Ultra-wideband high-power high-integration blade type active subarray

Abstract

The invention relates to the technical field of active subarrays, in particular to an ultra-wideband high-power high-integration blade type active subarray. According to the technical scheme, the antenna comprises an active sub-array frame, an antenna unit integrated with a calibration network, a T / R assembly and a driving assembly which adopt floating coaxial connectors and are inserted in a double-face manner, a multifunctional comprehensive network board integrated through a hot melting pressing process, and a side edge integrated external port. According to the invention, through the design of module double-side plug-in, a blind plug-in structure and floating connection, high-density integration, high performance and high maintainability of the active sub-array are realized; light weight and efficient heat dissipation are achieved through frame hollowing and S-shaped water channel design; and the manufacturing cost is effectively reduced through split pressing of the network board and standardized board splicing of the antenna. The invention is particularly suitable for an airborne radar platform with strict requirements on weight, volume and maintainability.

Description

Technical Field

[0001] This invention relates to the field of active subarray technology, and more particularly to an ultra-wideband, high-power, highly integrated blade-type active subarray. Background Technology

[0002] Active phased array radars achieve system modularity and maintainability by dividing a large antenna array into multiple active subarrays with independent transmit and receive functions. Each active subarray typically integrates antenna elements, calibration networks, T / R components, drive components, integrated networks, and cooling systems. With advancements in gallium nitride and microwave monolithic integrated circuit technologies, the power and integration density of active devices such as T / R components have significantly increased, placing higher demands on the heat dissipation, structural density, and electrical performance of the subarrays. However, existing active subarrays often face the following challenges when designed for airborne platforms with stringent weight and size requirements: 1. The contradiction between high-density integration and high maintainability: the dense arrangement of a large number of components makes it difficult to replace individual modules and results in long maintenance time; II. The challenge of balancing high performance with lightweight and low cost: To achieve high power and ultra-wideband performance, complex structures and expensive processes are often used, resulting in high weight and cost. Third, the system-level assembly efficiency is low. The connection between subarrays and antennas, and between subarrays and array surfaces, usually requires precise alignment and cumbersome wiring, which affects the deployment speed. Summary of the Invention

[0003] The purpose of this application is to address the problems existing in the background technology by proposing an ultrawideband, high-power, highly integrated blade-type active subarray that can balance high integration, high performance, high maintainability, low cost, and lightweight design.

[0004] The technical solution of this application is: an ultra-wideband, high-power, highly integrated blade-type active subarray, including an active subarray frame, wherein the active subarray frame integrates cooling water channels and is provided with water connectors, and the active subarray frame is provided with line end guide pins, line end mounting holes, subarray end guide pins and subarray end mounting holes for quick installation. At least one antenna array, the antenna array being fixed to one side of the active subarray frame via a first blind-plug structure consisting of line-end guide pins and line-end mounting holes, the antenna array comprising multiple Vivaldi-type antenna elements, each antenna element having an integrated calibration network. Multiple T / R components are installed on both sides of the antenna array in a double-sided interlocking mirror layout, and at least one drive component is installed on the back of the active subarray frame. Both the T / R components and the drive component adopt a brick-type design and integrate floating coaxial connectors. A multifunctional integrated network board is nested and fixed within the active subarray frame and located below the T / R component and the drive component. The multifunctional integrated network board integrates the energy storage capacitor board, the radio frequency power divider network control board and the current-carrying power board into one unit through a hot melt pressing process. A multifunctional integrated network board cover is provided on the top of the T / R component. The external ports integrated on the side of the active subarray frame include a left RF main port connector, a right RF main port connector, a low-frequency control connector, an RF calibration connector, and a cut-off high-power power supply finger connector. The multi-functional integrated network board is connected to external signals through KK1 connectors and KK2 connectors.

[0005] Optionally, the active subarray frame forms a second blind-plug structure through subarray end guide pins and second subarray end mounting holes, and the active subarray frame is plugged into the overall array frame through the second blind-plug structure.

[0006] Optionally, the floating coaxial connectors of the T / R component and the drive component can be pluggably connected to the corresponding interfaces on the multi-functional integrated network board.

[0007] Optionally, the energy storage capacitor board is electrically connected to the intercepted high-power power supply contact finger and the current-carrying power supply board. The current-carrying power supply board distributes power to the T / R component and the drive component. The radio frequency power divider network control board is used for radio frequency signal distribution and control signal transmission.

[0008] Optionally, the active subarray frame is made of aluminum alloy, the active subarray frame has internal reinforcing ribs, and the active subarray frame has cover plates on both sides.

[0009] Optionally, the calibration network integrated within the antenna unit is coupled and ohmic load matching is performed.

[0010] Optionally, the antenna array is composed of four standardized antenna sub-unit panels, the four antenna sub-units including a single real unit V1, a single real unit V2, a single virtual unit V1, and a single virtual unit V2.

[0011] Optionally, the hot melt pressing process involves filling high-temperature hot melt adhesive strips between the energy storage capacitor board, the radio frequency power divider network control board, and the current-carrying power board using a customized mold, and then forming them as a single unit after heating and pressurization.

[0012] In summary, this application includes the following beneficial technical effects: This application employs a double-sided interlocking mirror layout for T / R components, nested within a multi-functional integrated network board, achieving high-density integration of 48 channels within a limited space. Combined with the Vivaldi antenna and built-in calibration network, it ensures beam quality and channel consistency under ultra-wideband operating conditions. Floating coaxial connectors enable lossless and rapid insertion and removal of active components, and the two-stage blind-mating structure for the antenna and subarrays allows the subarrays to be quickly replaced as field-replaceable units, significantly improving system maintenance efficiency.

[0013] The antenna unit integrates a calibration network. This integrated design brings the calibration function forward to the radiation source, enabling real-time and accurate monitoring and calibration of the amplitude and phase consistency of each channel, laying the foundation for the high performance and stable beam quality of the radar system.

[0014] The S-curve flow channel layout increases the contact area and heat exchange time between the coolant and the high heat density area, significantly improving heat dissipation efficiency and meeting the heat dissipation requirements of high-power devices during long-term operation. At the same time, the compact flow channel design also helps to reduce the overall weight.

[0015] The hot-melt bonding process uses a custom mold to fill the gaps between the energy storage capacitor board, the RF power divider network control board, and the current-carrying power board with high-temperature hot-melt adhesive strips, which are then heated and pressurized to form a single integrated structure. This process ensures the mechanical strength and long-term reliability of the connections between the three sub-boards, and achieves precise electrical interconnection between layers through metallized through-holes, guaranteeing the integrity of power, RF, and control signal transmission. Attached Figure Description

[0016] Figure 1 An exploded view of an active subarray; Figure 2 This is the overall integrated diagram of the active subarray; Figure 3 A schematic diagram of a lightweight design for active subarrays; Figure 4 A schematic diagram of the inter-element panel structure of an active subarray antenna; Figure 5 This is a schematic diagram of the T / R component. Figure 6 This is a schematic diagram of the drive component. Figure 7 This is a block diagram illustrating the working principle of an active subarray.

[0017] Reference numerals: M1, Active subarray frame; M2, Antenna element; M3, Energy storage capacitor board; M4, RF power divider network control board; M5, Current-carrying power supply board; M6, Multifunctional integrated network board; M7, Multifunctional integrated network board cover; M8, T / R assembly; M9, Drive assembly; M10, Retained high-power power supply contact finger connector; M11, Line end guide pin; M12, Line end mounting hole; M13, Subarray end guide pin; M14, Subarray end mounting hole; M15, Water connector; M16, Left RF main port connector; M17, Right RF main port connector; M18, Low-frequency control connector; M19, RF calibration connector; M20, KK1 connector; M21, KK2 connector. Detailed Implementation

[0018] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0019] Example: Figures 1 to 3 As shown, this application proposes an ultra-wideband, high-power, highly integrated blade-type active subarray, including an active subarray frame M1. The active subarray frame M1 is made of aluminum alloy, which has the characteristics of low density and high specific strength, and is the key to achieving the overall lightweight design of the subarray. The active subarray frame M1 is provided with internal reinforcing ribs, including D1, D2, D3, D4, D5, D6, D7, D8, D9, D10, D11, D12, D13, D14, D15, D16, D17, D18, and D19. 9. D20, D21, D22, D23, D24, D25, D26, D27, D28, and D29 are the main load-bearing structures of the frame, ensuring its stability under mechanical vibration and impact. The active subarray frame M1 has cover plates on both sides, and the areas below the cover plates are D30 and D31. Both D30 and D31 adopt a hollow design. This hollow design effectively reduces redundant materials while ensuring the structural support strength and the impact strength of the coolant channel, which is an important measure to achieve the goal of lightweighting.

[0020] Furthermore, the active subarray frame M1 integrates cooling channels and is equipped with water connectors M15. The cooling channels are located in the filling area D32 and adopt an S-bend layout. The S-bend layout can increase the contact area and heat exchange time between the coolant and the high heat density area, thereby significantly improving heat dissipation efficiency and meeting the heat dissipation requirements of high-power devices for long-term operation. At the same time, this compact flow channel design also helps to reduce the overall weight.

[0021] like Figures 1 to 4As shown in this embodiment, the active subarray frame M1 is provided with wire end guide pins M11, wire end mounting holes M12, subarray end guide pins M13, and subarray end mounting holes M14 for quick installation. These guiding and positioning structures together constitute the core of the two-level blind-plug interface inside and outside the subarray, which greatly simplifies the installation process. The connection between the antenna array and the active subarray frame M1, as well as between the entire subarray and the radar array, can be completed quickly without the need for precision alignment tools, which significantly improves the maintainability and deployment efficiency of the system.

[0022] like Figures 1 to 4 and Figure 7 As shown, this embodiment also includes at least one antenna array. The antenna array is fixed to one side of the active subarray frame M1 by a first blind insertion structure consisting of a wire end guide pin M11 and a wire end mounting hole M12. The antenna array includes multiple Vivaldi-type antenna elements M2. This antenna type has ultra-wideband characteristics and perfectly matches the operating frequency band requirements of 7-13GHz. The antenna element M2 integrates a calibration network. This integrated design brings the calibration function forward to the radiation source, which can monitor and calibrate the amplitude and phase consistency of each channel in real time and accurately. It is the basis for ensuring the high performance and beam quality of the radar system.

[0023] The calibration network integrated inside the antenna element M2 adopts a coupling method and performs 50-ohm load matching. The coupling method can extract the forward signal for calibration non-invasively, while the 50-ohm matching ensures signal integrity during the calibration process and minimizes the impact on the main radiation performance.

[0024] It is worth noting that the antenna array is composed of four standardized antenna sub-unit panels. The four antenna sub-units include a single real unit V1, a single real unit V2, a single virtual unit V1, and a single virtual unit V2. The standardized panel format greatly improves the design and manufacturing flexibility of the antenna array. It can meet the different array layout requirements by combining a limited number of units, effectively reducing the high mold opening costs and processing cycles caused by multi-variety customization.

[0025] The active subarray frame M1 forms a second blind-plug structure through the subarray end guide pin M13 and the second subarray end mounting hole M14. The active subarray frame M1 is plugged into the overall array frame through the second blind-plug structure. This allows a single subarray to be used as an independent field-replaceable unit. In case of failure, the entire board can be quickly replaced, which greatly improves the battlefield maintainability and operational efficiency of the radar system.

[0026] like Figure 1 , Figure 5 , Figure 6As shown, this embodiment also includes multiple T / R components M8 installed on both sides of the antenna array in a double-sided interlocking mirror layout, and at least one drive component M9 installed on the back of the active subarray frame M1. Both the T / R components M8 and the drive component M9 adopt a brick-type design and integrate floating coaxial connectors. The double-sided interlocking mirror layout makes full use of three-dimensional space and achieves extremely high channel integration density, while ensuring the consistency of the spacing of all antenna elements in the horizontal and vertical directions. This is crucial for maintaining beam performance with low sidelobes and high pointing accuracy. The brick-type modular design facilitates standardized production and testing.

[0027] Furthermore, the floating coaxial connectors of the T / R component M8 and the drive component M9 enable pluggable RF connections with the corresponding interfaces on the multi-functional integrated network board M6. The floating connector structure allows for a certain installation tolerance in the vertical direction, which not only solves the space compression problem under extremely small unit spacing, but also enables non-destructive and rapid plugging and unplugging between active components and the network board. This is a core technical means to achieve the goal of high maintainability.

[0028] like Figure 1 As shown, this embodiment also includes a multifunctional integrated network board M6 nested and fixed within the active subarray frame M1 and located below the T / R component M8 and the drive component M9. This nested installation method greatly improves the space utilization within the subarray. At the same time, the network board itself also serves as internal filling and support, helping to enhance the overall structural rigidity. The multifunctional integrated network board M6 integrates the energy storage capacitor board M3, the RF power divider network control board M4, and the current-carrying power supply board M5 into one unit through a hot-melt pressing process. This innovative process breaks down the originally high-difficulty and high-cost hybrid board that required integrated manufacturing into three sub-boards with clear functions and relatively simple manufacturing for secondary integration. This significantly reduces the processing difficulty of complex PCBs, shortens the production cycle, improves the yield rate, and significantly reduces the mold opening cost of the substrate. A multifunctional integrated network board cover M7 is provided above the T / R component M8. The multifunctional integrated network board cover M7 mainly serves as protection and shielding, and the cavity treatment on it effectively prevents the risk of short circuits at the internal solder joints.

[0029] Among them, the hot melt pressing process uses a customized mold to fill the space between the energy storage capacitor board M3, the radio frequency power divider network control board M4 and the current-carrying power board M5 with high-temperature hot melt adhesive strips. After heating and pressing, the boards are integrated into one piece. This process ensures the mechanical strength and long-term reliability of the connection between the three sub-boards. At the same time, the metallized through-holes enable precise electrical interconnection between the layers, ensuring the integrity of power, radio frequency and control signal transmission.

[0030] like Figure 1 , Figure 2 and Figure 7As shown, this embodiment also includes external ports integrated on the side of the active subarray frame M1. The external ports include a left RF main port connector M16, a right RF main port connector M17, a low-frequency control connector M18, an RF calibration connector M19, and a cut-off high-power power supply contact connector M10. This centralized and standardized arrangement of various interfaces on the side allows all connections between the subarray and the system, such as RF, control, power, and calibration, to be completed quickly and easily in one go, further enhancing the modularity and maintainability of the system. The multi-functional integrated network board M6 connects to external signals through KK1 connector M20 and KK2 connector M21, realizing reliable interconnection between the internal network of the subarray and the system backplane.

[0031] Furthermore, the energy storage capacitor board M3 is electrically connected to the intercepted high-power power supply contact connector M10 and the current-carrying power supply board M5, providing instantaneous energy buffer for high-power transmission pulses, effectively suppressing voltage drop, and ensuring the power supply stability and efficiency of the T / R components during pulse operation. The current-carrying power supply board M5 distributes power to the T / R components M8 and the drive components M9. The layered wiring design can carry currents up to tens of amperes, and ensures consistent performance of each channel through uniform distribution. The RF power divider network control board M4 is used for RF signal distribution and control signal transmission. It adopts a high-low frequency mixed voltage design, and simultaneously completes the power division / synthesis of RF signals and the reliable transmission of low-frequency signals such as wave control commands and temperature monitoring within a limited space. It is the central hub for realizing the high-density integration of subarray comprehensive functions.

[0032] Working principle: In the transmitting state, the external radio frequency signal enters the radio frequency power divider network control board M4 in the multi-functional integrated network board M6 through the left radio frequency main port connector M16 and the right radio frequency main port connector M17. After being divided into multiple paths, it is transmitted to each drive component M9 and T / R component M8 through floating coaxial connectors for amplification. Finally, the double-sided plug-in T / R component M8 excites the Vivaldi antenna unit M2 to radiate electromagnetic waves outward. In the receiving state, the echo signal received by the antenna unit M2 is amplified with low noise by the T / R component M8, and then synthesized by the multi-functional integrated network board M6 before being output from the radio frequency main port. Throughout the process, the calibration network integrated within the antenna unit M2 extracts the forward signal through coupling and uses it for system calibration via the RF calibration connector M19 to ensure channel consistency. Beam control commands are sent through the low-frequency control connector M18 and distributed to each T / R component M8 and drive component M9 via the RF power divider network control board M4 to achieve beam scanning. The intercepted high-power power supply contact connector M10 connects to an external power supply, which is buffered by the energy storage capacitor board M3 and then supplies power to each component via the current-carrying power supply board M5. At the same time, coolant flows into the S-curve cooling water channel integrated within the active subarray frame M1 through the water connector M15 to efficiently dissipate heat from the high-heat-density T / R component M8 area. Through the two-stage blind mating structure of the line end guide pin M11 and line end mounting hole M12 and the subarray end guide pin M13 and subarray end mounting hole M14, rapid installation and connection of the antenna array to the subarray and the subarray to the system array surface are achieved.

[0033] The above specific embodiments are merely several optional embodiments of the present invention. Based on the technical solutions of the present invention and the relevant teachings of the above embodiments, those skilled in the art can make various alternative improvements and combinations to the above specific embodiments.

Claims

1. A blade-type active subarray with ultra-wideband, high power, and high integration, characterized in that: include: An active subarray frame (M1) is provided, which integrates cooling water channels and is equipped with a water connector (M15). The active subarray frame (M1) is provided with a wire end guide pin (M11), a wire end mounting hole (M12), a subarray end guide pin (M13), and a subarray end mounting hole (M14) for quick installation. At least one antenna array, the antenna array being fixed to one side of the active subarray frame (M1) via a first blind-plug structure consisting of a wire-end guide pin (M11) and a wire-end mounting hole (M12), the antenna array comprising a plurality of Vivaldi-type antenna elements (M2), the antenna elements (M2) having an integrated calibration network inside; Multiple T / R components (M8) are installed on both sides of the antenna array in a double-sided interlocking mirror layout, and at least one drive component (M9) is installed on the back of the active subarray frame (M1). Both the T / R components (M8) and the drive component (M9) adopt a brick-type design and integrate floating coaxial connectors. A multifunctional integrated network board (M6) is nested and fixed within the active subarray frame (M1) and located below the T / R component (M8) and the drive component (M9). The multifunctional integrated network board (M6) integrates the energy storage capacitor board (M3), the radio frequency power divider network control board (M4), and the current-carrying power supply board (M5) into one unit through a hot melt pressing process. A multifunctional integrated network board cover plate (M7) is provided on the top of the T / R component (M8). The external ports integrated on the side of the active subarray frame (M1) include a left RF main port connector (M16), a right RF main port connector (M17), a low-frequency control connector (M18), an RF calibration connector (M19), and a cut-off high-power power contact connector (M10). The multi-functional integrated network board (M6) is connected to external signals through KK1 connector (M20) and KK2 connector (M21).

2. The ultra-wideband, high-power, highly integrated blade-type active subarray according to claim 1, characterized in that, The active subarray frame (M1) forms a second blind-plug structure through the subarray end guide pin (M13) and the second subarray end mounting hole (M14). The active subarray frame (M1) is plugged into the overall array frame through the second blind-plug structure.

3. The ultra-wideband, high-power, highly integrated blade-type active subarray according to claim 2, characterized in that, The floating coaxial connectors of the T / R component (M8) and the drive component (M9) enable pluggable radio frequency connections to the corresponding interfaces on the multi-functional integrated network board (M6).

4. The ultra-wideband, high-power, highly integrated blade-type active subarray according to claim 3, characterized in that, The energy storage capacitor board (M3) is electrically connected to the intercepted high-power power supply contact finger connector (M10) and the current-carrying power supply board (M5). The current-carrying power supply board (M5) distributes power to the T / R component (M8) and the drive component (M9). The radio frequency power divider network control board (M4) is used for radio frequency signal distribution and control signal transmission.

5. The ultra-wideband, high-power, highly integrated blade-type active subarray according to claim 4, characterized in that, The active subarray frame (M1) is made of aluminum alloy. The active subarray frame (M1) has internal reinforcing ribs. The active subarray frame (M1) has cover plates on both sides. The area below the cover plates on both sides has a hollow design. The active subarray frame (M1) integrates cooling water channels and has water connectors (M15). The cooling water channels adopt an S-curve layout.

6. The ultra-wideband, high-power, highly integrated blade-type active subarray according to claim 5, characterized in that, The calibration network integrated within the antenna element (M2) is coupled and has undergone 50-ohm load matching.

7. The ultra-wideband, high-power, highly integrated blade-type active subarray according to claim 6, characterized in that, The antenna array is composed of four standardized antenna sub-unit panels, which include a single real unit V1, a single real unit V2, a single virtual unit V1, and a single virtual unit V2.

8. The ultra-wideband, high-power, highly integrated blade-type active subarray according to claim 7, characterized in that, The hot melt pressing process uses a customized mold to fill high-temperature hot melt adhesive strips between the energy storage capacitor board (M3), the radio frequency power divider network control board (M4), and the current-carrying power board (M5), and then heats and pressurizes them to form an integrated shape.

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