Millimeter wave coupled cavity traveling wave tube core welding method

Abstract

The invention relates to the field of millimeter wave coupled cavity traveling wave tube manufacturing, and discloses a millimeter wave coupled cavity traveling wave tube core welding method, which comprises the following steps of: dividing a tube core into five parts, namely an input section, a first connecting ring combination, a middle section, a second connecting ring combination and an output section, and performing brazing on a magnetic circuit tube shell and a slow wave line by adopting active brazing filler metal, an accurate positioning mold is used for positioning and fixing; after brazing, brazing filler metal is filled, and stable connection between components is ensured; and finally, all the components are connected into a complete tube core through argon arc welding, and it is ensured that the tube core has high straightness and good heat conduction performance. According to the method, the assembly precision of the tube core is improved, the heat conduction effect and the signal transmission efficiency are enhanced, the production process is optimized, the welding error is reduced, and the service life of the tube core is prolonged.

Description

Technical Field

[0001] The present invention relates to the technical field of manufacturing millimeter-wave coupled-cavity traveling-wave tubes, and specifically to a method for welding the core of a millimeter-wave coupled-cavity traveling-wave tube. Background Art

[0002] In the current manufacturing process of millimeter-wave coupled-cavity traveling-wave tubes, traditional core welding methods have certain technical defects. Especially in high-frequency and high-power applications, the core structure of the traveling-wave tube has strict requirements for thermal conductivity, signal transmission efficiency, and mechanical strength. However, common welding processes in the existing technology usually rely on manual welding or simple automated welding, resulting in uneven welding seams and incomplete contact surfaces, thus affecting the overall performance of the core.

[0003] In the existing welding process, due to the low assembly and welding precision of each part of the core, docking errors between components often occur, resulting in poor concentricity of the core and affecting its high-frequency transmission effect. In addition, some traditional welding methods cannot effectively avoid the thermal stress and mechanical stress generated during welding, which may lead to damage to the welding part or performance degradation during long-term operation.

[0004] Although some methods attempt to make up for these defects by improving the selection of solder and welding techniques, due to the lack of precise positioning molds and automated control means, the errors in the entire assembly process are still large, and it is easy to cause the straightness and thermal conductivity of the core to not reach the optimal state. In addition, in some welding processes, the uneven filling of solder or the inaccurate control of soldering temperature will further affect the strength and stability of the core, resulting in reliability problems during long-term use.

[0005] Therefore, the main problems of the existing technology are the low welding process and assembly precision, which limit the performance of millimeter-wave coupled-cavity traveling-wave tubes and reduce their adaptability in harsh environments such as high power and high frequency. Summary of the Invention

[0006] In view of the deficiencies of the existing technology, the present invention provides a method for welding the core of a millimeter-wave coupled-cavity traveling-wave tube, which solves the problems of insufficient welding precision, poor core concentricity, and unsatisfactory thermal conductivity and signal transmission efficiency in the existing technology.

[0007] To achieve the above objectives, the present invention is realized through the following technical solutions: A method for welding the core of a millimeter-wave coupled-cavity traveling-wave tube, comprising the following steps:

[0008] Divide the core into five parts: an input section, a first connection ring assembly, an intermediate section, a second connection ring assembly, and an output section, and nest slow-wave lines inside the magnetic circuit tube shell of each part;

[0009] Use an active filler metal to braze the magnetic circuit housing and the slow-wave line of each part, and use a welding mold for positioning and fixing;

[0010] Push the brazed slow-wave line into the corresponding magnetic circuit housing, fill the active filler metal between the slow-wave line and the magnetic circuit housing, and continue to use the mold for positioning and fixing;

[0011] Assemble all the components and use argon arc welding to connect each part to complete the welding.

[0012] Preferably, the welding mold includes an upper clamping mold, a lower clamping mold and several welding clamping rods, wherein:

[0013] The upper clamping mold and the lower clamping mold are connected by several welding clamping rods;

[0014] The several welding clamping rods are used to clamp the parts to be welded to control the straightness of the welded parts.

[0015] Preferably, the number of the welding clamping rods is at least three.

[0016] Preferably, each part of the tube core, including the input section, the first connection ring combination, the middle section, the second connection ring combination, and the output section, is positioned using a welding mold.

[0017] Preferably, a positioning mold is used for positioning welding during the argon arc welding process.

[0018] Preferably, the positioning mold includes:

[0019] An input section positioning shaft and an output section positioning shaft for controlling the concentricity of the input section and the output section;

[0020] A first positioning shaft support block and a second positioning shaft support block for respectively supporting the input section positioning shaft and the output section positioning shaft;

[0021] A tube core positioning support seat for supporting the assembled tube core;

[0022] A tube core pressing plate for fixing the tube core to prevent movement.

[0023] Preferably, the input section positioning shaft and the output section positioning shaft are concentrically arranged.

[0024] Preferably, the positioning mold further includes a calibration bottom plate for connecting the first positioning shaft support block and the second positioning shaft support block.

[0025] The present invention provides a welding method for a millimeter-wave coupled cavity traveling wave tube core. It has the following beneficial effects:

[0026] 1. The present invention divides the input section, output section and middle section into independent parts for welding and assembly, and each part is positioned by a precise positioning mold, thereby ensuring the high docking accuracy between the components of the tube core. This segmented design and precise positioning method significantly improves the straightness and structural stability of the entire tube core, thereby enhancing the overall performance of the millimeter wave coupled cavity traveling wave tube.

[0027] 2. In the present invention, active solder is used for brazing between the magnetic circuit shell and the slow wave line, which not only effectively improves the strength of the connection part, but also optimizes the thermal conductivity. The filled solder can ensure the heat dissipation effect of the tube core, improve the durability of the tube core in high-power applications, reduce signal attenuation, and enhance the transmission efficiency of millimeter wave signals.

[0028] 3. The present invention effectively avoids welding errors caused by component displacement or asymmetry during assembly and welding. The positioning mold not only ensures the concentricity of the tube core and the accurate docking of the components, but also prevents possible deviations during welding, thereby improving the overall consistency and performance of the tube core.

[0029] 4. The design of the present invention makes the production process simpler and easier to control through segmented assembly and mold-assisted positioning. This method can reduce manual operation errors, and improve production efficiency and reduce manufacturing costs through modular assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is a schematic diagram of the welding method flow of the present invention;

[0031] Figure 2 It is a schematic diagram of the tube core composition of the present invention;

[0032] Figure 3 This is a schematic diagram of the structure of the magnetic circuit shell with embedded slow-wave line in the present invention;

[0033] Figure 4 It is a schematic diagram of the mold assembly for welding the slow-wave line and the magnetic circuit shell of the present invention;

[0034] Figure 5 It is a schematic diagram of the welding assembly of the magnetic circuit shell and the nested slow-wave line of the present invention;

[0035] Figure 6 It is a schematic diagram of the tube core argon arc welding positioning mold of the present invention. DETAILED DESCRIPTION

[0036] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0037] Please refer to the attached Figure 1 - attached Figure 6 , the present invention provides a welding method for the core of a millimeter-wave coupled-cavity traveling-wave tube. The core is divided into multiple parts, and brazing and argon arc welding technologies are used to tightly connect each part to ensure high-precision assembly. Especially in high-frequency, broadband, and high-power applications, it can maintain high welding precision and performance.

[0038] The welding method for the core of the millimeter-wave coupled-cavity traveling-wave tube may include the following steps:

[0039] S1. Segment the core and respectively nest the slow-wave line;

[0040] S2. Braze the magnetic circuit tube shell and the slow-wave line of each part;

[0041] S3. Push the brazed slow-wave line into the corresponding magnetic circuit tube shell and fill with active brazing filler metal;

[0042] S4. Assemble all components and use argon arc welding to connect each part.

[0043] The following will elaborate on each step of this method in detail.

[0044] In this embodiment, step S1 is to design and construct the core of the millimeter-wave kilowatt-level high-power traveling-wave tube by dividing it into multiple parts. Specifically, the core is disassembled into five parts, namely the input section 1, the connection ring assembly 2, the middle section 3, the connection ring assembly 2, and the output section 4. This disassembly design is to improve the machining accuracy of parts and optimize the performance of the magnetic field focusing system. Especially when dealing with small-size optical slow-wave circuits, it can effectively improve the overall efficiency of the system.

[0045] According to the design of this embodiment, the corresponding slow-wave lines 1-2, 3-2, and 4-2 are nested inside the magnetic circuit tube shells 1-1, 3-1, and 4-1 of the input section 1, the output section 4, and the middle section 3 respectively. By separately designing the magnetic circuit tube shell and the slow-wave line and performing refined machining on each part, it can effectively ensure the stability and efficiency of the slow-wave circuit at high frequencies. This design not only improves the machining accuracy of parts but also optimizes the performance during signal transmission, enabling each component to maximize its efficiency under its working conditions.

[0046] Specifically, the input section 1 is responsible for receiving signals and transmitting them to the subsequent parts. Its design must ensure that the signal transmission is not interfered with. Therefore, the slow-wave line 1-2 is embedded in the magnetic circuit housing 1-1 of the input section 1, enabling the signal to be effectively transmitted to the downstream parts. Similarly, the output section 4 is designed in the same way. It is responsible for outputting signals to the external system and also needs to ensure the stable output of signals through the slow-wave line 4-2 in the magnetic circuit housing 4-1 of the output section 4.

[0047] The middle section 3 is located at the core position of the die and plays a role in connecting and stabilizing. Its magnetic circuit housing 3-1 and the nested slow-wave line 3-2 work together to ensure the efficient operation of the entire die. The two connecting ring assemblies 2 play a role in fixedly connecting the input section 1, the output section 4, and the middle section 3, stabilizing the entire system, and ensuring the connection and signal transmission between various parts.

[0048] The design in this embodiment greatly improves the operability and reliability of the system by dividing each part into independent components and performing precise machining. At the same time, through this structured design, it can be ensured that each part of the die can be flexibly adapted during assembly, which helps to improve the stability of the overall performance.

[0049] In this embodiment, step S2 is to use active filler metal to braze the magnetic circuit housing and the slow-wave line of each part, and position and fix them through a mold. Specifically, the magnetic circuit housings 1-1, 3-1, 4-1 of the input section 1, the middle section 3, and the output section 4 and the corresponding slow-wave lines 1-2, 3-2, 4-2 are welded by the active filler metal 5.

[0050] During the welding process, the active filler metal 5 plays a role in filling the joints, making the connection between the magnetic circuit housing and the slow-wave line stronger. In the brazing process, the selection of the active filler metal 5 is crucial. Its melting point should be reasonably matched according to the materials of the slow-wave line and the magnetic circuit housing to ensure that it can fully fill the joints under high-temperature conditions without affecting the performance of other parts.

[0051] In this embodiment, upper clamping die 6, lower clamping die 7, and welding clamping rod 8 and other molds are used to ensure the correct positioning of each component during the welding process and avoid any unnecessary displacement. The upper clamping die 6 and the lower clamping die 7 are connected by the welding clamping rod 8. These mold components play a key role in the brazing process, ensuring the structural stability during the entire welding process.

[0052] The welding clamping rod 8 helps to ensure the correct docking surface and straightness between the magnetic circuit housing and the slow-wave line of the input section 1, the output section 4, and the middle section 3 during this process. The number of welding clamping rods is usually at least three, and through the clamping and positioning functions, it ensures that the brazed components do not displace, maintaining the stability of the welding joints.

[0053] These welding molds, especially the welding clamping rod 8, play a crucial role in controlling the straightness of the welded parts during the brazing process. Especially for high-frequency, high-power millimeter-wave applications, ensuring the straightness of each component after brazing is essential for the final performance.

[0054] In summary, the brazing process in this embodiment ensures the stable butt joint of each part during the welding process and forms a firm connection through the application of positioning molds and active brazing filler metal.

[0055] In this embodiment, in step S3, after brazing is completed, the slow-wave line is pushed into the magnetic circuit housing, and active brazing filler metal is filled between the two, thereby ensuring the stability and firmness of the welded joint. Specifically, the slow-wave lines 1-2, 3-2, and 4-2 of the input section 1, the intermediate section 3, and the output section 4 after brazing need to be pushed into the corresponding magnetic circuit housings 1-1, 3-1, and 4-1 respectively. During this process, a seam will be formed between the pushed-in slow-wave line and the magnetic circuit housing, and active brazing filler metal 5 is filled in this seam.

[0056] The function of the active brazing filler metal 5 is to ensure a more stable connection between the slow-wave line and the magnetic circuit housing, and to avoid signal loss or structural instability caused by voids or poor material contact. The filled brazing filler metal needs to flow completely and cover the seam area under heating conditions to ensure its good thermal conductivity and mechanical strength. Specifically, after the active brazing filler metal 5 is filled, it is necessary to ensure that its distribution is uniform and the seam is fully filled, preventing the appearance of any bubbles or unfilled areas.

[0057] To ensure the stability and precision of each component after brazing, molds are used in this embodiment for further positioning and fixing. During this process, the molds can ensure that each component will not be displaced or skewed after welding. In particular, the welding clamping rod 8 plays a role in controlling the straightness of the welded parts at this stage. The welding clamping rod 8 clamps each component and maintains its position, ensuring that during the brazing filler metal filling and cooling processes, the contact and butt joint surfaces between the slow-wave line and the magnetic circuit housing are always in an ideal state, avoiding offsets caused by thermal expansion or contraction during the welding process.

[0058] Through this design, the brazed seam can maintain high strength and good thermal conductivity, while ensuring the stability and high efficiency of the overall structure. The assembly and connection of each component are strictly controlled in terms of precision to ensure that there will be no problems with the die after brazing during subsequent TIG welding.

[0059] In addition, the positioning of the molds and the control of the welding clamping rod 8 throughout the process ensure the concentricity and butt joint precision between each part, thus laying a solid foundation for the subsequent TIG welding step.

[0060] In summary, step S3 ensures the precise alignment and firm connection between components after brazing by filling the active brazing filler metal and combining with the positioning control of a high-precision mold, avoiding any risks that may cause signal attenuation or structural instability.

[0061] In this embodiment, step S4 is a process of assembling components such as the input section 1, connection ring assembly 2, intermediate section 3, connection ring assembly 2, and output section 4 and connecting them by argon arc welding. The goal of this step is to ensure high-precision connection between all components and ultimately obtain a stable and highly straight tube core.

[0062] First of all, all components are assembled according to the Figure 5 structure shown. Specifically, during this process, the input section 1, connection ring assembly 2, intermediate section 3, connection ring assembly 2, and output section 4 are precisely positioned and fixed to ensure their correct connection. In particular, the input section positioning shaft 10 and the output section positioning shaft 11 are used to ensure the concentricity of the input section 1 and the output section 4. These two positioning shafts are supported by the first positioning shaft support block 12 and the second positioning shaft support block 13 to ensure that they always maintain an accurate position during the assembly process.

[0063] In addition, the tube core positioning support base 14 and the calibration base plate 15, as key molds, play an important role in the entire assembly process. The tube core positioning support base 14 is responsible for supporting the assembled tube core to ensure the stability of the entire assembly, while the calibration base plate 15 ensures the alignment of the central axis of the tube core with the central axis of the mold by adjusting its position, thus ensuring the assembly of all components in a straight line.

[0064] After all components are firmly installed and correctly aligned, the tube core pressing plate 16 is used to fix the tube core to prevent any movement or displacement during the welding process. This operation is very crucial and can avoid welding errors caused by the movement of components, ensuring the precise connection of all components during argon arc welding.

[0065] Next, argon arc welding is performed at the connection 9 between the input section 1, output section 4, and connection ring assembly 2. The main purpose of argon arc welding is to firmly weld all connection parts together and finally complete the assembly of the tube core. During the welding process, argon arc welding technology ensures the firmness and high strength of the welded parts, guaranteeing the structural stability and good electrical performance of the tube core.

[0066] Through the above assembly and welding steps, the finally obtained tube core will have excellent mechanical strength and electrical performance and high straightness. The entire assembly and welding process of the tube core strictly follows high-precision control, avoiding performance problems caused by welding errors, and ensuring the high efficiency and stability of the millimeter-wave coupled cavity traveling-wave tube.

[0067] Although embodiments of the present invention have been shown and described, it will be understood by those of ordinary skill in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for welding a millimeter wave coupled cavity traveling wave tube core, characterized in that: The following steps are involved: The tube core is divided into five parts: an input section, a first connecting ring combination, an intermediate section, a second connecting ring combination, and an output section, and a slow-wave line is embedded inside the magnetic circuit shell of each part; Use active solder to braze the magnetic circuit shell and slow wave line of each part, and use welding mold to position and fix them; Push the brazed slow-wave wire into the corresponding magnetic circuit shell, fill the space between the slow-wave wire and the magnetic circuit shell with active brazing material, and continue to position and fix it using a mold; Assemble all the parts and use TIG welding to connect the parts and complete the welding.

2. A method for welding a millimeter wave coupled cavity traveling wave tube core according to claim 1, characterized in that: The welding mold comprises an upper clamping mold, a lower clamping mold and a plurality of welding clamping rods, wherein: The upper clamping die and the lower clamping die are connected by a plurality of welded clamping rods; The plurality of welding clamping rods are used to clamp the parts to be welded so as to control the straightness of the welded parts.

3. A method for welding a millimeter wave coupled cavity traveling wave tube core according to claim 2, characterized in that: The number of the welding clamping rods is at least three.

4. A method for welding a millimeter wave coupled cavity traveling wave tube core according to claim 2 or 3, characterized in that: Each part of the tube core, including the input section, the first connecting ring combination, the middle section, the second connecting ring combination, and the output section, is positioned using a welding mold.

5. The method for welding a millimeter wave coupled cavity traveling wave tube core according to claim 1, characterized in that: During the argon arc welding process, a positioning mold is used to perform positioning welding.

6. A method for welding a millimeter wave coupled cavity traveling wave tube core according to claim 5, characterized in that: The positioning mold comprises: The input section positioning axis and the output section positioning axis are used to control the concentricity of the input section and the output section; The first positioning shaft support block and the second positioning shaft support block are used to support the input section positioning shaft and the output section positioning shaft respectively; The tube core positioning support seat is used to support the assembled tube core; The tube core pressure plate is used to fix the tube core to prevent movement.

7. A method for welding a millimeter wave coupled cavity traveling wave tube core according to claim 6, characterized in that: The input section positioning shaft and the output section positioning shaft are arranged concentrically.

8. The method for welding a millimeter wave coupled cavity traveling wave tube core according to claim 1, characterized in that: The positioning mold also includes a calibration base plate for connecting the first positioning shaft support block and the second positioning shaft support block.

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