Traveling wave tube input end cap assembly welding tip shoe assembly centering device and method of assembly

Abstract

The disclosure provides a traveling wave tube input end cover assembly welding electrode shoe assembly centering device and an assembly method thereof, and relates to the technical field of electric vacuum devices and assembly thereof. The assembly centering device comprises a base, a centering base nested in a lower groove of the base, an end cover assembly nested in a groove of the centering base, a centering transition block nested in an upper groove of the base, and a guide pressing block with a lowermost cylindrical structure penetrating a center hole of the centering transition block and pressing on the end cover assembly, and the center hole of the guide pressing block is sleeved on the outer periphery of a core rod of the end cover assembly. The components of the assembly centering device support each other and tightly fit, so that the parallelism and concentricity of the welded traveling wave tube input end cover assembly can meet the precision requirements.

Description

Technical Field

[0001] This disclosure relates to the field of electronic vacuum devices and their assembly technology, and in particular to a device and method for assembling and aligning welding pole shoes for a traveling wave tube input end cap assembly. Background Technology

[0002] In the development of high-frequency space traveling wave tubes (TWTs), the electron beam throughput must reach over 99% to ensure sufficient energy exchange between the electron beam and the high-frequency field. This places higher demands on the concentricity of the electron beam channel. As a key component connecting the electron gun and high-frequency field in the TWT, the concentricity and parallelism of the end cap assembly directly affect the concentricity of the electron beam channel. During actual assembly, the concentricity of the electron beam channel must not exceed Φ (diameter) by more than 0.03 mm. If the concentricity of the end cap assembly varies by 0.01 mm to 0.02 mm, or the parallelism exceeds 0.025 mm, the electron beam will hit the helix, affecting the TWT throughput and even its reliability. Therefore, improving the concentricity, parallelism, and assembly welding precision of the end cap assembly becomes a critical issue for the reliability of high-frequency, high-power space TWTs.

[0003] Unlike ordinary centering assembly, the centering of end cap assemblies has its own characteristics, which brings the following challenges to the design of high-precision centering assembly molds:

[0004] 1. For vacuum electronic devices, any contact with oil, dust, organic matter, etc. will cause serious contamination of the critical components in the device, resulting in a significant drop in vacuum level during operation, affecting the performance of the entire tube product, and even causing the entire tube product to be scrapped.

[0005] 2. The end cap assembly undergoes a high-temperature welding process. The centering and assembly of the end cap assembly is completed by furnace brazing. Under normal temperature conditions, the centering and assembly accuracy of the assembly is high. However, under high-temperature welding conditions, factors such as furnace temperature, uneven solder fusion, mold material, placement position, mold and assembly volume, and temperature measurement system can affect the concentricity and parallelism of the assembly after centering and welding in a normal temperature environment.

[0006] The existing welding method for end cap assemblies involves placing a small gravity block on the assembled end cap assembly. This small gravity block has no centering function and cannot guarantee the parallelism of the assembly after welding. It only serves to compress and prevent the ring-shaped solder from bouncing up. Moreover, during transportation, the small gravity block is prone to tilting or falling because it lacks support and restraint. Summary of the Invention

[0007] To address the aforementioned technical problems, this disclosure provides a device and method for assembling and aligning the welding pole shoes of a traveling wave tube input end cap assembly, which at least partially solves the above technical problems.

[0008] This disclosure provides a centering device for assembling welding pole shoes for a traveling wave tube input end cap assembly, comprising: a base, a centering base, a centering transition block, a guide block, and an end cap assembly. The base is formed by stacking two hollow annular structures, each with a first annular groove on its inner edge. The two first annular grooves are interconnected. The centering base is nested within the first annular groove of the lower hollow annular structure, and the centering transition block is nested within the first annular groove of the upper hollow annular structure. The end cap assembly includes a core rod and a vertically disposed element at the bottom of the core rod. The disc-shaped end cap has a second annular groove on the upper surface of the centering base, and the disc-shaped end cap is nested in the second annular groove; the centering transition block has a first circular through hole on its upper surface; the guide pressure block is a stepped columnar structure along the vertical direction, and a second circular through hole is opened in the center of the stepped columnar structure; the outer wall of the lowest columnar structure of the stepped columnar structure passes through the first circular through hole and extends into the first annular groove of the upper hollow annular structure; the second circular through hole is fitted around the outer periphery of the core rod; the outer periphery of the core rod is nested with an pole shoe, and the upper surface of the pole shoe is in contact with the lower surface of the lowest columnar structure.

[0009] According to an embodiment of this disclosure, a hollow structure is provided on the sidewall between the upper and lower hollow annular structures.

[0010] According to embodiments of this disclosure, the base, centering base, centering transition block, guide pressure block, and end cap assembly are all symmetrically arranged along the central axis of the core rod.

[0011] According to an embodiment of this disclosure, a third annular groove is formed on the lower surface of the intermediate transition block, which is recessed upwards; the lower surface of the lowest columnar structure of the stepped columnar structure is lower than the bottom surface of the third annular groove.

[0012] According to an embodiment of this disclosure, the upper surface of the centering base is lower than the upper surface of the disc-shaped end cap; a third circular through hole is provided in the center of the centering base, and a fourth annular groove is provided on the lower surface of the disc-shaped end cap, which is recessed upwards. The fourth annular groove and the third circular through hole are interconnected and are symmetrically arranged about the central axis of the core rod.

[0013] This disclosure also provides an assembly method for a centering device for welding electrode shoes of a traveling wave tube input end cap assembly, comprising: providing a base, a centering base, a centering transition block, a guide block, and an end cap assembly; assembling the centering base into a first annular groove in the lower hollow annular structure of the base, such that the assembly accuracy between the centering base and the base meets a first predetermined accuracy requirement; assembling the disc-shaped end cap of the end cap assembly into a second annular groove on the upper surface of the centering base, such that the assembly accuracy between the end cap assembly and the centering base meets a second predetermined accuracy requirement; and assembling the centering transition block onto the base. The upper hollow annular structure of the base is placed in the first annular groove, so that the assembly accuracy of the centering transition block and the base meets the third predetermined accuracy requirement; the outer wall of the lowest columnar structure of the guide block is passed through the first circular through hole on the upper surface of the centering transition block and assembled into the first annular groove of the upper hollow annular structure of the base, so that the second circular through hole of the guide block is sleeved on the outer periphery of the core rod in the end cap assembly, and the assembly accuracy of the guide block with the centering transition block and the end cap assembly respectively meets the fourth predetermined accuracy requirement, thus obtaining the assembled traveling wave tube input end cap assembly welding pole shoe assembly centering device.

[0014] According to embodiments of this disclosure, the first predetermined accuracy requirement includes: the concentricity between the centering base and the base does not exceed Φ0.015mm, the difference between the diameter of the centering base and the diameter of the first annular groove of the lower hollow annular structure does not exceed 0.015mm, and the flatness of the upper surface of the assembled device does not exceed 0.01mm; the second predetermined accuracy requirement includes: the concentricity between the end cap assembly and the centering base does not exceed Φ0.015mm, the difference between the diameter of the disc-shaped end cap and the diameter of the second annular groove does not exceed 0.01mm, and the flatness of the upper surface of the assembled device does not exceed 0.01mm; the third predetermined accuracy requirement includes: the concentricity between the centering transition block and the centering base does not exceed Φ0.015mm, the difference between the diameter of the disc-shaped end cap and the diameter of the second annular groove does not exceed 0.01mm, and the flatness of the upper surface of the assembled device does not exceed 0.01mm; The concentricity of the base shall not exceed Φ0.015mm, the difference between the diameter of the centering transition block and the diameter of the first annular groove of the upper hollow annular structure shall not exceed 0.015mm, and the flatness of the upper surface of the assembled device shall not exceed 0.01mm; the fourth predetermined accuracy requirements include: the concentricity of the guide block with the centering transition block and the end cap assembly shall not exceed Φ0.015mm, the difference between the diameter of the lowest columnar structure of the guide block and the diameter of the first circular through hole shall not exceed 0.01mm, the difference between the diameter of the second circular through hole and the diameter of the core rod shall not exceed 0.01mm, and the flatness of the upper surface of the assembled device shall not exceed 0.01mm.

[0015] According to embodiments of this disclosure, the base, centering base, and centering transition block are made of constant expansion ceramic seal alloy; the guide pressure block is made of stainless steel, and the surface of the stainless steel has a ferric oxide film layer formed by black oxidation treatment; the surface roughness Ra (Roughness Average, profile arithmetic mean deviation) of the base, centering base, centering transition block, and guide pressure block does not exceed 1.6 μm.

[0016] According to embodiments of this disclosure, the assembly method further includes: using a height measuring instrument and / or an optical measuring instrument to determine whether the assembly accuracy of each assembly component meets the corresponding predetermined accuracy requirements.

[0017] According to embodiments of this disclosure, the assembly method further includes: placing the assembled traveling wave tube input end cap assembly welding electrode shoe assembly alignment device in a hydrogen furnace for welding.

[0018] Compared with the prior art, the welding pole shoe assembly and alignment device and assembly method for the traveling wave tube input end cap assembly provided in this disclosure have at least the following advantages:

[0019] (1) The assembly alignment device disclosed herein has a base that provides support for the entire structure, ensuring the stability of transport, and also works with the alignment base and alignment transition block to ensure the concentricity and parallelism of the assembly alignment device. The alignment base provides support and fit for the end cap assembly. The alignment transition block works with the guide pressure block to ensure the concentricity of the guide pressure block. The guide pressure block provides clamping and fit for the end cap assembly. The entire assembly alignment device can ensure the concentricity and parallelism of the end cap assembly alignment, resulting in good concentricity, good consistency, and small dispersion of the electron beam channel emitted by the electron gun after assembly and welding.

[0020] (2) The assembly and alignment device disclosed herein has a simple structure and is easy to manufacture. The corresponding assembly method is clear, simple and reliable, which is conducive to its widespread application. Attached Figure Description

[0021] The above and other objects, features and advantages of this disclosure will become clearer from the following description of embodiments with reference to the accompanying drawings, in which:

[0022] Figure 1 A perspective view of a traveling wave tube input end cap assembly welding pole shoe assembly centering device according to an embodiment of the present disclosure is shown schematically.

[0023] Figure 2 A schematic cross-sectional view of a welding pole shoe assembly centering device for a traveling wave tube input end cap assembly according to an embodiment of the present disclosure is shown.

[0024] Figure 3 A perspective view of a base according to an embodiment of the present disclosure is shown schematically;

[0025] Figure 4 A cross-sectional view of a base according to an embodiment of the present disclosure is shown schematically;

[0026] Figure 5 A perspective view of the centering base according to an embodiment of the present disclosure is shown schematically;

[0027] Figure 6A schematic cross-sectional view of the centering base according to an embodiment of the present disclosure is shown;

[0028] Figure 7 A perspective view of an end cap assembly according to an embodiment of the present disclosure is shown schematically;

[0029] Figure 8 A cross-sectional view of an end cap assembly according to an embodiment of the present disclosure is shown schematically;

[0030] Figure 9 A perspective view of a centering transition block according to an embodiment of the present disclosure is shown schematically;

[0031] Figure 10 A cross-sectional view of a centering transition block according to an embodiment of the present disclosure is shown schematically;

[0032] Figure 11 A perspective view of a guide block according to an embodiment of the present disclosure is shown schematically;

[0033] Figure 12 A schematic cross-sectional view of a guide block according to an embodiment of the present disclosure is shown;

[0034] Figure 13 The flowchart illustrates an assembly method of a traveling wave tube input end cap assembly welding pole shoe assembly centering device according to an embodiment of the present disclosure.

[0035] [Explanation of Labels in the Attached Image]

[0036] 1-Base; 11-First annular groove;

[0037] 2- Centering base; 21- Second annular groove;

[0038] 3-Centering transition block; 31-First circular through hole;

[0039] 4-Guide block; 41-Second circular through hole;

[0040] 5-End cap assembly; 51-Core rod; 52-Disc end cap; 53-Pole shoe. Detailed Implementation

[0041] To make the objectives, technical solutions, and advantages of this disclosure clearer, the following detailed description is provided in conjunction with specific embodiments and the accompanying drawings.

[0042] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit this disclosure. The terms “comprising,” “including,” etc., as used herein indicate the presence of the stated features, steps, operations, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, or components.

[0043] All terms used herein, including technical and scientific terms, have the meanings commonly understood by those skilled in the art, unless otherwise defined. It should be noted that the terms used herein are to be interpreted in a manner consistent with the context of this specification, and not in an idealized or overly rigid way.

[0044] When using expressions such as "at least one of A, B, and C", they should generally be interpreted in accordance with the meaning commonly understood by those skilled in the art. For example, "a system having at least one of A, B, and C" should include, but is not limited to, a system having A alone, having B alone, having C alone, having A and B, having A and C, having B and C, and / or having A, B, and C.

[0045] It should also be noted that the directional terms mentioned in the embodiments, such as "up," "down," "front," "back," "left," and "right," are only for reference to the directions in the accompanying drawings and are not intended to limit the scope of protection of this disclosure. Throughout the drawings, the same elements are represented by the same or similar reference numerals. Conventional structures or constructions will be omitted where they may cause confusion in understanding this disclosure.

[0046] In the development of high-frequency space traveling wave tubes (TWTs), the electron beam throughput must reach over 99% to ensure sufficient energy exchange between the electron beam and the high-frequency field. This places higher demands on the concentricity of the electron beam channel. As a key component connecting the electron gun and high-frequency field in the TWT, the concentricity and parallelism of the end cap assembly directly affect the concentricity of the electron beam channel. Therefore, this disclosure provides a device and method for assembling and aligning the welding electrode shoes of the TWT input end cap assembly, which can effectively ensure the concentricity and parallelism of the welded end cap assembly. Specific embodiments are described below.

[0047] Figure 1 A perspective view of a traveling wave tube input end cap assembly welding pole shoe assembly alignment device according to an embodiment of the present disclosure is shown schematically. Figure 2 A schematic cross-sectional view of a traveling wave tube input end cap assembly welding pole shoe assembly centering device according to an embodiment of the present disclosure is shown.

[0048] like Figure 1 and Figure 2 As shown, embodiments of this disclosure provide a traveling wave tube input end cap assembly welding pole shoe assembly centering device (hereinafter referred to as "assembly centering device"), including a base 1, a centering base 2, a centering transition block 3, a guide pressure block 4, and an end cap assembly 5.

[0049] The base 1 is composed of two hollow annular structures stacked together. The inner edge of each of the two hollow annular structures is provided with a first annular groove 11. The two first annular grooves 11 are connected to each other. The centering base 2 is nested in the first annular groove 11 of the lower hollow annular structure, and the centering transition block 3 is nested in the first annular groove 11 of the upper hollow annular structure.

[0050] The end cap assembly 5 includes a core rod 51 and a disc-shaped end cap 52 vertically disposed at the bottom of the core rod 51. A second annular groove 21 is provided on the upper surface of the centering base 2, and the disc-shaped end cap 52 is nested in the second annular groove 21.

[0051] The upper surface of the centering transition block 3 is provided with a first circular through hole 31. The guide pressure block 4 is a stepped columnar structure along the vertical direction. The center of the stepped columnar structure is provided with a second circular through hole 41. The outer wall of the lowest columnar structure of the stepped columnar structure passes through the first circular through hole 31 and extends into the first annular groove 11 of the upper hollow annular structure. The second circular through hole 41 is sleeved on the outer periphery of the core rod 51.

[0052] The core rod 51 is nested with a pole shoe 53, and the upper surface of the pole shoe 53 is in contact with the lower surface of the bottom columnar structure.

[0053] The following detailed description of each component in the assembly alignment device is provided in conjunction with the accompanying drawings.

[0054] Figure 3 A perspective view of a base according to an embodiment of the present disclosure is shown schematically. Figure 4 A cross-sectional view of a base according to an embodiment of the present disclosure is shown schematically.

[0055] like Figure 3 and Figure 4 As shown, the base 1 has two hollow annular structures, namely an upper hollow annular structure and a lower hollow annular structure, and each of these two hollow annular structures has a first annular groove 11 on its inner edge. The first annular groove 11 of the lower hollow annular structure includes a support surface A4 at the bottom and a mating surface A2 on the side wall. The first annular groove 11 of the upper hollow annular structure includes a support surface A3 at the bottom and a mating surface A1 on the side wall. In addition, the base 1 also has a bottom hole A5, which helps ensure the flatness of the bottom surface of the base 1 and, in conjunction with the center hole of other components in the assembly centering device, ensures the flow of gas during welding.

[0056] Figure 5 A perspective view of a centering base according to an embodiment of the present disclosure is shown schematically. Figure 6 A cross-sectional view of the centering base according to an embodiment of the present disclosure is shown schematically.

[0057] like Figure 5 and Figure 6 As shown, the centering base 2 includes a support surface B4 at the bottom and a mating surface B1 on the side wall. A second annular groove 21 is formed on the upper surface of the centering base, which includes a support surface B3 at the bottom and a mating surface B2 on the side wall.

[0058] like Figures 1-6 As shown, the centering base 2 is nested within the first annular groove 11 of the lower hollow annular structure of the base 1. Support surface B4 contacts support surface A4. The base 1 provides support for the centering base 2, ensuring its stability, and the flatness of the base 1 ensures the flatness of the centering base 2. Simultaneously, mating surface B1 mates with mating surface A2, ensuring the concentricity of the base 1 and the centering base 2.

[0059] Figure 7 A perspective view of an end cap assembly according to an embodiment of the present disclosure is shown schematically. Figure 8 A cross-sectional view of an end cap assembly according to an embodiment of the present disclosure is shown schematically.

[0060] like Figure 7 and Figure 8 As shown, the end cap assembly 5 includes a core rod 51, a disc-shaped end cap 52 vertically disposed at the bottom of the core rod, and an pole shoe 53 nested around the outer periphery of the core rod 51. The core rod 51 includes a mating surface E2 located on its sidewall. The disc-shaped end cap 52 includes a support surface E3 located at its bottom and a mating surface E1 located on its sidewall. The upper surface of the pole shoe 53 is a support surface E4, and an annular step E5 is provided at its center. The annular step E5 is nested around the outer periphery of the core rod 51.

[0061] like Figure 1 , Figure 2 and Figures 5-8 As shown, the disc-shaped end cap 52 is nested within the second annular groove 21 on the upper surface of the centering base 2. Support surface E3 contacts support surface B3, and the centering base 2 provides support for the end cap assembly 5, ensuring its stability. The flatness of the centering base 2 ensures the flatness of the end cap assembly 5. Simultaneously, mating surface E1 mates with mating surface B2, ensuring the concentricity of the end cap assembly 5 and the centering base 2.

[0062] Figure 9 A perspective view of a centering transition block according to an embodiment of the present disclosure is shown schematically. Figure 10 A cross-sectional view of a centering transition block according to an embodiment of the present disclosure is shown schematically.

[0063] like Figure 9 and Figure 10As shown, the centering transition block 3 includes a support surface C3 at the bottom and a mating surface C1 on the side wall. A first circular through hole 31 is formed at the center of the upper surface of the centering transition block 3, and the first circular through hole 31 includes a mating surface C2 on the side wall. In addition, the centering transition block 3 has open sides as operating and adjustment openings for easy observation, gripping, operation and adjustment.

[0064] like Figures 1-4 , Figure 9 and Figure 10 As shown, the centering transition block 3 is nested within the first annular groove 11 of the upper hollow annular structure of the base 1. Support surface C3 contacts support surface A3, and the base 1 provides support for the centering transition block 3, ensuring its stability. The flatness of the base 1 ensures the flatness of the centering transition block 3. Simultaneously, mating surface C1 mates with mating surface A1, ensuring the concentricity of the base 1 and the centering transition block 3.

[0065] Figure 11 A perspective view of a guide block according to an embodiment of the present disclosure is shown schematically. Figure 12 A schematic cross-sectional view of a guide block according to an embodiment of the present disclosure is shown.

[0066] like Figure 11 and Figure 12 As shown, the guide block 4 is a stepped cylindrical structure along the vertical direction, with a second circular through hole 41 in the center. The guide block 4 includes a support surface D3 at the bottom, and a bottom hole D4 is opened at the center of the bottom. The outer wall of the lowest cylindrical structure of the guide block 4 is a mating surface D1. The side wall of the second circular through hole 41 is a mating surface D2.

[0067] like Figures 1-4 and Figures 7-12 As shown, the lowest cylindrical structure of the guide block 4 extends through the first circular through-hole 31 of the centering transition block 3 into the first annular groove 11 of the upper hollow annular structure of the base 1. The second circular through-hole 41 at the center of the guide block 4 is fitted around the outer periphery of the core rod 51 of the end cap assembly 5. The support surface D3 contacts the support surface E4, and the guide block 4 presses the end cap assembly 5 tightly to prevent the annular solder used for welding in the end cap assembly 5 from bouncing up and causing welding failure. The mating surface D1 mates with the mating surface C2, and the centering transition block 3 provides support and limits for the guide block 4, preventing the guide block 4 from tilting or falling during transportation, while ensuring the concentricity of the centering transition block 3 and the guide block 4. The mating surface D2 mates with the mating surface E2, and the guide block 4 further ensures the concentricity of the end cap assembly 5 assembly. In addition, the annular step E5 at the center of the upper surface of the pole shoe 53 is located in the bottom hole D4 of the guide block 4. The function of the bottom hole D4 is to avoid the overflow of solder during the welding process and prevent the solder from welding the guide block 4 and the end cap assembly 5 together.

[0068] Optionally, such as Figure 1 , Figure 2 , Figure 11 and Figure 12 As shown, the height of the guide block 4 can also vary according to the size of the end cap assembly 5. Guide blocks 4 of different heights have different weights and different expansion rates at high temperatures. If the guide block 4 is too light, it cannot effectively prevent the annular solder ring from bouncing up. The elasticity of the solder ring will push the guide block 4 up, and it will not be able to fall down in time at high temperatures, causing the solder to spread everywhere, resulting in insufficient weld filling and welding failure. If the guide block 4 is too heavy, it will cause uneven heating of the assembly alignment device, uneven melting of the solder and uneven thermal expansion of the components, affecting the welding and alignment results.

[0069] According to embodiments of this disclosure, a centering device for assembling the electrode shoe of a traveling wave tube input end cap assembly, comprising a base 1, a centering base 2, a centering transition block 3, a guide pressure block 4, and an end cap assembly 5, is provided. The components are assembled through nesting, with corresponding support surfaces supporting each other and corresponding mating surfaces mating with each other, ensuring the fixation of the relative positions of each component and the stability of the assembly centering device. The base 1 provides support for the entire structure, ensuring stability during transport, and also works with the centering base 2 and the centering transition block 3 to ensure the concentricity and parallelism of the assembly centering device. The centering base 2 provides support and mating for the end cap assembly 5. The centering transition block 3 works with the guide pressure block 4 to ensure the concentricity and stability of the guide pressure block 4. The guide pressure block 4 provides clamping and mating for the end cap assembly 5. This assembly centering device ensures the concentricity and parallelism of the end cap assembly 5, resulting in good concentricity, consistency, and low dispersion of the electron beam channels emitted by the electron gun after assembly and welding.

[0070] In some embodiments, such as Figure 3 As shown, the side wall between the upper and lower hollow annular structures of the base 1 has a hollow structure as an auxiliary opening, which facilitates observation of the assembly from the side and allows for assembly or adjustment operations to ensure accurate assembly and meet requirements.

[0071] In some embodiments, the base 1, centering base 2, centering transition block 3, guide pressure block 4 and end cap assembly 5 are all symmetrically arranged along the central axis of the core rod 51 of the end cap assembly 5, which helps to ensure that the nested parts of each component fit together and better ensures the concentricity of the end cap assembly 5 assembly.

[0072] In some embodiments, such as Figure 2 , Figure 9 and Figure 10 As shown, the lower surface of the centering transition block 3 has an upwardly recessed third annular groove, and the lower surface of the lowest columnar structure of the guide block 4 is lower than the bottom surface of the third annular groove. This structural design facilitates observation from the side to ensure that the guide block 4 and the end cap assembly 5 fit together, thus better guaranteeing the alignment effect.

[0073] In some embodiments, such as Figure 2 and Figures 5-8 As shown, the upper surface of the centering base 2 is lower than the upper surface of the disc-shaped end cap 52, facilitating observation and measurement of the flatness of the disc-shaped end cap 52 from the side. A third circular through-hole (i.e., bottom hole B5) is provided in the center of the centering base 2, which helps ensure the flatness of the bottom surface of the centering base 2. A fourth annular groove is recessed upwards on the lower surface of the disc-shaped end cap 52. This fourth annular groove communicates with the third circular through-hole in the center of the centering base 2, and both are symmetrically arranged about the central axis of the core rod 51. Combined with the central holes of other components in the centering device, this ensures the flow of gas during welding.

[0074] Figure 13 A flowchart illustrating a method for aligning and assembling welding pole shoes for a traveling wave tube input end cap assembly according to an embodiment of the present disclosure is shown.

[0075] like Figure 13 As shown, embodiments of this disclosure also provide an assembly method for a traveling wave tube input end cap assembly welding electrode shoe assembly and alignment device, which can assemble the traveling wave tube input end cap assembly welding electrode shoe assembly and alignment device of any of the above embodiments. The method includes the following steps S1 to S5.

[0076] Step S1, providing base 1, centering base 2, centering transition block 3, guide pressure block 4 and end cap assembly 5.

[0077] Step S2: Assemble the centering base 2 into the first annular groove 11 of the lower hollow annular structure of the base 1, so that the assembly accuracy of the centering base 2 and the base 1 meets the first predetermined accuracy requirement.

[0078] Step S3: Assemble the disc-shaped end cap 52 of the end cap assembly 5 into the second annular groove 21 on the upper surface of the centering base 2, so that the assembly accuracy of the end cap assembly 5 and the centering base 2 meets the second predetermined accuracy requirement.

[0079] Step S4: Assemble the centering transition block 3 into the first annular groove 11 of the upper hollow annular structure of the base 1, so that the assembly accuracy of the centering transition block 3 and the base 1 meets the third predetermined accuracy requirement.

[0080] Step S5: The outer wall of the lowest columnar structure of the guide block 4 is passed through the first circular through hole 31 on the upper surface of the centering transition block 3 and assembled into the first annular groove 11 of the upper hollow annular structure of the base 1, so that the second circular through hole 41 of the guide block 4 is sleeved on the outer periphery of the core rod 51 in the end cap assembly 5, and the assembly accuracy of the guide block 4 with the centering transition block 3 and the end cap assembly 5 respectively meets the fourth predetermined accuracy requirement, thus obtaining the assembled traveling wave tube input end cap assembly welding pole shoe assembly centering device.

[0081] In some embodiments, in step S2 above, the first predetermined accuracy requirement includes: the concentricity of the centering base 2 and the base 1 does not exceed Φ0.015mm, the difference between the diameter of the centering base 2 and the diameter of the first annular groove 11 of the lower hollow annular structure does not exceed 0.015mm, and the flatness of the upper surface of the assembled device does not exceed 0.01mm.

[0082] In step S3 above, the second predetermined accuracy requirements include: the concentricity of the end cap assembly 5 and the centering base 2 does not exceed Φ0.015mm, the difference between the diameter of the disc-shaped end cap 52 and the diameter of the second annular groove 21 does not exceed 0.01mm, and the flatness of the upper surface of the assembled device does not exceed 0.01mm.

[0083] In step S4 above, the third predetermined accuracy requirements include: the concentricity of the centering transition block 3 and the base 1 does not exceed Φ0.015mm, the difference between the diameter of the centering transition block 3 and the diameter of the first annular groove 11 of the upper hollow annular structure does not exceed 0.015mm, and the flatness of the upper surface of the assembled device does not exceed 0.01mm.

[0084] In step S5 above, the fourth predetermined accuracy requirement includes: the concentricity of the guide block 4 with the centering transition block 3 and the end cap assembly 5 shall not exceed Φ0.015mm; the difference between the diameter of the lowest columnar structure of the guide block 4 and the diameter of the first circular through hole 31 shall not exceed 0.01mm; the difference between the diameter of the second circular through hole 41 and the diameter of the core rod 51 shall not exceed 0.01mm; and the flatness of the upper surface of the assembled device shall not exceed 0.01mm.

[0085] The accuracy requirements regarding diameter difference ensure a tight fit and prevent movement of all components during assembly, thus guaranteeing the stability of the assembly alignment device. The concentricity requirements between components ensure the concentricity of all components in the assembly alignment device. The flatness requirements for the upper surface of the device after each assembly step ensure the flatness of the horizontal surface of the assembly alignment device. Ultimately, this ensures that the concentricity and parallelism of the end cap assembly 5 meet the requirements.

[0086] In some embodiments, the base 1, the centering base 2, and the centering transition block 3 are made of a constant expansion ceramic seal alloy. For example, a constant expansion ceramic seal alloy with the grade 4J33 can be selected, whose coefficient of thermal expansion matches that of the end cap assembly 5. This can effectively reduce the displacement stress caused by the inconsistent expansion between the end cap assembly 5 and other parts of the assembly centering device during high-temperature welding, and improve the consistency of cold assembly accuracy and hot welding assembly accuracy.

[0087] The guide block 4 is made of stainless steel with a magnetite film layer formed by black oxidation. Magnesium tetroxide has good non-wetting or weak wettability to most brazing solders (such as silver-based and copper-based solders). The solder will agglomerate into spheres on the film surface due to surface tension, rather than spreading and sticking together. At the same time, the magnetite film layer can maintain its structural integrity during the short-term high-temperature process of brazing, continuously playing a barrier role against the stainless steel substrate and the solder, preventing the solder from undergoing a metallurgical reaction with the stainless steel substrate, thereby preventing the solder from welding the guide block 4 to the end cap assembly 5 together.

[0088] The surface roughness Ra of base 1, centering base 2, centering transition block 3, and guide pressure block 4 shall not exceed 1.6 μm. Since the components in the centering assembly device need to fit and nest tightly, limiting the surface roughness can prevent assembly or disassembly from being impossible due to excessive roughness.

[0089] Optionally, the mating points of the base 1, centering base 2, centering transition block 3, and guide pressure block 4 need to be chamfered to prevent the components from being unable to be assembled or from not fitting tightly, thereby ensuring the realization of the expected assembly effect.

[0090] In some embodiments, during the assembly process, a height gauge is used to measure the flatness of the assembled device, and an optical measuring instrument is used to measure the relative positions and mating relationships between the components. Based on the measurement results, components that do not meet the assembly accuracy requirements are replaced in a timely manner to ensure that the assembly accuracy of each component meets the corresponding predetermined accuracy requirements, thereby guaranteeing the concentricity and parallelism of the end cap assembly 5.

[0091] In some embodiments, the assembled traveling wave tube input end cap assembly welding electrode shoe assembly and alignment device is placed in a hydrogen furnace for welding to obtain the assembled, aligned and welded traveling wave tube input end cap assembly.

[0092] It should also be noted that the details not covered in the method embodiment section are similar to those in the device embodiment section, and will not be repeated here.

[0093] In summary, the embodiments of this disclosure provide a device and method for assembling and aligning the welding pole shoes of a traveling wave tube input end cap assembly. The components of this assembly and alignment device support each other and fit tightly together, ensuring that the parallelism and concentricity of the welded traveling wave tube input end cap assembly meet accuracy requirements. The assembly and alignment device has a simple structure and is easy to manufacture. The corresponding assembly method is clear, simple, and reliable, facilitating its widespread application.

[0094] The embodiments of this disclosure have been described above. However, these embodiments are for illustrative purposes only and are not intended to limit the scope of this disclosure. Although various embodiments have been described above, this does not mean that the measures in the various embodiments cannot be used advantageously in combination. Various substitutions and modifications can be made by those skilled in the art without departing from the scope of this disclosure, and all such substitutions and modifications should fall within the scope of this disclosure.

Claims

1. A device for aligning and assembling welding pole shoes for a traveling wave tube input end cap assembly, characterized in that, include: The components are: base (1), centering base (2), centering transition block (3), guide pressure block (4), and end cap assembly (5), wherein: The base (1) is made of two layers of hollow annular structures stacked together. The inner edges of the upper and lower hollow annular structures are provided with first annular grooves (11). The two first annular grooves (11) are connected to each other. The centering base (2) is nested in the first annular groove (11) of the lower hollow annular structure. The centering transition block (3) is nested in the first annular groove (11) of the upper hollow annular structure. The end cap assembly (5) includes a core rod (51) and a disc-shaped end cap (52) vertically disposed at the bottom of the core rod (51). A second annular groove (21) is provided on the upper surface of the centering base (2), and the disc-shaped end cap (52) is nested in the second annular groove (21). The centering transition block (3) has a first circular through hole (31) on its upper surface. The guide pressure block (4) is a stepped columnar structure in the vertical direction. The center of the stepped columnar structure has a second circular through hole (41). The outer wall of the lowest columnar structure of the stepped columnar structure passes through the first circular through hole (31) and extends into the first annular groove (11) of the upper hollow annular structure. The second circular through hole (41) is sleeved on the outer periphery of the core rod (51). The core rod (51) is nested with a pole shoe (53) on its outer periphery, and the upper surface of the pole shoe (53) is in contact with the lower surface of the lowest columnar structure.

2. The alignment device for welding electrode shoes of the traveling wave tube input end cap assembly according to claim 1, characterized in that, The sidewall between the upper and lower hollow annular structures has a hollow structure.

3. The alignment device for welding electrode shoes of the traveling wave tube input end cap assembly according to claim 1, characterized in that, The base (1), centering base (2), centering transition block (3), guide pressure block (4) and end cap assembly (5) are all symmetrically arranged along the central axis of the core rod (51).

4. The alignment device for welding electrode shoes of the traveling wave tube input end cap assembly according to claim 1 or 3, characterized in that, The lower surface of the centering transition block (3) is provided with an upwardly recessed third annular groove; The lower surface of the lowest columnar structure of the stepped columnar structure is lower than the bottom surface of the third annular groove.

5. The alignment device for welding electrode shoes of the traveling wave tube input end cap assembly according to claim 1 or 3, characterized in that, The upper surface of the centering base (2) is lower than the upper surface of the disc-shaped end cap (52); The center of the centering base (2) has a third circular through hole, and the lower surface of the disc-shaped end cap (52) has a fourth annular groove that is recessed upward. The fourth annular groove and the third circular through hole are interconnected and are symmetrically arranged about the central axis of the core rod (51).

6. An assembly method for a welding pole shoe assembly and alignment device for a traveling wave tube input end cap assembly according to any one of claims 1 to 5, characterized in that, include: Step S1, providing a base (1), a centering base (2), a centering transition block (3), a guide block (4), and an end cap assembly (5); Step S2: The centering base (2) is assembled into the first annular groove (11) of the lower hollow annular structure of the base (1), so that the assembly accuracy of the centering base (2) and the base (1) meets the first predetermined accuracy requirement. Step S3: Assemble the disc-shaped end cap (52) of the end cap assembly (5) into the second annular groove (21) on the upper surface of the centering base (2), so that the assembly accuracy of the end cap assembly (5) and the centering base (2) meets the second predetermined accuracy requirement. Step S4: Assemble the centering transition block (3) into the first annular groove (11) of the upper hollow annular structure of the base (1), so that the assembly accuracy of the centering transition block (3) and the base (1) meets the third predetermined accuracy requirement. Step S5: The outer wall of the lowest columnar structure of the guide block (4) is passed through the first circular through hole (31) on the upper surface of the centering transition block (3) and assembled into the first annular groove (11) of the upper hollow annular structure of the base (1), so that the second circular through hole (41) of the guide block (4) is sleeved on the outer periphery of the core rod (51) in the end cap assembly (5), and the assembly accuracy of the guide block (4) with the centering transition block (3) and the end cap assembly (5) meets the fourth predetermined accuracy requirement, thus obtaining the assembled traveling wave tube input end cap assembly welding pole shoe assembly centering device.

7. The assembly method of the welding pole shoe assembly and alignment device for the traveling wave tube input end cap assembly according to claim 6, characterized in that, The first predetermined accuracy requirement includes: the concentricity of the centering base (2) and the base (1) does not exceed Φ0.015mm, the difference between the diameter of the centering base (2) and the diameter of the first annular groove (11) of the lower hollow annular structure does not exceed 0.015mm, and the flatness of the upper surface of the assembled device does not exceed 0.01mm. The second predetermined accuracy requirement includes: the concentricity of the end cap assembly (5) and the centering base (2) does not exceed Φ0.015mm, the difference between the diameter of the disc-shaped end cap (52) and the diameter of the second annular groove (21) does not exceed 0.01mm, and the flatness of the upper surface of the assembled device does not exceed 0.01mm. The third predetermined accuracy requirement includes: the concentricity of the centering transition block (3) and the base (1) does not exceed Φ0.015mm, the difference between the diameter of the centering transition block (3) and the diameter of the first annular groove (11) of the upper hollow annular structure does not exceed 0.015mm, and the flatness of the upper surface of the assembled device does not exceed 0.01mm. The fourth predetermined accuracy requirement includes: the concentricity of the guide block (4) with the centering transition block (3) and the end cap assembly (5) shall not exceed Φ0.015mm; the difference between the diameter of the lowest columnar structure of the guide block (4) and the diameter of the first circular through hole (31) shall not exceed 0.01mm; the difference between the diameter of the second circular through hole (41) and the diameter of the core rod (51) shall not exceed 0.01mm; and the flatness of the upper surface of the assembled device shall not exceed 0.01mm.

8. The assembly method of the welding pole shoe assembly and alignment device for the traveling wave tube input end cap assembly according to claim 6, characterized in that, The base (1), centering base (2) and centering transition block (3) are made of constant expansion ceramic seal alloy; The guide block (4) is made of stainless steel, and the surface of the stainless steel has a layer of iron oxide film formed by black oxidation treatment. The surface roughness Ra of the base (1), centering base (2), centering transition block (3) and guide pressure block (4) shall not exceed 1.6 μm.

9. The assembly method of the welding pole shoe assembly and alignment device for the traveling wave tube input end cap assembly according to claim 6, characterized in that, The assembly method further includes: Use a height gauge and / or optical measuring instrument to determine whether the assembly accuracy of each assembly component meets the corresponding predetermined accuracy requirements.

10. The assembly method of the welding pole shoe assembly and alignment device for the traveling wave tube input end cap assembly according to claim 6, characterized in that, The assembly method further includes: The assembled traveling wave tube input end cap assembly welding electrode shoe assembly centering device is placed in a hydrogen furnace for welding.

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