A manufacturing method and system for a 5G base station radome

Abstract

The present invention relates to the field of wireless communication technologies, and specifically to a manufacturing method and system for a 5G base station radome, comprising the following steps: Select an electromagnetic shielding material that matches the 5G radome based on the electromagnetic wave absorption rate, conduct material performance tests, adjust the material composition according to the test results, optimize the conduction path of the material, evaluate the shielding effect, and obtain the selected shielding material specifications. In the present invention, by optimizing the material, electromagnetic performance, and structural design, the performance of the 5G base station radome is improved. The shielding material composition is selected and adjusted, the conduction path is optimized to enhance the electromagnetic shielding performance, the microstructure is designed and optimized to enhance the electromagnetic wave reflection and absorption performance, radiation leakage is reduced, 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, and the actual performance of the radome is verified through environmental compatibility tests, enhancing the shielding effectiveness and reliability, providing technical support for the deployment of 5G base stations.

Description

Technical Field

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

[0002] The field of wireless communication technologies involves various technologies that utilize electromagnetic waves to transmit information, including radio, microwave, fiber optic communication, and other technical means. The application scope of this field is extensive, ranging from traditional radio and television to mobile communication (such as 2G, 3G, 4G, 5G), as well as satellite communication, Wi-Fi, Bluetooth, and other short-distance communication technologies, all of which belong to the category of wireless communication technologies. The core of wireless communication technologies lies in ensuring the efficient and stable transmission, amplification, and reception of signals through devices 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 technologies is constantly evolving towards higher speeds, lower latency, and more connected devices, covering multiple aspects such as wireless networks, mobile terminals, and base station equipment.

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

[0004] Existing technologies have problems such as insufficient electromagnetic shielding performance, poor structural matching, and low environmental stability in the manufacture of 5G base station radomes. The selection of materials in existing technologies is mainly guided by single performance, without fully considering the electromagnetic shielding efficiency in complex multi-band environments, resulting in insufficient signal interference suppression ability and easy communication interruption. The design of the micro-structure of the radome fails to effectively balance the signal transmittance and radiation leakage control, and there are limitations in the selection and optimization of the micro-structure form, resulting in unstable signal transmission, especially obvious in high-density base station deployment environments. The existing radome structure is prone to losses or deformations under climate change and long-term mechanical vibrations, lacking effective design and verification for environmental matching ability, affecting the overall operation efficiency of 5G base stations, restricting the further improvement of 5G base station radomes in terms of efficient communication and environmental matching ability, and being unfavorable for supporting large-scale 5G communication networks with higher requirements. Summary of the Invention

[0005] The object of the present invention is to solve the drawbacks existing in the prior art, and to propose a manufacturing method and system for a 5G base station radome.

[0006] To achieve the above object, the present invention adopts the following technical solutions: A manufacturing method for a 5G base station radome, comprising the following steps:

[0007] S1: Based on the electromagnetic wave absorption rate, select an electromagnetic shielding material that matches the 5G radome, conduct material performance tests, adjust the material composition according to the test results, optimize the conduction 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 microstructure, conduct structural simulation to estimate the reflection and absorption performance of electromagnetic waves, obtain microstructure performance analysis data, and conduct signal interference suppression analysis and processing, adjust the size and shape of the microstructure, and obtain the optimized design scheme of the microstructure;

[0009] S3: Based on the optimized design scheme of the microstructure, analyze the overall structural stability and mechanical strength of the radome, obtain structural stress analysis data, conduct analysis on the matching of the structure and material, adjust the design parameters according to the analysis results, determine the structural layout and material distribution of the radome, and obtain the design scheme of the radome structure and material;

[0010] S4: According to the design scheme of the radome structure and material, produce a sample of the radome, conduct material processing and assembly, conduct environmental matching tests on the sample in a simulated 5G environment, record the test data, analyze the shielding effect and environmental matching ability of the radome, and obtain the radome performance verification result.

[0011] As a further solution of the present invention, the specific steps for obtaining the selected shielding material specifications are as follows:

[0012] S111: Based on the electromagnetic wave absorption rate, select an electromagnetic shielding material that matches the 5G radome, conduct a preliminary performance test, measure the electromagnetic wave absorption rate, conductivity, and material thickness, record the key performance indicators, and generate the preliminary test results of the shielding material;

[0013] S112: According to the preliminary test results of the shielding material, adjust the composition of the electromagnetic shielding material, optimize the conduction path by simulating the electromagnetic field distribution, and conduct a secondary performance test to obtain the optimized test data;

[0014] S113: Analyze the optimized test data, and use the formula:

[0015]

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

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

[0018] As a further solution of the present invention, the steps for obtaining the microstructural performance analysis data are specifically as follows:

[0019] S211: Based on the selected shielding material specifications, draft designs of various microstructures are carried out, including honeycomb, porous, and layered structures, and 3D modeling is performed to obtain a preliminary design model of the microstructures;

[0020] S212: Apply the preliminary design model of the microstructures to the electromagnetic characteristic analysis process, set the corresponding electromagnetic wave frequencies and boundary conditions, analyze the reflection and absorption performances of each microstructure, and obtain electromagnetic wave performance data;

[0021] S213: Analyze the electromagnetic wave performance data, evaluate the performance of the microstructures, and use the formula:

[0022]

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

[0024] where 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 to be analyzed, and R represents the performance deviation value of the microstructure.

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

[0026] S221: According to the microstructural performance analysis data, adjust the size and shape parameters of the data, set the upper and lower limits of the parameters and control the variation range to obtain the adjusted microstructural parameter data;

[0027] S222: According to the adjusted microstructural parameter data, apply the signal interference suppression process, optimize the data filtering and signals, adjust the filtering threshold and enhance the signals to obtain the signal processing data;

[0028] S223: Utilize the signal processing data to optimize the shape and size of the microstructures, compare the performances of each design solution, adjust the design parameters according to the performance evaluation results, test the parameters and match the optimal design to obtain the microstructural optimization design solution.

[0029] As a further solution of the present invention, the steps for obtaining the structural stress analysis data are specifically as follows:

[0030] S311: Based on the micro-structure optimization design scheme, perform mesh generation. By decomposing the geometric model, divide the model into multiple small elements, and adjust the size and distribution of the elements according to the shape and size of the differential region to generate the mesh generation result;

[0031] S312: Based on the mesh generation result, apply boundary conditions and load conditions to the structure. Set fixed constraints at the support positions of the structure, and apply external loads under the real-time working environment on the surface of the radome, including gravity, airflow, and temperature change, to establish the boundary conditions and load application result;

[0032] S313: Based on the boundary conditions and load application result, analyze the stress and strain of the radome under differential loads, evaluate the stress and deformation of each mesh element, output the stress value and deformation data of each point, and obtain the structural stress analysis data.

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

[0034] S321: According to the structural stress analysis data, extract the stress distribution of the radome under differential loads, analyze the relationship between the stress value and the critical value of material strength, perform the comparison between stress and material strength, judge the material matching, select the matching material area, and generate the material matching analysis data;

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

[0036] S323: According to the adjusted structural parameter data and material matching analysis data, perform the evaluation of the structure and material, and use the formula:

[0037]

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

[0039] Wherein, C represents the matching index of the radome design, w1 and w2 respectively 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 amount.

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

[0041] S411: Based on the design scheme of the radome structure and materials, carry out material processing and assembly. Combine the structure in the design scheme and the selected materials to process the radome sample and perform the assembly operation to form a radome sample to be tested.

[0042] S412: According to the radome sample to be tested, conduct a 5G environment simulation test on the radome sample. Set the test conditions to conform to the real-time 5G environment parameters, and detect each performance of the sample in the simulated environment, including signal attenuation, shielding effect, and anti-interference ability. Use the formula:

[0043]

[0044] Obtain the shielding effect data of the radome.

[0045] where P shield represents the percentage increase in shielding effect, S after is the shielding effect after the simulation environment test, S before is the shielding effect during the preliminary test, λ1, λ2, λ3 are weighting 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 to conduct data analysis and evaluate the performance of the radome. If the shielding performance does not reach the standard threshold, return to the design scheme for optimization and retest. If it meets the standard, determine the performance and obtain the radome performance verification result.

[0047] A 5G base station radome manufacturing system, which is used to execute the above 5G base station radome manufacturing method. The system includes:

[0048] The material formulation development module selects an electromagnetic shielding material that matches the 5G radome based on the electromagnetic wave absorption rate, fine-tunes the conductivity characteristics of the material composition according to the test results, evaluates the shielding effect of different formulations, and obtains an optimized material formulation.

[0049] The micro-structure design and simulation module uses the optimized material formulation to design the micro-structure of the radome, simulate the electromagnetic wave reflection and absorption performance, adjust the micro-structure parameters according to the performance feedback, and establish a micro-structure design scheme.

[0050] The structure and material integration module analyzes the structural stability and mechanical strength based on the micro-structure design scheme, adjusts the radome design parameters, optimizes the material distribution, and forms a design scheme for the structure and materials.

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

[0052] The performance test and evaluation module conducts performance tests on the completed radome sample in a simulated 5G environment, evaluates the shielding effect and environmental compatibility, and obtains the radome performance verification result.

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

[0054] In the present invention, through the optimization of multiple aspects such as materials, electromagnetic properties, and structural design, the comprehensive performance of the 5G base station radome is improved. By selecting shielding materials based on the electromagnetic wave absorption rate and adjusting their composition, optimizing the conduction path and evaluating the shielding effect, the electromagnetic shielding performance of the materials in the complex 5G frequency band is improved, and the problem of insufficient signal interference suppression ability is solved. By designing and optimizing the microstructure shape and size of the radome, the reflection and absorption performance of electromagnetic waves are enhanced, radiation leakage is reduced, and the stability of signal transmission is significantly improved. Through the analysis and design adjustment of the overall structural stability and mechanical strength, the radome can maintain reliable operation for a long time in a high-frequency vibration environment and climate change. At the same time, the material distribution is optimized to reduce the weight burden. Through comprehensive environmental compatibility tests in a simulated 5G environment, the performance of the radome under actual working conditions is verified, ensuring the shielding efficiency and environmental matching ability, and significantly increasing the signal transmission efficiency and reliability of the 5G base station radome, providing a solid technical support for large-scale 5G base station deployment. Description of the Drawings

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

[0056] Figure 2 It is a flowchart of the selected shielding material specifications in the present invention;

[0057] Figure 3 It is a flowchart of the microstructure performance analysis data in the present invention;

[0058] Figure 4 It is a flowchart of the microstructure optimization design scheme in the present invention;

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

[0060] Figure 6 It is a flowchart of the design scheme of the radome structure and materials in the present invention;

[0061] Figure 7 It is a flowchart of the radome performance verification result in the present invention. Detailed implementation manners

[0062] In order to make the objectives, technical solutions and advantages of the present invention more clear and understandable, the present invention will be further described in detail below with reference to 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 used to limit the present invention.

[0063] In the description of the present invention, it should be understood that the orientation or positional relationships indicated by the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. are based on the orientation or positional relationships shown in the accompanying drawings. These 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 thus should not be construed as limiting the present invention. In addition, in the description of the present invention, "a plurality of" means two or more, unless otherwise specifically defined.

[0064] Embodiment 1

[0065] Please refer to Figure 1 , the present invention provides a technical solution: a manufacturing method for a 5G base station radome, including the following steps:

[0066] S1: Select an electromagnetic shielding material that matches the 5G radome based on the electromagnetic wave absorption rate, conduct material performance tests, adjust the material composition according to the test results, optimize the conduction 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, conduct structural simulation estimates of the reflection and absorption performance of electromagnetic waves, obtain microstructure performance analysis data, and conduct signal interference suppression analysis and processing. Adjust the size and shape of the microstructure to obtain an optimized design scheme for the microstructure;

[0068] S3: Based on the optimized design scheme of the microstructure, analyze the overall structural stability and mechanical strength of the radome, obtain structural stress analysis data, conduct analysis on the matching of the structure and the material, adjust the design parameters according to the analysis results, and determine the structural layout and material distribution of the radome to obtain the design scheme of the radome structure and material;

[0069] S4: According to the design scheme of the radome structure and material, fabricate a sample of the radome, conduct material processing and assembly, conduct environmental matching tests on the sample in a simulated 5G environment, record the test data, analyze the shielding effect and environmental matching ability of the radome, and obtain the performance verification results of the radome.

[0070] The selected shielding material specifications include the shielding material type, conductivity index, electromagnetic wave absorption efficiency. The microstructure performance analysis data includes reflection performance parameters, absorption performance parameters, and scattering intensity parameters. The microstructure optimization design scheme includes the 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 radome structure and material design scheme 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 ability, and environmental compatibility test data.

[0071] Please refer to Figure 2 , and the specific steps for obtaining the selected shielding material specifications are as follows:

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

[0073] Conduct the initial comprehensive performance test on the selected electromagnetic shielding material for the 5G radome in the laboratory environment. By using a multi-band electromagnetic wave signal generator to emit electromagnetic waves of different wavelengths, measure the electromagnetic wave absorption rate of the material. At the same time, use a high-precision network analyzer to collect the reflection loss and transmission loss to ensure that the shielding effectiveness data of the material in different frequency bands can be obtained. Subsequently, use Fourier transform to perform spectral analysis on the collected reflection signal and transmission signal, extract the specific values of each frequency band. After completing the test of the absorption rate, conduct a four-point probe test on the surface conductivity of the material to obtain the average value of the surface resistance of the material, and combine the thickness of the material to calculate the theoretical value of the shielding effectiveness of the material through the conduction path model. Use an electromagnetic interference simulator to simulate the actual interference intensity and the shielding effect of the material in the 5G signal environment, and record the value of the shielding effectiveness in the actual signal environment. Comprehensively analyze the deviation between the theoretical value and the actual test value to generate the preliminary test results of the shielding material.

[0074] S112: According to the preliminary test results of the shielding material, adjust the composition of the electromagnetic shielding material, optimize the conduction path by simulating the electromagnetic field distribution, and conduct the secondary performance test to obtain the optimized test data;

[0075] According to the electromagnetic shielding performance parameters of the material recorded in the preliminary test results of the shielding material, precisely adjust the material composition. By varying the composition ratios of metal powder, conductive polymer, and insulating matrix, adjust the density and distribution structure of the conductive paths formed in the mixed state. Subsequently, use the finite element simulation method to establish a three-dimensional conductive path model, analyze the influence of the conductive paths on the shielding effectiveness, and after adjusting the composition ratio, perform uniform mixing and compression molding on the material to ensure that the optimized conductive paths form a continuous network structure. After completing the adjustment of the material composition, measure the electromagnetic wave shielding performance by testing the multi-band absorption rate, transmittance, and reflectance of the optimized material, record the performance data for each frequency band, and simultaneously record the absorption rate, surface conductivity, and conductive path distribution parameters of the material before and after improvement. Combine the test records and simulation calculation data to obtain the optimized test data.

[0076] S113: Analyze the optimized test data and use the formula:

[0077]

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

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

[0080] The benefit of the formula is that it introduces the weight parameter w i , performs a weighted average on the shielding effectiveness of different frequency bands, avoids the situation where the direct average masks the performance deficiencies of key frequency bands, and at the same time accurately reflects the cumulative effect of performance deviations through absolute value operations, 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 a multi-band signal test device. The absorption rates of 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, 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 the deviation for each frequency band |P i-T| to obtain [0.07, 0.02, 0.01, 0.04, 0.01];

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

[0086] Sum and divide by the number of test frequency bands to calculate S:

[0087]

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

[0089] Please refer to Figure 3 , and the specific steps for obtaining the microstructure performance analysis data are as follows:

[0090] S211: Based on the selected shielding material specifications, conduct preliminary designs of various microstructures, including honeycomb, porous, and layered structures, and perform 3D modeling to obtain the preliminary design model of the microstructure;

[0091] Based on the selected shielding material specifications, design preliminary drafts of various microstructures, which are successively used to refine the microstructure solutions of the radome into three basic design solutions, namely honeycomb type, porous type, and layered type. Through 3D modeling tools, gradually complete the microstructure design process, including the hexagonal arrangement structure of the honeycomb type unit, the pore size and distribution position of the porous type, and the thickness and spacing parameters of the layered structure. Optimize the size and shape of the geometric models generated during the design process, and use the boundary adjustment method to determine the complete geometric morphology of each microstructure. Finally, output three microstructure design models to generate the preliminary design model of the microstructure.

[0092] S212: Apply the preliminary design model of the microstructure to the electromagnetic characteristic analysis process, set the corresponding electromagnetic wave frequency and boundary conditions, analyze the reflection and absorption performance of each microstructure, and obtain the electromagnetic wave performance data;

[0093] Import the preliminary design models of the microstructures into the electromagnetic simulation environment one by one, set the simulation parameters, including the electromagnetic wave frequency range, incident angle, and material boundary conditions. By gradually adjusting the density of the simulation grid and the boundary characteristics of the microstructure, ensure that the geometric accuracy of each microstructure in the simulation environment meets the input requirements. Conduct reflection and absorption rate simulations on the honeycomb type, porous type, and layered type microstructure models respectively, record the reflection and absorption characteristics of each microstructure at each frequency band, and organize the reflection and absorption performance lists according to the simulation output data. Finally, output the electromagnetic wave performance data.

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

[0095]

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

[0097] where, 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 to be analyzed, and R represents the microstructure performance deviation value;

[0098] The benefit of the formula is to adjust the importance of different frequency bands in the evaluation by introducing the frequency weight w k and use the square of the deviation between the target value D k and the simulation value S k to express 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 actual applications;

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

[0101] S k is the absorption or reflectivity of this frequency band obtained by simulation and 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 k - S k ) for each frequency band. Set D1 = 0.9, D2 = 0.8, D3 = 0.85, corresponding to S1 = 0.88, S2 = 0.78, S3 = 0.82, and obtain 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 obtain the weighted square of the deviation [0.0004, 0.00048, 0.00081];

[0105] Find the sum of the weighted squares of the deviation to obtain R = 0.0004 + 0.00048 + 0.00081 = 0.00169;

[0106] The result shows that the calculated comprehensive deviation R = 0.00169 represents the average deviation degree between the simulation performance of the current microstructure and the target performance. The design can be further optimized by adjusting the microstructure parameters to obtain the microstructure performance analysis data.

[0107] Please refer to Figure 4 , and the steps to obtain the microstructure optimization design scheme are specifically as follows:

[0108] S221: According to the microstructure performance analysis data, adjust the size and shape parameters of the data, set the upper and lower limits of the parameters and control the variation range to obtain the adjusted microstructure parameter data;

[0109] To adjust the size and shape parameters of the data, each microstructure parameter in the dataset needs to be classified and marked. The data range is limited within the upper and lower limit intervals set by the parameters through the screening function, and adjustment operations are carried out according to the set rules of the variation range, including trimming data points outside the range and linearly interpolating and filling missing data to ensure data integrity and usability. During the data adjustment process, a fixed ratio scaling strategy is adopted for the size parameters. For example, the adjustment ratio is determined based on the median within the initial size range, while the shape parameters are corrected for irregular features by fitting curves with discrete points and further adjusted to approximate the standardized curve. The adjusted data needs to pass through an error verification process to verify whether the distribution law of the data conforms to the established standard by repeated sampling, and at the same time record the statistical characteristics of the changes before and after adjustment for reference in subsequent optimization designs. Obtain the adjusted microstructure parameter data.

[0110] S222: According to the adjusted microstructure parameter data, apply the signal interference suppression process to optimize data filtering and signals, adjust the filtering threshold and enhance the signal to obtain signal processing data;

[0111] By introducing a layer-by-layer noise reduction method to segmentally optimize the filtering effect of the data, first determine the upper and lower threshold ranges for filtering to exclude data in the non-target signal part. In specific implementation, by calculating the change amplitude and fluctuation frequency of the adjusted parameter data, select a suitable segmentation interval, group the data and perform low-pass filtering one by one to eliminate high-frequency interference signals, and further enhance the effective part of the signal. When enhancing the signal, correct the target frequency band using a gain function to ensure that the amplification factor of the effective signal can meet the requirements of the original data analysis. After processing, check the signal quality to detect whether the filtered data meets the requirements of uniformity and stability, and at the same time record the change comparison results of the signal intensity before and after processing to obtain signal processing data.

[0112] S223: Utilize the signal processing data 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 to obtain the microstructure optimization design scheme;

[0113] It is necessary to gradually analyze the data performance under different design schemes, make fine adjustments to the microstructural dimensions of each scheme, and gradually match the shape parameters to ensure that the performance indicators of each parameter combination reach the best. During the execution, first extract the key performance values from the signal-processed data, such as shape rigidity, dimensional stability, etc., and record the performance of each scheme. Subsequently, combined with the performance evaluation results, perform weighted normalization calculations on each parameter, select the parameter combination with better performance for in-depth testing. During the testing phase, small-range fluctuation tests need to be carried out on the selected combination to ensure the stability and repeatability of its optimization direction. According to the parameter design with the best performance in multiple rounds of tests, form a microstructural optimization design scheme, and provide support for subsequent research by recording the optimization path.

[0114] Please refer to Figure 5 , and the specific steps for obtaining the structural stress analysis data are as follows:

[0115] S311: Based on the microstructural optimization design scheme, perform mesh division. By decomposing the geometric model, divide the model into multiple small units, and adjust the size and distribution of the units according to the shape and size of the differentiated regions to generate the mesh division result;

[0116] During the mesh division process, first select an appropriate division method according to the overall shape of the geometric model and perform three-dimensional decomposition on the model. Taking a typical radome as an example, if the model includes complex curved surfaces and polygonal structures, a gradually refined strategy is adopted. In the support positions of the radome and areas where large deformations may occur, finer mesh units are used to improve the calculation accuracy. For example, in the edge area of the radome, the size of the mesh unit is 10 mm, while in the central area, it can be set to 20 mm. Conduct a local analysis of the geometric features of the model, and dynamically adjust the size and distribution of the units based on the force-bearing conditions and deformation characteristics of each area to ensure that the division result can reflect the physical properties of the structure. Generate the mesh for the model using finite element software, check the mesh quality, and ensure that each unit meets good shape standards to avoid generating deformed units, thereby improving the accuracy and stability of subsequent calculations.

[0117] S312: Based on the mesh division result, apply boundary conditions and load conditions to the structure. Set fixed constraints at the support positions of the structure, and apply external loads under the real-time working environment on the surface of the radome, including gravity, airflow, and temperature changes, to establish the boundary conditions and load application results;

[0118] When applying boundary conditions and loads to the structure, first, according to the design requirements and the actual working environment, set the fixed constraints of the support points. For example, at the bottom support position of the radome, the constraint conditions can be set. Assume that the support point is in a fixed position and cannot move. According to the external loads in the working environment, apply the effects of gravity, airflow, and temperature changes on the radome respectively. For the gravity load, by calculating the mass of the radome material and the acceleration due to gravity, apply a force in the vertical direction. For the airflow load, according to the different surface shapes of the radome and the airflow directions, apply distributed pressures on the surface respectively. For example, it can be assumed that the airflow flows along a certain direction on the radome surface at a speed of 10 m / s, thus generating corresponding aerodynamic pressures. In terms of temperature changes, by simulating the temperature change from -40°C to +85°C, apply thermal stress and convert it into a thermal load, and apply it on the radome surface to simulate the effects caused by the thermal expansion or contraction of the material, obtaining the boundary conditions and load application results, which provides 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 different loads, evaluate the stress and deformation of each grid element, output the stress values and deformation data of each point, and obtain the structural stress analysis data;

[0120] In the structural load analysis, calculate the stress and strain of each grid element through finite element analysis. According to the applied boundary conditions and loads, solve the stress distribution on each grid element. In the edge area of the radome, due to large deformation and stress concentration, higher stress values will appear. Assume that the stress value calculated on a certain small element is 50 MPa. At this time, conduct a detailed analysis of this element, and combine the tensile strength and compressive strength of the material to evaluate whether it exceeds the design limit. If it exceeds, it is necessary to increase the material thickness in this area or optimize the grid division accuracy. In the central area of the radome, the stress is small, but the deformation may be large. Therefore, it is necessary to pay attention to the deformation situation in the area. When evaluating the deformation of each grid element, in addition to referring to the influence of external loads, it is also necessary to refer to the influence of thermal stress caused by temperature changes on the deformation, record and output the structural stress analysis data, and gradually obtain the overall stress and deformation analysis results of the radome. The analysis process will provide accurate stress distribution information and deformation data, which is helpful for subsequent optimization design to ensure the safety and reliability of the radome.

[0121] Please refer to Figure 6 , the steps for obtaining the design scheme of the radome structure and material are specifically 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 respectively 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 amount;

[0130] By introducing the two parameters of load distribution stability and stress deformation amount, 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 optimized design of the radome;

[0131] C represents the matching index of the radome design, which reflects the matching performance after the comprehensive optimization of the structure and materials. w1 and w2 are the two main evaluation indexes, the weight coefficients of material matching and structural optimization. The weight coefficients reflect the importance of each index in the overall design. X1 is the index calculated based on the material matching analysis data, X2 is the result after the structural optimization analysis, X3 represents the load distribution stability, and X4 is the stress deformation amount, all of which are 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. Set X1 to 0.85, X2 to 0.75, X3 to 50N, X4 to 0.04 (the unit has been standardized according to the actual application), the weight coefficient w1 to 0.6, and w2 to 0.4, and substitute them into the formula to calculate:

[0132]

[0133]

[0134] C = 0.81·250

[0135] C = 202.5

[0136] This result shows 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, and the matching score indicates that the optimized performance of this design scheme reaches the expected goal and meets the conditions for further application.

[0137] Please refer to Figure 7 , and the specific steps for obtaining the radome performance verification results are as follows:

[0138] S411: Based on the design scheme of the radome structure and materials, carry out material processing and assembly. Combine the structure in the design scheme and the selected materials to process the radome sample and perform the assembly operation to form the radome sample to be tested;

[0139] First, select materials that meet the design requirements. Based on standards such as the electromagnetic properties, mechanical strength, and temperature resistance of the materials, conduct bulk procurement to ensure that they meet the performance requirements in the design. The selected materials include metals or synthetic materials with high electrical conductivity and high-temperature resistance to ensure that they can effectively perform the shielding and isolation functions of the radome under different environmental conditions. The procurement process is carried out strictly according to the design specifications, and the inspection reports of each batch of materials are reviewed. Cut, shape, and process the materials according to the design drawings. During the cutting process, accurately cut the materials according to the size requirements to ensure that the geometric shape of each component meets the requirements, including processing parts such as the outer shell, support structure, and shielding layer of the radome to ensure that the size, angle, and surface quality of each component reach the design standards. After processing, start assembling each part, including ensuring the stable combination of each component through welding, connecting, bonding, etc. Through precise docking and welding operations, ensure the connection strength and shielding effect of each component of the radome. Conduct a rigorous inspection of the structural components of the radome to avoid any poor contact or structural defects, forming a radome sample to be tested. After the sample is completed, conduct a preliminary structural inspection to ensure that all interfaces and structural components are installed firmly and without defects, and confirm that the radome meets the design requirements in terms of shape, size, and assembly quality.

[0140] S412: According to the radome sample to be tested, conduct a 5G environment simulation test on the radome sample, set the test conditions and conform to the real-time 5G environment parameters, and detect each performance of the sample in the simulated environment, including signal attenuation, shielding effect, and anti-interference ability. Use the formula:

[0141]

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

[0143] where, P shield represents the percentage increase in shielding effect, S after is the shielding effect after the simulation environment test, 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 advantage of the formula is that by introducing factors such as temperature change, frequency change, and the temperature difference of the radome sample, a comprehensive evaluation of the shielding performance can be carried out, which 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 during actual use;

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

[0146] The specific value of each parameter is determined according to the experimental data. λ1, λ2, and λ3 are all obtained through regression analysis. According to the experimental data, set the values of the coefficients. λ1 = 0.02, λ2 = 0.01, λ3 = 0.015. The values of the coefficients are from the average value 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 radome sample is ΔT temp = 2°C, substitute into the formula for calculation:

[0147]

[0148] This result shows that the percentage of the shielding effect improvement is about 7.25%. This value reflects that under the test conditions, the shielding performance of the radome has been improved by 7.25%, verifying its matching under various environmental changes. This value further proves the effectiveness of the radome design, and finally generates the shielding performance result of the environmental matching test and serves as the basis for subsequent optimization and verification.

[0149] S413: Combine the shielding effect data of the radome with the experimental threshold, conduct data analysis, and evaluate the performance of the radome. If the shielding performance does not reach the standard threshold, return the design scheme 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, combine the obtained shielding performance data, set the standard threshold to evaluate the performance of the radome. If the shielding performance P 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 the preferred embodiments of the present invention, and do not limit the present invention in other forms. Any person skilled in the art may use the technical content disclosed above to make changes or modifications into equivalent embodiments with equivalent changes and apply them to other fields. However, as long as it does not depart from the technical solution content of the present invention, any simple modification, equivalent change and modification made to the above embodiments according to the technical essence of the present invention still fall within the protection scope of the technical solution of the present invention.

Claims

1. A manufacturing method of a 5G base station radome, characterized in that, It includes the following steps: Select an electromagnetic shielding material that matches the 5G radome 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; Based on the selected shielding material specifications, design the physical microstructure of the radome, select the type of microstructure, conduct structural simulation estimates of the reflection and absorption performance of electromagnetic waves, obtain microstructure performance analysis data, and conduct signal interference suppression analysis and processing, adjust the size and shape of the microstructure, and obtain the optimized design scheme of the microstructure; Based on the optimized design scheme of the microstructure, analyze the overall structural stability and mechanical strength of the radome, obtain structural stress analysis data, conduct analysis of the matching of the structure and materials, adjust the design parameters according to the analysis results, determine the structural layout and material distribution of the radome, and obtain the design scheme of the radome structure and materials; According to the design scheme of the radome structure and materials, fabricate a sample of the radome, conduct material processing and assembly, conduct environmental matching tests on the sample in a simulated 5G environment, record the test data, analyze the shielding effect and environmental matching ability of the radome, and obtain the performance verification results of the radome.

2. The manufacturing method of the 5G base station radome according to claim 1, wherein The specific steps for obtaining the selected shielding material specifications are as follows: Select an electromagnetic shielding material that matches the 5G radome based on the electromagnetic wave absorption rate, conduct initial performance tests, measure the electromagnetic wave absorption rate, conductivity, and material thickness, record the key performance indicators, and generate preliminary test results of the shielding material; According to the preliminary test results of the shielding material, adjust the composition of the electromagnetic shielding material, optimize the conductive path by simulating the electromagnetic field distribution, and conduct secondary performance tests to obtain the optimized test data; Analyze the optimized test data and use the formula: Calculate the adjusted average deviation, evaluate the shielding effect, and generate the selected shielding material specifications; Among them, S represents the adjusted average deviation, P i represents the electromagnetic wave absorption rate of the i-th optimization test, T represents the target absorption rate threshold, w i is the weight factor, and n represents the total number of tests.

3. The manufacturing method of the 5G base station radome according to claim 2, characterized in that The specific steps for obtaining the microstructure performance analysis data are as follows: Based on the selected shielding material specifications, conduct preliminary designs of multiple microstructures, including honeycomb, porous, and layered structures, and conduct 3D modeling to obtain a preliminary design model of the microstructure; Apply the preliminary design model of the microstructure to the electromagnetic characteristic analysis process, set the corresponding electromagnetic wave frequency and boundary conditions, analyze the reflection and absorption performance of each microstructure, and obtain electromagnetic wave performance data; Analyze the electromagnetic wave performance data, evaluate the performance of the microstructure, and use the formula: Calculate the performance deviation of each microstructure and obtain the microstructure performance analysis data; where, w k is the weight of frequency k, D k is the target absorption or reflectance, S k is the absorption or reflectance obtained by simulation, K represents the number of frequency points to be analyzed, and R represents the performance deviation value of the microstructure.

4. The manufacturing method of the 5G base station radome according to claim 3, wherein, The specific steps for obtaining the optimized design scheme of the microstructure are as follows: According to the microstructure performance analysis data, adjust the size and shape parameters of the data, set the upper and lower limits of the parameters and control the variation range, and obtain the adjusted microstructure parameter data; According to the adjusted microstructure parameter data, apply the signal interference suppression process, optimize data filtering and signals, adjust the filtering threshold and enhance the signals, and obtain the signal processing data; Use the said signals to process data, 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 to obtain the optimized design scheme of the microstructure.

5. The manufacturing method of the 5G base station radome according to claim 4, characterized in that, The specific steps for obtaining the structural stress analysis data are as follows: Based on the optimized design scheme of the microstructure, perform mesh division. By decomposing the geometric model, divide the model into multiple small units, and adjust the size and distribution of the units according to the shape and size of the differential region to generate the mesh division result. Based on the mesh division result, apply boundary conditions and load conditions to the structure. Set fixed constraints at the support positions of the structure, and apply external loads under the real-time working environment, including gravity, airflow, and temperature changes, on the surface of the radome to establish the boundary conditions and the load application result. Based on the boundary conditions and the load application result, analyze the stress and strain of the radome under differential loads, evaluate the stress and deformation of each mesh unit, output the stress value and deformation data of each point, and obtain the structural stress analysis data.

6. The manufacturing method of the 5G base station radome according to claim 5, wherein The specific steps for obtaining the design scheme of the radome structure and materials are as follows: According to the structural stress analysis data, extract the stress distribution of the radome under differential loads, analyze the relationship between the stress value and the critical value of material strength, perform a comparison of stress and material strength, judge the material matching, select the matching material area, and generate the material matching analysis data. Based on the material matching analysis data, perform structural optimization analysis, analyze the influence of the differential material distribution on the radome structure, optimize the geometric shape and thickness distribution of the radome, and obtain the adjusted structural parameter data. According to the adjusted structural parameter data and the material matching analysis data, perform an evaluation of the structure and materials, 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 respectively 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 amount.

7. The manufacturing method of the 5G base station radome according to claim 6, characterized in that The specific steps for obtaining the radome performance verification result are as follows: Based on the design scheme of the radome structure and materials, perform material processing and assembly. Combine the structure in the design scheme and the selected materials to process the radome sample and perform the assembly operation to form the radome sample to be tested. According to the radome sample to be tested, conduct a 5G environment simulation test on the radome sample. Set the test conditions to conform to the real-time 5G environment parameters, detect each performance of the sample in the simulated environment, including signal attenuation, shielding effect, and anti-interference ability, using the formula: Obtain the shielding effect data of the radome. Among them, P shield represents the percentage increase in shielding effect, S after is the shielding effect after the simulation environment test, S before is the shielding effect during the preliminary test, λ1, λ2, λ3 are weighting coefficients, ΔT is the temperature difference before and after the test, ΔF is the frequency change value under the test conditions, D temp is the temperature difference of the radome sample; Combine the shielding effect data of the radome with the experimental threshold, conduct data analysis, evaluate the performance of the radome. If the shielding performance does not reach the standard threshold, return to the design scheme for optimization and retest. If it meets the standard, determine the performance to obtain the radome performance verification result.

8. A manufacturing system for a 5G base station radome, characterized in that, The manufacturing method of a 5G base station radome according to any one of claims 1 to 7, the system comprising: The material formulation development module selects and matches the electromagnetic shielding material for the 5G radome 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 different formulations, and obtains the optimized material formulation; The microstructure design and simulation module uses the optimized material formulation 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 the microstructure design scheme; The structure and material integration module analyzes the structural stability and mechanical strength based on the microstructure design scheme, adjusts the radome design parameters, optimizes the material distribution, and forms the design scheme of the structure and material; The radome sample manufacturing module executes sample manufacturing according to the design scheme of the structure and material, including material processing and assembly, and conducts preliminary functional tests to obtain the completed radome sample; The performance test and evaluation module performs performance tests on the completed radome sample in a simulated 5G environment, evaluates the shielding effect and environmental compatibility, and obtains the antenna radome performance verification result.

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