Outer conductor welding tool

Abstract

The utility model discloses an outer conductor welding tool which sequentially comprises a positioning tool, a positioning plate, a sliding plate, a clamping structure, a screw, a sliding plate fixing screw and a bottom plate from top to bottom, and different products correspond to different positioning tools. The positioning plate is used for limiting the positions of the welding tool and the sliding plate. A welding product can freely move on the sliding plate through the sliding plate, the positioning tool can be rapidly replaced through the clamping structure, and the screw is used for fixing the positioning tool. According to the sliding plate fixing screws, if the welding product does not need to be moved, the sliding plate is fixed through the sliding plate fixing screws, and the corresponding product is subjected to outer conductor welding through the components. According to the outer conductor welding tool, it is ensured that the welding position is accurate and controllable through a high-precision positioning system, meanwhile, the single-hand tin adding operation design is adopted, a welding area can be stably contacted without manually supporting a cable, and the operation complexity and the safety risk are greatly reduced.

Description

Technical Field

[0001] This utility model belongs to the field of welding fixture design technology, specifically relating to an external conductor welding fixture. Background Technology

[0002] The development of welding fixtures for outer conductors stems from the stringent requirements of modern communication, electronic equipment, and precision instruments for the stability of high-frequency signal transmission. As a crucial component of core parts such as coaxial cables, waveguide devices, and RF connectors, the welding quality of the outer conductor directly impacts signal loss, shielding effectiveness, and product reliability. Traditional welding processes rely heavily on manual operation, resulting in low positioning accuracy and unstable heat input control. This is particularly problematic when dealing with irregularly shaped structures, thin-walled materials, or multilayer composite conductors, easily leading to defects such as incomplete soldering, overheating, and deformation. With the accelerated miniaturization and integration of high-frequency components in fields like 5G communication, satellite navigation, and aerospace, the structural complexity of outer conductors has significantly increased. Applications such as gradient grooves, three-dimensional curved surfaces, and dissimilar metal combinations place multi-dimensional technical demands on welding fixtures, including precise positioning, dynamic compensation, and thermal management. Against this backdrop, welding fixtures are gradually evolving from simple mechanical clamps to intelligent systems, requiring the integration of multiple disciplines such as materials science, thermodynamics, and automation control to meet the challenges of micron-level welding accuracy in the millimeter-wave band.

[0003] In recent years, technological innovations in external conductor welding fixtures have mainly manifested in three aspects: First, the precision positioning system employs high-rigidity composite materials and a hybrid drive technology combining air flotation and hydraulics, along with visual recognition and laser tracking, achieving a repeatability accuracy of ±5μm to meet the needs of multi-station synchronous welding. Second, thermal field control technology, through the coordinated monitoring of distributed thermocouples and infrared thermal imagers, coupled with an adaptive pulse power supply, controls the welding temperature field gradient within ±3℃, effectively suppressing thermal deformation. Finally, the introduction of a modular design concept enables the fixture to have rapid reconfiguration capabilities. Through standardized interfaces and parametric programming, it can adapt to welding external conductors of different diameters (0.5-50mm), materials (copper alloys, stainless steel, aluminum-based composite materials), and structural forms. Notably, for emerging processes such as vacuum welding and laser brazing, the fixture system has begun to integrate specialized functions such as dynamic sealing of the vacuum chamber and real-time beam path correction. The current technological bottleneck lies in the clamping and deformation prevention mechanism of ultra-thin-walled (<0.1mm) outer conductors, as well as the precise control of the metallurgical reaction at the interface of dissimilar materials. This has driven the engineering application of innovative technologies such as bionic clamping mechanisms and ultrasonic-assisted welding. Utility Model Content

[0004] To address the problems in the existing technology, this utility model provides an outer conductor welding fixture, which adopts a single-hand soldering operation design, allowing for stable contact with the welding area without manual support of the cable, thus significantly reducing operational complexity and safety risks.

[0005] To achieve the above objectives, the technical solution adopted by this utility model is as follows: from top to bottom, the components are a positioning fixture, a positioning plate, a sliding plate, a clamping structure, screws, sliding plate fixing screws, and a base plate. Different products require different positioning fixtures. The positioning plate restricts the position of the welding fixture and the sliding plate. The sliding plate allows the welding product to move freely on the plate. The clamping structure and screws allow for quick replacement of the positioning fixture and fixation with the screws. The sliding plate fixing screws are used to fix the sliding plate if the welding product does not need to be moved. The corresponding product is welded to its outer conductor through these components. The base plate has a guide rail slider structure.

[0006] Preferably, the positioning fixture achieves a split-type quick-change structure by making multiple modules independent and customized for the shape and size of different products.

[0007] Preferably, the positioning fixture is made of aluminum and high-speed steel.

[0008] Preferably, the positioning fixture adopts a lever-type clamping device that is easy to operate with one hand.

[0009] Preferably, the positioning plate is composed of a multi-layer composite material consisting of a carbon steel substrate and a silicon carbide coating.

[0010] Preferably, the surface of the skateboard has a plurality of permanent magnets made of high-strength magnetic material evenly distributed, thereby forming a regular permanent magnet array structure.

[0011] Preferably, the skateboard uses a polyurethane cushioning pad made of highly elastic polyurethane material.

[0012] Preferably, the skateboard is manufactured using a molding process of T800 grade carbon fiber and epoxy resin.

[0013] Preferably, the inner side of the clamping structure is designed as a spiral chip removal groove made of a wear-resistant and high-temperature-resistant material.

[0014] Preferably, a nickel-titanium alloy spring is incorporated into the clamping structure.

[0015] Preferably, the clamping structure is equipped with guide holes to facilitate quick screw alignment and installation.

[0016] Preferably, the screw replaces the traditional hexagonal screw with an eccentric cam quick-lock handle screw.

[0017] Preferably, the skateboard fixing screw is a self-adjusting nut driven by a shape memory alloy.

[0018] Preferably, the surface processing of the base plate facilitates the fixing and adjustment of the matrix T-slots of the positioning fixture and the slide plate.

[0019] Preferably, the base plate is a double-layer hollow design formed by welding an upper layer of high-strength alloy steel plate and a lower layer of lightweight aviation aluminum plate through honeycomb-shaped support ribs.

[0020] Compared with existing technologies, this invention ensures precise and controllable welding position through a high-precision positioning system. It also features a single-handed soldering operation design, eliminating the need for manual cable support for stable contact with the welding area, significantly reducing operational complexity and safety risks. The welded product has a smooth, flawless appearance, with a pass rate exceeding 98%. Combined with a modular quick-change positioning device, it can quickly meet the needs of multiple product specifications, increasing production efficiency by 40%. For sliding structure welding scenarios, the guide mechanism and clamping stability are optimized, completely eliminating rework problems caused by displacement deviations in traditional processes, achieving efficient, high-quality, and flexible production throughout the entire process. The positioning fixture adopts a split quick-change structure, enabling rapid switching of positioning plates through standardized interfaces to adapt to different outer conductor sizes. The positioning plate is designed with multi-layer composite materials, combined with high-precision wire cutting of the positioning groove, with tolerances controlled within ±0.01mm, ensuring the axial and radial positioning accuracy of the outer conductor.

[0021] Furthermore, the positioning fixtures are made of aluminum and high-speed steel, and by designing multiple modules independently and customizing them for the shape and size of different products, a split-type quick-change structure is achieved. Each module is optimized according to the specific product requirements to ensure that the outer conductor cable can be accurately positioned and fixed, and a lever-type clamping device that is easy to operate with one hand is also used.

[0022] Furthermore, the positioning plate is made of a multi-layer composite material consisting of a carbon steel substrate and a silicon carbide coating, which can withstand mechanical stress and impact during the welding process, ensuring that the positioning plate will not deform or be damaged during long-term use.

[0023] Furthermore, multiple permanent magnets made of high-strength magnetic material are evenly distributed on the skateboard surface, forming a regular permanent magnet array structure. Combined with an electromagnetic locking module, the skateboard's movement and fixation are controlled by a single button, enabling one-handed operation. A buffer damper is installed at the end of the skateboard's stroke to prevent displacement of the outer conductor due to impact. The skateboard body is manufactured using a molding process with T800 grade carbon fiber and epoxy resin, reducing weight by 40% while maintaining an elastic modulus of ≥200GPa. A polyurethane buffer pad is made of high-elasticity polyurethane material. The high elasticity and fatigue resistance of polyurethane ensure that the buffer pad is not easily deformed or damaged during long-term use, extending the skateboard's service life. Its corrosion resistance and high-temperature resistance also make it suitable for complex welding environments.

[0024] Furthermore, the inner side of the clamping structure is designed with a spiral chip-removing groove made of wear-resistant and high-temperature-resistant material to prevent welding spatter from accumulating and affecting positioning accuracy. A nickel-titanium alloy spring is also incorporated, utilizing its superelastic properties to achieve self-adaptive locking. When the outer conductor diameter fluctuates, the SMA spring automatically adjusts its deformation, avoiding clamping force attenuation due to mechanical fatigue. Guide holes are installed to facilitate quick screw alignment and installation, significantly improving installation efficiency and accuracy, reducing operation time and human error. Simultaneously, the guide hole design simplifies the operation process, supports one-handed operation and modular replacement, adapting to the needs of multi-variety production. By reducing wear and maintenance costs, not only is production efficiency and product qualification rate improved, but the user experience is also optimized.

[0025] Furthermore, the screws replace the traditional hexagonal screws with eccentric cam quick-lock handle screws, which only require a 90° rotation to fix the skateboard, without the need for tools.

[0026] Furthermore, the slide plate fixing screws adopt shape memory alloy driven self-adjusting nuts, which can use the shape memory effect of shape memory alloy to achieve adaptive adjustment, automatically compensate for loosening and adapt to temperature changes, ensuring that the slide plate remains stable during the welding process.

[0027] Furthermore, the matrix T-slots machined on the base plate surface significantly enhance the flexibility and intelligence of the welding fixture. The matrix T-slot design allows for flexible adjustment of the positioning fixture and slide plate, adapting to the welding requirements of different products. Simultaneously, the precision machining of the T-slots ensures stable component fixation, improving welding accuracy. The base plate consists of an upper layer of high-strength alloy steel plate and a lower layer of lightweight aerospace aluminum plate, welded together with honeycomb-shaped support ribs to form a double-layer hollow design. These honeycomb support ribs not only enhance the overall strength and stability of the base plate but also further reduce weight and improve vibration resistance through the hollow design. This double-layer hollow design achieves lightweight and high efficiency while ensuring high strength and durability, making it suitable for high-precision, high-efficiency welding scenarios and significantly improving the performance of the fixture and production efficiency. Attached Figure Description

[0028] Figure 1 This is a front view of an embodiment of the present utility model;

[0029] Figure 2 This is a top view of an embodiment of the present utility model.

[0030] Among them, 1-positioning fixture, 2-positioning plate, 3-slide plate, 4-clamping structure, 5-screw, 6-slide plate fixing screw, 7-base plate. Detailed Implementation

[0031] The present invention will be further explained and described below with reference to the accompanying drawings and specific embodiments. Obviously, the described embodiments are only some, not all, of the embodiments of this application. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0032] This utility model embodiment provides an external conductor welding fixture, which is particularly suitable for situations where the welding position of the corresponding product needs to be frequently changed. See [link to documentation]. Figure 1 and Figure 2 From top to bottom, the components are: positioning fixture 1, positioning plate 2, sliding plate 3, clamping structure 4, screw 5, sliding plate fixing screw 6, and base plate 7. Different products require different positioning fixtures 1. The positioning plate 2 restricts the position of the welding fixture 1 and the sliding plate 3. The sliding plate 3 allows the welding product to move freely on it. The clamping structure 4 and the screw 5 allow for quick replacement of the positioning fixture 1 and fixation using the screw 5. The sliding plate fixing screw 6 is used to fix the sliding plate 3 if the welding product does not need to be moved. These components are used to weld the outer conductor of the corresponding product. The base plate 7 is a guide rail slider structure.

[0033] The positioning fixture 1 used in this embodiment is made of aluminum and high-speed steel. By designing multiple modules independently and customizing them for the shape and size of different products, a split-type quick-change structure is achieved. Each module is optimized according to the specific product requirements, ensuring accurate positioning and fixation of the outer conductor cable. This design not only improves the versatility of the positioning fixture 1 but also adapts to welding requirements for different outer conductor sizes and shapes, significantly shortening changeover time and accommodating multi-variety, small-batch production environments. The split-type quick-change structure also facilitates maintenance and upgrades; damage or wear of a single module will not affect the overall fixture's use, reducing maintenance costs. Through this modular and standardized design, the positioning fixture can flexibly respond to diverse production needs, while also employing a lever-type clamping device for easy one-handed operation.

[0034] Preferably, the positioning plate is made of a multi-layer composite material consisting of a carbon steel substrate and a silicon carbide coating, which can withstand the mechanical stress and impact during the welding process, ensuring that the positioning plate will not deform or be damaged during long-term use. The silicon carbide coating has extremely high hardness and wear resistance, which can effectively resist the wear and scratches generated during the welding process and extend the service life of the positioning plate.

[0035] Preferably, multiple permanent magnets made of high-strength magnetic material are evenly distributed on the surface of the slide plate 3, forming a regular permanent magnet array structure. Combined with an electromagnetic locking module, the slide plate 3 can be moved and fixed with a single button, enabling one-handed operation. A buffer damper is installed at the end to prevent displacement of the outer conductor due to impact. The main body of the slide plate 3 is manufactured using a T800 grade carbon fiber and epoxy resin molding process, reducing weight by 40% while maintaining an elastic modulus of ≥200GPa. A polyurethane buffer pad made of high-elasticity polyurethane material is used; the high elasticity and fatigue resistance of polyurethane make the buffer pad less prone to deformation or damage during long-term use, extending the service life of the slide plate. Its corrosion resistance and high-temperature resistance also make it suitable for complex welding environments.

[0036] Preferably, the inner side of the clamping structure is designed with a spiral chip-removing groove made of wear-resistant and high-temperature-resistant material to prevent welding spatter from accumulating and affecting positioning accuracy. A nickel-titanium alloy spring is introduced, utilizing its superelastic properties to achieve self-adaptive locking. When the outer conductor diameter fluctuates, the SMA spring can automatically adjust its deformation, avoiding clamping force attenuation due to mechanical fatigue. Guide holes are also installed to facilitate quick screw alignment and installation, significantly improving installation efficiency and accuracy, reducing operation time and human error. Simultaneously, the guide hole design simplifies the operation process, supports one-handed operation and modular replacement, adapting to the needs of multi-variety production. By reducing wear and maintenance costs, not only is production efficiency and product qualification rate improved, but the user experience is also optimized.

[0037] Preferably, screw 5 replaces the traditional hexagonal screw with an eccentric cam quick-lock handle screw, requiring only a 90° rotation without the need for tools. The slide plate fixing screw 6 uses a shape memory alloy driven self-adjusting nut, which can utilize the shape memory effect of the shape memory alloy to achieve adaptive adjustment, automatically compensate for looseness and adapt to temperature changes, ensuring that the slide plate 3 remains stable throughout the welding process.

[0038] Preferably, the base plate 7 is machined with matrix-style T-slots, which significantly improves the flexibility and intelligence of the welding fixture. This allows components such as the positioning fixture 1 and the slide plate 3 to be flexibly adjusted to adapt to the welding requirements of different products. Simultaneously, the precision machining of the T-slots ensures the components are firmly fixed, improving welding accuracy. The base plate is constructed with an upper layer of high-strength alloy steel plate and a lower layer of lightweight aerospace aluminum plate, welded together with honeycomb-shaped support ribs to form a double-layer hollow design. The honeycomb support ribs not only enhance the overall strength and stability of the base plate but also further reduce weight and improve vibration resistance through the hollow design. This double-layer hollow design achieves lightweight and high efficiency while ensuring high strength and durability, making it suitable for high-precision, high-efficiency welding scenarios and significantly improving the performance and production efficiency of the fixture.

[0039] The specific workflow of this product is as follows: The workflow of this outer conductor welding fixture begins with preparation. First, a suitable positioning fixture (1) is selected according to the size of the outer conductor and quickly installed on the positioning plate (2) on the bottom plate (7) using the clamping structure (4) and screws (5). The state of the sliding plate (3) is adjusted and the stability of the positioning fixture (1) is checked. Next, the outer conductor is placed into the positioning fixture (1) and fixed. After adjusting the welding position using the sliding plate (3), the welding equipment is started. After welding is completed, the outer conductor is released and the welding quality is checked. Then, the positioning fixture (1) is replaced and the fixture is cleaned as needed.

[0040] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it; although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.

Claims

1. An outer conductor welding fixture, characterized by, From top to bottom, the components are: positioning fixture (1), positioning plate (2), sliding plate (3), clamping structure (4), screw (5), sliding plate fixing screw (6), and base plate (7). The positioning fixture (1) is different for different products. The positioning plate (2) restricts the position of the outer conductor welding fixture and the sliding plate (3). The sliding plate (3) allows the welding product to move freely on the sliding plate (3). The clamping structure (4) allows for quick replacement of the positioning fixture (1). The screw (5) is used to fix the positioning fixture (1). The sliding plate fixing screw (6) is used to fix the sliding plate (3) if the welding product does not need to be moved. The corresponding products are welded to the outer conductor through these components. The base plate (7) is a guide rail slider structure.

2. An outer conductor welding fixture as defined in claim 1, wherein, The positioning fixture (1) achieves a split quick-change structure by making multiple modules independent and customizing them for the shape and size of different products. The positioning fixture (1) is made of aluminum and high-speed steel and adopts a lever-type clamping device that is easy to operate with one hand.

3. An outer conductor welding fixture as set forth in claim 1, wherein, The positioning plate (2) is composed of a multi-layer composite material of carbon steel substrate and silicon carbide coating.

4. An outer conductor welding fixture as set forth in claim 1, wherein, The surface of the slide plate (3) is uniformly distributed with multiple permanent magnets made of high-strength magnetic materials, thereby forming a regular permanent magnet array structure. The slide plate (3) uses a polyurethane buffer pad made of high-elasticity polyurethane material. The slide plate (3) is manufactured by molding T800 grade carbon fiber and epoxy resin.

5. An outer conductor welding fixture as defined in claim 1, wherein, The clamping structure (4) is equipped with guide holes to facilitate quick alignment and installation of screws (5). The inner side of the clamping structure (4) is designed as a spiral chip removal groove made of wear-resistant and high-temperature resistant material. A nickel-titanium alloy spring is introduced into the clamping structure (4).

6. An outer conductor welding fixture as defined in claim 1, wherein, The screw (5) replaces the traditional hexagonal screw with an eccentric cam quick-lock handle screw.

7. An outer conductor welding fixture as defined in claim 1, wherein, The skateboard fixing screw (6) is a self-adjusting nut driven by a memory alloy.

8. An outer conductor welding fixture as set forth in claim 1, wherein, The surface processing of the base plate (7) facilitates the fixing and adjustment of the matrix T-slots of the positioning fixture (1) and the slide plate (3). The base plate (7) is a double-layer hollow design formed by welding the upper high-strength alloy steel plate and the lower lightweight aviation aluminum plate through honeycomb support ribs.

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