A feed horn hole bottom processing structure
By employing a split design and welding process, the problem of narrow spacing and high precision in the corrugated groove at the bottom of the feedhorn hole was solved, improving high-frequency signal transmission performance and processing efficiency, and ensuring the stability and reliability of the product.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SHANGHAI YAMEI MICROWAVE INSTRUMENT FACTORY CO LTD
- Filing Date
- 2025-08-21
- Publication Date
- 2026-06-19
AI Technical Summary
In the existing technology, the corrugated groove of the feedhorn is difficult to meet the requirements of narrow spacing and high precision due to integrated processing, which leads to a decrease in high frequency signal transmission performance, and the processing is difficult and the product qualification rate is low.
The design adopts a split-type design, which disassembles the corrugated groove structure at the bottom of the speaker hole into multiple first circular blocks and second circular blocks for assembly. By precisely controlling the size of each block and stacking them together, combined with welding and integral molding processes, the tightness and precision of the structure are ensured.
The design of high-density, low-pitch corrugated grooves has been achieved, which has improved signal transmission stability and bandwidth, reduced processing difficulty and dimensional errors, and improved product qualification rate and overall processing efficiency.
Smart Images
Figure CN224384534U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the technical fields of deep space exploration, meteorological measurement, and satellite remote sensing, and in particular to a bottom hole processing structure for a feedhorn. Background Technology
[0002] As a key component in millimeter-wave communication and detection systems, feedhorns are widely used in deep space exploration, meteorological measurement, and satellite remote sensing. Their performance directly affects core indicators such as signal transmission stability, loss rate, and bandwidth. In high-frequency short millimeter-wave applications (such as the 89GHz band), extremely high requirements are placed on the structural precision and corrugated groove design of feedhorns.
[0003] In existing technologies, the corrugated grooves of feedhorns are typically manufactured using an integrated machining method. However, this is limited by the technical bottlenecks of traditional machining processes (such as turning and milling). Due to the small size of the horn's inner hole (e.g., in some scenarios, an inner hole of Φ2.56±0.02mm needs to be machined), and the corrugated grooves need to meet the requirements of narrow spacing (e.g., 0.65±0.05mm) and high precision, conventional cutting tools cannot reach the bottom of the hole for machining, resulting in insufficient corrugated groove density and excessively large groove spacing. In integrated machining, uneven groove depth is common, which can easily cause impedance abrupt changes, leading to increased high-frequency signal transmission loss and narrowed operating bandwidth. At the same time, groove spacing errors can cause an increase in cross-polarization level and sidelobe level, resulting in gain loss and decreased stability. Utility Model Content
[0004] In view of the above-mentioned prior art, in order to solve the problems that the prior art cannot achieve high-density, low-pitch corrugated grooves and the processing accuracy is difficult to guarantee, which leads to the degradation of the transmission performance of high-frequency short millimeter wave signals, this application provides a hole bottom processing structure for a feedhorn.
[0005] This application provides a bottom hole machining structure for a feedhorn, which adopts the following technical solution:
[0006] A bottom-processing structure for a feedhorn includes a horn body and an annular assembly. The annular assembly is connected to the horn body. The horn body has multiple corrugated grooves of different diameters. A mounting block is provided on the side of the horn body near the bottom of the hole. The mounting block has a mounting cavity. One end of the mounting cavity communicates with the interior of the horn body, and the other end of the mounting cavity, away from the horn body, communicates with the outside. The annular assembly is installed in the mounting cavity. The annular assembly includes a first circular block and a second circular block. There are multiple first circular blocks, each with a groove on one side. Each groove of the multiple first circular blocks has a first central hole. The second circular block and the multiple first circular blocks are stacked and fixedly connected within the mounting cavity and connected by welding. Before welding, the assembly pressure is controlled to ensure a tight fit and no deformation. The second circular block and the multiple first circular blocks are fixed to the safety cavity by welding.
[0007] By adopting the above technical solution and employing a split design, the corrugated groove structure at the bottom of the hole, which originally required integrated machining, is disassembled into a combination of multiple first and second circular blocks. This completely solves the technical bottleneck in traditional machining where conventional tools cannot reach the bottom of the hole due to the narrow inner hole of the horn (e.g., Φ2.56±0.02mm). Multiple first circular blocks can be pre-machined individually, allowing for precise control of their dimensional accuracy. These blocks are then stacked to form the corrugated groove structure at the bottom of the hole. This not only meets the design requirements of high-density, low-spacing corrugated grooves but also ensures the overall structure's tightness, stability, and accuracy through strict control of assembly pressure and welding processes. Simultaneously, this split design significantly reduces the machining difficulty of individual parts, minimizes the complex process requirements associated with integrated machining, facilitates effective control of dimensional errors during mass production, and significantly improves overall machining efficiency and product qualification rate. The mounting cavity on the mounting block provides precise assembly space for the annular assembly, further ensuring the relative positional accuracy of each component and laying a solid foundation for subsequent welding and fixing.
[0008] Preferably, the diameters of the first central holes of the plurality of first circular blocks are different, and the edges of the first central holes form continuous corrugated grooves.
[0009] By adopting the above technical solution, and by using the first central holes with different diameters on multiple first circular blocks, after being stacked and combined, a continuous corrugated groove can be naturally formed at its edge. The continuous corrugated groove structure can effectively optimize the transmission path of high-frequency signals in the speaker, reduce signal reflection and scattering, and significantly improve the working bandwidth and signal transmission stability of the feed speaker in the high-frequency band (such as 89GHz). This solves the signal transmission problem caused by the discontinuity and insufficient precision of the corrugated groove in traditional integrated processing.
[0010] Preferably, the mounting block is integrally formed with the speaker body.
[0011] By adopting the above technical solution and using a one-piece molding process to manufacture the mounting block and the speaker body, it is possible to ensure that there are no connection gaps or assembly errors between the two, significantly improving the rigidity and stability of the overall structure. This integrated structure avoids signal transmission interference and structural loosening problems that may occur when the mounting block and the speaker body are connected separately. At the same time, it reduces assembly steps and lowers the risk of performance degradation due to improper assembly, providing a reliable structural foundation for the stable operation of the feedhorn speaker in complex environments.
[0012] Preferably, the mounting block has a flange structure for connection on its outer periphery, and the flange structure is located on the side of the mounting block away from the horn body.
[0013] By adopting the above technical solution, the flange structure provides a standardized and high-precision interface for the connection between the feed horn and external equipment (such as antenna systems, detectors, signal transmission lines, etc.), ensuring positioning accuracy during installation and guaranteeing the tightness and stability of the connection. The flange connection method offers excellent disassembly, facilitating later maintenance, repair, and component replacement. It also effectively reduces signal transmission loss and interference caused by loose connections, improving the reliability and ease of use of the entire system.
[0014] Preferably, the width of the corrugated groove is 0.65±0.05mm.
[0015] By adopting the above technical solution, the width of the corrugated groove is precisely controlled within a narrow spacing range of 0.65±0.05mm, which perfectly meets the stringent structural precision requirements for high-frequency short millimeter-wave signal transmission. This dimensional design effectively suppresses cross-polarization interference, reduces sidelobe levels, significantly improves the gain performance of the feed horn, ensures signal stability during long-distance transmission, and reduces signal quality degradation caused by corrugated groove size errors.
[0016] Preferably, a groove is formed on the side of the second circular block that connects to the first circular block, and a second central hole is formed through the groove of the second circular block. The diameter of the second central hole is the same as that of the circular hole on the first circular block near the second circular block. The side of the second central hole near the first circular block is connected to the inside of the speaker body, and the side of the second central hole away from the first circular block is connected to the outside.
[0017] By adopting the above technical solution, the second central hole plays a crucial role in connecting the inside and outside of the speaker body, enabling smooth signal transmission. Its equal-diameter design with the first central hole of the adjacent first circular block ensures a smooth transition in the signal transmission path, effectively avoiding impedance mismatch problems caused by abrupt changes in aperture, and reducing signal reflection and loss. Simultaneously, the groove structures on the first and second circular blocks work together to form continuous corrugated grooves, further optimizing the signal transmission environment.
[0018] In summary, this application includes at least one of the following beneficial technical effects:
[0019] 1. By adopting a split design, the corrugated groove structure at the bottom of the hole, which originally required integrated machining, is broken down into multiple first and second circular blocks for assembly. This completely solves the technical bottleneck in traditional machining where conventional tools cannot reach the bottom of the hole due to the narrow inner hole of the horn (e.g., Φ2.56±0.02mm). Multiple first circular blocks can be pre-machined individually, allowing for precise control of their dimensional accuracy. These blocks are then stacked to form the corrugated groove structure at the bottom of the hole. This not only meets the design requirements for high-density, low-spacing corrugated grooves but also ensures the overall structure's tightness, stability, and precision through strict control of assembly pressure and welding processes. Simultaneously, this split design significantly reduces the machining difficulty of individual parts, minimizes the complex process requirements associated with integrated machining, facilitates effective control of dimensional errors during mass production, and significantly improves overall machining efficiency and product qualification rate. The mounting cavity on the mounting block provides precise assembly space for the annular assembly, further ensuring the relative positional accuracy of each component and laying a solid foundation for subsequent welding and fixing.
[0020] 2. By using an integrated molding process to manufacture the mounting block and the speaker body, it is ensured that there are no connection gaps or assembly errors between the two, which significantly improves the rigidity and stability of the overall structure. This integrated structure avoids signal transmission interference and structural loosening problems that may occur when the mounting block and the speaker body are connected separately. At the same time, it reduces assembly steps and lowers the risk of performance degradation due to improper assembly, providing a reliable structural foundation for the stable operation of the feed speaker in complex environments.
[0021] 3. The second central aperture plays a crucial role in connecting the inside and outside of the speaker body, enabling smooth signal transmission. Its equal diameter design with the first central aperture of the adjacent first circular block ensures a smooth transition in the signal transmission path, effectively avoiding impedance mismatch problems caused by abrupt aperture changes and reducing signal reflection and loss. Simultaneously, the groove structures on the first and second circular blocks work together to form continuous corrugated grooves, further optimizing the signal transmission environment. Attached Figure Description
[0022] Figure 1 This is a schematic diagram of the overall structure of this utility model;
[0023] Figure 2 yes Figure 1 Cross-sectional view at point AA;
[0024] Figure 3 yes Figure 2 Exploded view.
[0025] Reference numerals: 1. Horn body; 2. Annular assembly; 21. First circular block; 211. First central hole; 22. Second circular block; 221. Second central hole; 3. Mounting block; 31. Mounting cavity; 4. Corrugated groove; 5. Flange structure. Detailed Implementation
[0026] The following is in conjunction with the appendix Figure 1-3 This application will be described in further detail.
[0027] This application discloses a hole bottom processing structure for a feedhorn.
[0028] Reference Figure 1 and Figure 2 A bottom-processing structure for a feedhorn includes a horn body 1 and an annular fitting 2. The annular fitting 2 is connected to the horn body 1. The horn body 1 has multiple corrugated grooves 4 with different apertures. A mounting block 3 is provided on the side of the horn body 1 near the bottom of the hole. A mounting cavity 31 is formed within the mounting block 3, with both sides of the mounting cavity 31 penetrating through it. One side of the mounting cavity 31 communicates with the interior of the horn body 1. The annular fitting 2 is installed within the mounting cavity 31. The annular fitting 2 includes five first circular blocks 21 and two second circular blocks 22. The edges of adjacent first circular blocks 21 are fitted together. The first circular blocks 21 and the second circular blocks 22 are fixed to the inner wall of the mounting cavity 31 by laser welding.
[0029] Reference Figure 3Specifically, a groove is formed on one side of the first circular block 21, and a first central hole 211 is formed in the groove. The second circular block 22 is stacked and welded to multiple first circular blocks 21 and fixedly installed in the mounting cavity 31. Before welding, the assembly pressure is controlled to ensure that the assembly fits tightly and without deformation. The edges of the first central holes 211 of the five first circular blocks 21 form continuous corrugated grooves 4, and the width of the corrugated grooves 4 is 0.65±0.05mm. This achieves a high-density, low-pitch corrugated groove 4 structure, which improves the performance of the feed speaker in the high-frequency short millimeter-wave signal transmission. This structural design avoids the problems of high-density, low-pitch corrugated grooves 4 and ensuring processing accuracy that are difficult to achieve with traditional processing methods. This reduces problems such as increased cross-polarization level, increased sidelobe level, increased gain loss, and decreased stability. It also avoids impedance abrupt changes caused by uneven groove depth, reduces high-frequency loss, and widens the operating bandwidth.
[0030] The outer periphery of the mounting block 3 is provided with a connecting flange structure 5, which is located on the side of the mounting block 3 away from the horn body 1.
[0031] The five first circular blocks 21 have different diameters in their first center holes 211, with the inner diameter difference between adjacent first circular blocks 21 ranging from 0.15 to 0.33 mm. The circular blocks can be made of H62 copper rod, which has good conductivity and processing performance. For replaceable features, the first center hole 211 can also be made of other metals with good conductivity, such as brass or copper, depending on actual needs. The annular assembly 2 is assembled by stacking the ring-shaped components in ascending order of center hole diameter, with the edge faces of adjacent annular components 2 fitting together. This assembly method creates a corrugated groove 4 structure along the edge of the center hole of each annular assembly 2, achieving a high-density, low-pitch corrugated groove 4. The combined effect improves the signal transmission performance of the feedhorn, due to the high-density, low-pitch design and uniform groove depth of the corrugated groove 4, which reduces interference and loss during signal transmission.
[0032] The second circular block 22 abuts against the first circular block 21, which has the smallest diameter of the first central hole 211. A groove is formed on the side of the second circular block 22 closest to the first circular block 21, and a second central hole 221 is formed through the groove. The diameter of the second central hole 221 is the same as the diameter of the first central hole 211 of the first circular block 21 closest to the second first central hole 211. The first circular block 21 and the second circular block 22 are stacked and pressed into the bottom of the horn hole in sequence. During assembly, the pressure must be controlled; too high or too low pressure will result in gaps due to insufficient pressure, while too high pressure will cause deformation of the assembly. After pressing, the assembly is welded to the horn using laser welding.
[0033] After the first circular block 21 and the second circular block 22 are welded and installed, there are a total of 40 corrugated grooves 4 in the mounting cavity 31 and the horn hole of the horn body 1. The distance between the grooves is 1.3±0.05mm, the minimum groove depth is 0.76mm, the maximum groove depth is 1.62mm, and the hole diameter at the maximum groove depth position is only Φ2.56mm.
[0034] After the first circular block 21 and the second circular block 22 are welded, the grooves between the multiple first circular blocks 21 and the grooves between the second circular block 22 and the first circular block 21 need to be machined. When machining the inner holes and grooves, a low speed and slow feed should be used, and the tool should be retracted multiple times to remove debris. This is to prevent debris from getting stuck due to poor removal, which would affect the quality of the parts and, in severe cases, cause tool breakage, resulting in the parts being scrapped. After machining, the parts need to be electroplated and cleaned to remove debris and excess material from the holes.
[0035] After the welding, turning, and electroplating cleaning of the first circular block 21 and the second circular block 22 are completed, a comprehensive inspection of the parts is required to ensure that they simultaneously meet the structural, electrical performance, and environmental adaptability requirements. For structural inspection, the inner hole and corrugated groove 4 of the speaker body 1 have complex structures, making precise measurement difficult with conventional measuring tools. Therefore, one speaker body 1 part was selected for wire cutting inspection. Regarding electrical performance and environmental adaptability testing, the parts were first tested in the f0=89±0.35GHz frequency band. The results showed that the standing wave ratio (SWR) was ≤1.2 and the insertion loss was ≤0.12dB, meeting the initial performance indicators. Subsequently, multiple screening tests were conducted on the parts to verify their environmental adaptability. After the tests, the electrical performance was retested, and the data showed that the SWR was still ≤1.2 and the insertion loss was ≤0.13dB. All indicators met the design requirements of the drawings, fully demonstrating that the hole bottom processing structure of the feed speaker has stable and reliable performance in high-frequency short millimeter-wave signal transmission.
[0036] The implementation principle of this application embodiment is as follows: By splitting the corrugated groove 4 structure at the bottom of the hole, which is difficult to achieve with traditional integrated machining, into a separate combination design of five first circular blocks 21 and one second circular block 22, and utilizing the first central holes 211 with different diameters on each of the first circular blocks 21, after stacking them in order of increasing central hole diameter, a continuous high-density, low-spacing corrugated groove 4 with a width of 0.65±0.05mm is naturally formed at the edge. During assembly, the assembly pressure is precisely controlled to ensure that each circular block fits tightly without deformation. Then, laser welding is used to fix the stacked annular assembly 2 to the inner wall of the mounting cavity 31. This solves the problem that the narrow inner hole of the horn makes it impossible for the cutting tool to penetrate deeply, and also ensures the stability and precision of the structure. Subsequently, the grooves between each circular block are finished by turning, and impurities in the hole are removed by electroplating and cleaning to further optimize the structural precision. The inspection process involved wire cutting to verify the structural dimensions and then conducting electrical performance tests in the 89±0.35GHz band and multiple screening tests to confirm that the standing wave ratio, insertion loss, and other indicators met the design requirements. This ultimately improved the signal transmission performance in high-frequency short millimeter-wave scenarios and effectively avoided problems such as impedance abrupt changes and increased losses caused by insufficient precision of the corrugated groove 4 in traditional processing.
[0037] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.
Claims
1. A hole bottom machining structure for a feedhorn, characterized in that, The device includes a speaker body (1) and an annular fitting (2). The annular fitting (2) is connected to the speaker body (1). The speaker body (1) has multiple corrugated grooves (4) with different apertures. A mounting block (3) is provided on the side of the speaker body (1) near the bottom of the holes. A mounting cavity (31) is provided on the mounting block (3). One end of the mounting cavity (31) is connected to the inside of the speaker body (1), and the other end of the mounting cavity (31) away from the speaker body (1) is connected to the outside. The annular fitting (2) is installed in the mounting cavity (31). The annular fitting (2) includes a first circular block (21) and a second circular block (22). There are multiple first circular blocks (21), and each of the multiple first circular blocks (21) has a groove on one side. Each of the multiple first circular blocks (21) has a first central hole (211) in the groove. The second circular block (22) and the multiple first circular blocks (21) are stacked and fixedly connected. The second circular block (22) and the multiple first circular blocks (21) are stacked in the mounting cavity (31) and connected by welding. Before welding, the assembly pressure is controlled to ensure that the assembly fits tightly and without deformation. The second circular block (22) and the multiple first circular blocks (21) are fixed to the mounting cavity (31) by welding.
2. The hole bottom processing structure of a feedhorn according to claim 1, characterized in that, The first central holes (211) of the multiple first circular blocks (21) have different diameters, and the opening edge of the first central holes (211) forms a continuous corrugated groove (4).
3. The hole bottom processing structure of a feedhorn according to claim 1, characterized in that, The mounting block (3) is integrally formed with the speaker body (1).
4. The hole bottom processing structure of a feedhorn according to claim 3, characterized in that, The mounting block (3) has a flange structure (5) for connection on its outer periphery, and the flange structure (5) is located on the side of the mounting block (3) away from the horn body (1).
5. The hole bottom processing structure of a feedhorn according to claim 1, characterized in that, The width of the corrugated groove (4) is 0.65±0.05mm.
6. The hole bottom processing structure of a feedhorn according to claim 1, characterized in that, A groove is provided on the side of the second circular block (22) that is connected to the first circular block (21). A second central hole (221) is provided through the groove of the second circular block (22). The diameter of the second central hole (221) is the same as that of the circular hole on the first circular block (21) near the second circular block (22). The side of the second central hole (221) near the first circular block (21) is connected to the inside of the speaker body (1), and the side of the second central hole (221) away from the first circular block (21) is connected to the outside.