can be set, assuming that the support points are in a fixed position and cannot move. According to the external force loads in the working environment, the effects of gravity, airflow and temperature changes on the radome are applied respectively. For gravity loads, a vertical force is applied by calculating the mass of the radome material and the acceleration of gravity. For airflow loads, distributed pressure is applied on the surface according to the surface shape of the radome and the direction of airflow. For example, it can be assumed that the airflow flows at a speed of 10m / s in a certain direction on the surface of the radome, thereby generating corresponding aerodynamic pressure. In terms of temperature changes, thermal stress is applied by simulating the temperature change from -40℃ to +85℃, and converted into thermal load, which is applied to the surface of the radome to simulate the effect of thermal expansion or contraction of the material, and the boundary conditions and load application results are obtained, which provide a basis for subsequent stress analysis.

[0119] S313: Based on the boundary conditions and load application results, analyze the stress and strain of the radome under differentiated loads, evaluate the stress and deformation of each grid unit, output the stress value and deformation data of each point, and obtain structural stress analysis data;

[0120] In the structural load analysis, the stress and strain of each grid unit are calculated by finite element analysis. According to the applied boundary conditions and loads, the stress distribution on each grid unit is solved. In the edge area of ​​the radome, due to the large deformation and stress concentration, a higher stress value will appear. Assuming that the stress value calculated on a small unit is 50MPa, a detailed analysis of the unit is performed at this time, and the tensile strength and compressive strength of the material are combined to evaluate whether it exceeds the design limit. If it exceeds, it is necessary to increase the material thickness of the area or optimize the mesh division accuracy. In the central area of ​​the radome, the stress is small, but the deformation may be large, so it is necessary to pay attention to the deformation of the area. When evaluating the deformation of each grid unit, in addition to referring to the influence of external force loads, it is also necessary to refer to the influence of thermal stress caused by temperature changes on deformation, record and output structural stress analysis data, and gradually obtain the stress and deformation analysis results of the entire radome. The analysis process will provide accurate stress distribution information and deformation data, which will help the subsequent optimization design and ensure the safety and reliability of the radome.

[0121] See also Figure 6 , the specific steps for obtaining the design plan of the radome structure and materials are as follows:

[0122] S321: Extract the stress distribution of the radome under differentiated loads based on the structural stress analysis data, analyze the relationship between the stress value and the critical value of material strength, perform a comparison between the stress and material strength, determine the matching of the materials, select the matching material area, and generate material matching analysis data;

[0123] According to the preset calculation model, the stress of the antenna cover structure under different loads is simulated. Combined with the material strength standard, the stress and material strength of each area are compared and analyzed one by one, and the area that does not meet the bearing capacity requirements is identified. After eliminating this area, the area with bearing capacity that meets the requirements is selected as the appropriate material distribution area. The appropriate material is selected through the parameters such as tensile strength and compressive strength in the material standard data table. During the simulation process, the stress distribution under a specific load is set, and the distribution data is accurately calculated and verified. The final stress value is calculated using the load and stress formula. The simulated value is compared with the standard value to confirm the area that meets the requirements. The suitable material area obtained by the analysis is calibrated to generate material matching analysis data. According to the load distribution and stress limit, the specific distribution of the material area is finally determined to provide data support for subsequent optimization and ensure the scientificity and accuracy of material selection.

[0124] S322: Based on the material matching analysis data, perform structural optimization analysis, analyze the impact of differentiated material distribution on the radome structure, optimize the geometric shape and thickness distribution of the radome, and obtain adjusted structural parameter data;

[0125] By optimizing the material distribution, analyzing the impact of different distribution methods on structural performance, performing geometric shape and thickness change analysis, calculating the structural bearing capacity under different material configurations, and selecting the optimal configuration by comparing with preset standards, this process is based on the performance parameters of different materials and considers their impact on the shape and thickness of the radome. Different configurations are simulated through finite element analysis to ensure the stability and strength of the structure under different loads. The simulation results show that when a certain material distribution method causes local stress concentration, the local geometry must be adjusted, and the corresponding thickness configuration must be selected to enhance the local bearing capacity. The overall geometric structure of the radome is optimized, and the adjusted structural parameter data is generated to ensure that the radome structure can maintain optimal stability and durability under the specified load.

[0126] S323: Based on the adjusted structural parameter data and material matching analysis data, evaluate the structure and materials using the formula:

[0127]

[0128] Calculate the matching index of the radome design and generate the design scheme of the radome structure and materials;

[0129] Among them, C represents the matching index of the radome design, w1 and w2 represent the weight coefficients of material matching and structural optimization, X1 represents the material matching index, X2 represents the structural optimization index, X3 represents the load distribution stability, and X4 represents the stress deformation;

[0130] By introducing the two parameters of load distribution stability and stress deformation, the accuracy of the comprehensive evaluation of the radome design is further improved, including the judgment of structural matching under complex load conditions, so as to provide a more accurate basis for the optimal design of the radome;

[0131] C represents the matching index of the antenna cover design, which reflects the matching performance after the comprehensive optimization of the structure and materials. w1 and w2 are two main evaluation indicators, the weight coefficients of material matching and structural optimization. The weight coefficient reflects the importance of each indicator in the overall design. X1 is the indicator calculated based on the material matching analysis data, X2 is the result after the structural optimization analysis, X3 represents the stability of the load distribution, and X4 is the stress deformation, which are all calculated through simulation data. When calculating, the structural parameters and material data obtained in the early stage are substituted into the formula to calculate the matching index. X1 is set to 0.85, X2 is 0.75, X3 is 50N, and X4 is 0.04 (the unit has been standardized according to the actual application). The weight coefficient w1 is 0.6, and w2 is 0.4. The formula is substituted into the calculation to obtain:

[0132]

[0133]

[0134] C=0.81·250

[0135] C=202.5

[0136] The results show that the matching of the radome design is 202.5, which means that the design can meet the requirements of structural strength and material matching under the currently set load and stress standards. The matching score also shows that the performance of the optimized design has reached the expected goal and meets the conditions for further application.

[0137] See also Figure 7 , the specific steps for obtaining the radome performance verification results are as follows:

[0138] S411: Based on the design of the radome structure and materials, perform material processing and assembly, combine the structure and selected materials in the design, process the radome sample, and perform assembly operations to form the radome sample to be tested;

[0139] First, select materials that meet the design requirements, and purchase them in batches based on the electromagnetic properties, mechanical strength, and temperature resistance of the materials to ensure that they meet the performance requirements of the design. The selected materials include metals or synthetic materials with high electrical conductivity and high temperature resistance to ensure that they can effectively play the shielding and isolation functions of the antenna cover under different environmental conditions. The procurement process is strictly carried out according to the design specifications, and the test report of each batch of materials is reviewed. The materials are cut, formed, and processed according to the design drawings. During the cutting process, the materials are accurately cut according to the size requirements to ensure that the geometric shape of each component meets the requirements, including the processing of the antenna cover's outer shell, supporting structure, shielding layer, etc., to ensure that the size, angle, and surface quality of each component meet the design standards. After the processing is completed, the various parts are assembled, including ensuring the firm combination of the components through welding, connection, bonding, etc., and ensuring the connection strength and shielding effect of the radome components through precise docking and welding operations. The structural components of the radome are strictly inspected to avoid any poor contact or structural defects, forming the radome sample to be tested. After the sample is completed, a preliminary structural inspection is carried out to ensure that all interfaces and structural components are firmly installed and without defects, and to confirm that the radome meets the design requirements in terms of appearance, size and assembly quality.

[0140] S412: According to the antenna cover sample to be tested, the antenna cover sample is subjected to a 5G environment simulation test, the test conditions are set and meet the real-time 5G environment parameters, and each performance of the sample in the simulated environment is tested, including signal attenuation, shielding effect and anti-interference ability, using the formula:

[0141]

[0142] Obtain the shielding effectiveness data of the radome;

[0143] Among them, P shield Indicates the percentage of shielding effect improvement, S after To simulate the shielding effect after environmental testing, S before is the shielding effect during the preliminary test, λ1, λ2, λ3 are weight coefficients, ΔT is the temperature difference before and after the test, ΔF is the frequency change value under the test conditions, and D temp is the temperature difference of the radome sample;

[0144] The benefit of the formula is that it can comprehensively evaluate the shielding performance by introducing factors such as temperature change, frequency change and temperature difference of the radome samples, and can more accurately reflect the matching ability and performance of the radome in a complex environment, especially the impact of environmental changes on its performance in actual use;

[0145] Collect preliminary test results of the radome in simulated environments, including shielding effectiveness data before and Safter , respectively, are the shielding effects of the radome before and after adjustment. In the initial test, S before is 80, and the adjusted test result is S after is 85, then calculate the proportion of shielding effect improvement P shield ;

[0146] The specific value of each parameter is determined according to the experimental data. λ1, λ2 and λ3 are obtained through regression analysis. According to the experimental data, the values ​​of the coefficients are set as λ1 = 0.02, λ2 = 0.01, and λ3 = 0.015. The values ​​of the coefficients are derived from the average values ​​of the data generated by multiple experiments. When the temperature change is ΔT = 5 °C, the frequency change is ΔF = 3%, and the temperature difference of the antenna cover sample is ΔT temp =2℃, substitute into the formula to calculate:

[0147]

[0148] The results show that the shielding effect is improved by about 7.25%. This value reflects that under the test conditions, the shielding performance of the radome is improved by 7.25%, verifying its matching under various environmental changes. This value further proves the effectiveness of the radome design, and ultimately generates the shielding performance results of the environmental matching test, which serves as the basis for subsequent optimization and verification.

[0149] S413: Combine the shielding effect data of the radome with the experimental threshold, perform data analysis, and evaluate the performance of the radome. If the shielding performance does not meet the standard threshold, return to the design solution for optimization and retest. If it meets the standard, determine the performance and obtain the radome performance verification result.

[0150] Based on the environmental matching test and combined with the shielding performance data obtained, a standard threshold is set to evaluate the performance of the radome. shieldIf the standard requirement is not met, the design plan will be returned for optimization based on the experimental data, and the performance of the antenna cover in different environments will be analyzed. The impact of factors such as temperature fluctuations and frequency changes on its performance will be considered, and a detailed evaluation will be conducted. If the analysis shows that there are potential problems, such as improper material selection or insufficient thickness of the shielding layer, the optimization process will be initiated. The optimization process includes adjusting the material selection of the antenna cover, optimizing the structural design, improving the thickness and surface treatment of the shielding layer, etc. For material selection, the electromagnetic shielding effectiveness of the metal or synthetic material used will be re-evaluated, the thickness of the shielding layer will be further strengthened, or more efficient conductive materials will be selected to improve the performance of the antenna cover. In terms of structural optimization, it is necessary to change the geometric shape or support structure of the antenna cover and optimize the air circulation design to improve the heat dissipation performance and reduce the negative impact of frequency changes on the performance of the antenna cover. In order to improve the shielding layer, multi-layer materials or optimized coating treatment process are further adopted to enhance the shielding effect. All optimized designs will be mass-produced and sample processed, and reassembled and tested. After passing the test, the improved radome will be tested for environmental matching again to ensure that its performance meets the standard requirements. If it meets the requirements, the radome performance verification results will be generated as the basis for subsequent production and use. If it still does not meet the standard requirements, the design plan will be continuously optimized until the performance meets expectations, and a radome product that has undergone multiple rounds of testing and improvement will be obtained.

[0151] The 5G base station antenna cover manufacturing system is used to execute the above-mentioned 5G base station antenna cover manufacturing method, and the system includes:

[0152] The material formula development module selects electromagnetic shielding materials that match the 5G antenna cover based on the electromagnetic wave absorption rate, fine-tunes the conductivity characteristics of the material components according to the test results, evaluates the shielding effect of differentiated formulas, and obtains the optimized material formula;

[0153] The microstructure design and simulation module uses optimized material formulas to design the microstructure of the radome, simulates the electromagnetic wave reflection and absorption performance, adjusts the microstructure parameters based on performance feedback, and establishes a microstructure design plan;

[0154] The structure and material integration module analyzes the structural stability and mechanical strength based on the microstructure design plan, adjusts the radome design parameters, optimizes the material distribution, and forms a structural and material design plan;

[0155] The radome sample production module performs sample production according to the structural and material design plan, including material processing and assembly, and performs preliminary functional testing to obtain the completed radome sample;

[0156] The performance testing and evaluation module performs performance testing on the completed radome samples in a simulated 5G environment, evaluates the shielding effect and environmental compatibility, and obtains radome performance verification results.

[0157] The above are only preferred embodiments of the present invention and are not intended to limit the present invention in other forms. Any technician familiar with the profession may use the technical contents disclosed above to change or modify them into equivalent embodiments with equivalent changes and apply them to other fields. However, any simple modification, equivalent change and modification made to the above embodiments based on the technical essence of the present invention without departing from the technical solution of the present invention still falls within the protection scope of the technical solution of the present invention.

Claims

1. A method for manufacturing a 5G base station antenna cover, characterized in that: The following steps are involved: Select electromagnetic shielding materials that match the 5G antenna cover based on the electromagnetic wave absorption rate, conduct material performance tests, adjust material composition according to the test results, optimize the conductive path of the material, evaluate the shielding effect, and obtain the selected shielding material specifications; Based on the selected shielding material specifications, the physical microstructure of the radome is designed, the type of the microstructure is selected, a structural simulation is performed to estimate the reflection and absorption performance of electromagnetic waves, microstructure performance analysis data is obtained, and signal interference suppression analysis and processing are performed to adjust the size and shape of the microstructure to obtain a microstructure optimization design scheme; Based on the microstructure optimization design scheme, the overall structural stability and mechanical strength of the radome are analyzed, structural stress analysis data are obtained, and a matching analysis of the structure and materials is performed. According to the analysis results, the design parameters are adjusted, the structural layout and material distribution of the radome are determined, and a design scheme for the radome structure and materials is obtained; According to the design plan of the radome structure and materials, radome samples are produced, materials are processed and assembled, the samples are tested for environmental matching in a simulated 5G environment, the test data is recorded, the shielding effect and environmental matching capability of the radome are analyzed, and the radome performance verification results are obtained.

2. The method for manufacturing a 5G base station antenna cover according to claim 1, characterized in that: The steps for obtaining the selected shielding material specifications are specifically as follows: Select electromagnetic shielding materials that match the 5G antenna cover based on electromagnetic wave absorption rate, conduct initial performance tests, measure electromagnetic wave absorption rate, conductivity and material thickness, record key performance indicators, and generate preliminary test results for shielding materials; According to the preliminary test results of the shielding material, the composition of the electromagnetic shielding material is adjusted, the conductive path is optimized by simulating the electromagnetic field distribution, and a secondary performance test is performed to obtain optimized test data; Analyze the optimized test data using the formula: Calculate the adjusted mean deviation, evaluate the shielding effectiveness, and generate the selected shielding material specifications; Where S represents the adjusted mean deviation, P i represents the electromagnetic wave absorption rate of the i-th optimization test, T represents the target absorption rate threshold, and w i is the weight factor and n represents the total number of tests.

3. The method for manufacturing a 5G base station antenna cover according to claim 2, characterized in that: The steps for obtaining the microstructure performance analysis data are specifically as follows: Based on the selected shielding material specifications, a plurality of microstructures are drafted, including honeycomb, porous and layered structures, and three-dimensional modeling is performed to obtain a preliminary design model of the microstructure; Applying the preliminary design model of the microstructure to the electromagnetic characteristics analysis process, setting the corresponding electromagnetic wave frequency and boundary conditions, analyzing the reflection and absorption performance of each microstructure, and obtaining electromagnetic wave performance data; The electromagnetic wave performance data is analyzed to evaluate the performance of the microstructure using the formula: Calculate the performance deviation of each microstructure and obtain microstructure performance analysis data; Among them, w k is the weight of frequency k, D k is the target absorption or reflectivity, S k is the simulated absorption or reflectivity, K represents the number of frequency points analyzed, and R represents the performance deviation value of the microstructure.

4. The method for manufacturing a 5G base station antenna cover according to claim 3, characterized in that: The steps for obtaining the microstructure optimization design solution are specifically as follows: According to the microstructure performance analysis data, the size and shape parameters of the data are adjusted, the upper and lower limits of the parameters are set and the variation range is controlled, and the adjusted microstructure parameter data is obtained; According to the adjusted microstructure parameter data, applying a signal interference suppression process, optimizing data filtering and signals, adjusting filtering thresholds and enhancing signals, and obtaining signal processing data; The signal processing data is used to optimize the shape and size of the microstructure, compare the performance of each design scheme, adjust the design parameters according to the performance evaluation results, test the parameters and match the optimal design, and obtain the microstructure optimization design scheme.

5. The method for manufacturing a 5G base station antenna cover according to claim 4, characterized in that: The steps for obtaining the structural stress analysis data are specifically as follows: Based on the microstructure optimization design scheme, meshing is performed, the geometric model is decomposed, the model is divided into a plurality of small units, and the size and distribution of the units are adjusted according to the shape and size of the differentiated area to generate a meshing result; Based on the meshing results, boundary conditions and load conditions are applied to the structure, fixed constraints are set at the support positions of the structure, and external force loads in the real-time working environment are applied to the surface of the radome, including gravity, airflow, and temperature changes, to establish boundary conditions and load application results; Based on the boundary conditions and load application results, the stress and strain of the radome under differentiated loads are analyzed, the stress and deformation of each grid unit are evaluated, the stress value and deformation data of each point are output, and the structural stress analysis data is obtained.

6. The method for manufacturing a 5G base station antenna cover according to claim 5, characterized in that: The steps for obtaining the design scheme of the radome structure and materials are specifically as follows: Extract the stress distribution of the radome under the differentiated load according to the structural stress analysis data, analyze the relationship between the stress value and the critical value of the material strength, perform a comparison between the stress and the material strength, judge the matching of the material, select the matching material area, and generate the material matching analysis data; Based on the material matching analysis data, a structural optimization analysis is performed to analyze the influence of the differentiated material distribution on the radome structure, the geometric shape and thickness distribution of the radome are optimized, and the adjusted structural parameter data is obtained; According to the adjusted structural parameter data and material matching analysis data, the structure and material are evaluated using the formula: Calculate the matching index of the radome design and generate the design scheme of the radome structure and materials; Among them, C represents the matching index of the radome design, w1 and w2 represent the weight coefficients of material matching and structural optimization respectively, X1 represents the material matching index, X2 represents the structural optimization index, X3 represents the load distribution stability, and X4 represents the stress deformation.

7. The method for manufacturing a 5G base station antenna cover according to claim 6, characterized in that: The steps for obtaining the radome performance verification results are specifically as follows: Based on the design scheme of the radome structure and materials, material processing and assembly are performed, and the radome sample is processed and assembled in combination with the structure and selected materials in the design scheme to form the radome sample to be tested; According to the antenna cover sample to be tested, a 5G environment simulation test is performed on the antenna cover sample, the test conditions are set and meet the real-time 5G environmental parameters, and each performance of the sample in the simulated environment is tested, including signal attenuation, shielding effect and anti-interference ability, using the formula: Obtain the shielding effectiveness data of the radome; Among them, P shield Indicates the percentage of shielding effect improvement, S after To simulate the shielding effect after environmental testing, S before is the shielding effect during the preliminary test, λ1, λ2, λ3 are weight coefficients, ΔT is the temperature difference before and after the test, ΔF is the frequency change value under the test conditions, and D temp is the temperature difference of the radome sample; The shielding effect data of the radome are combined with the experimental threshold to perform data analysis and evaluate the performance of the radome. If the shielding performance does not reach the standard threshold, the design solution is returned for optimization and retesting. If it meets the standard, the performance is determined to obtain the radome performance verification result.

8. A 5G base station antenna cover manufacturing system, characterized in that: According to the method for manufacturing a 5G base station antenna cover according to any one of claims 1 to 7, the system comprises: The material formula development module selects electromagnetic shielding materials that match the 5G antenna cover based on the electromagnetic wave absorption rate, fine-tunes the conductivity characteristics of the material components according to the test results, evaluates the shielding effect of differentiated formulas, and obtains the optimized material formula; The microstructure design and simulation module uses the optimized material formula to design the microstructure of the radome, simulates the electromagnetic wave reflection and absorption performance, adjusts the microstructure parameters according to the performance feedback, and establishes a microstructure design plan; The structure and material integration module analyzes the structural stability and mechanical strength based on the microstructure design scheme, adjusts the antenna cover design parameters, optimizes the material distribution, and forms a structure and material design scheme; The radome sample production module performs sample production according to the design scheme of the structure and materials, including material processing and assembly, performs preliminary functional testing, and obtains the completed radome sample; The performance testing and evaluation module performs performance testing on the completed antenna cover sample in a simulated 5G environment, evaluates the shielding effect and environmental matching, and obtains the antenna cover performance verification result.

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