A tool for making large spherical antenna cover arc surface mold

Abstract

The utility model discloses a tooling for making large -scale spherical antenna cover cambered surface mould. The tooling includes base, fixed base, pivot, bearing seat, scraper and counterweight assembly. Fixed base installs on the base, and bearing seat is through bearing and is installed on the pivot and can rotate around it, and scraper is fixed in one side of bearing seat through screw and positioning pin, and its scraping edge is a circular arc with pivot axis as the center, and counterweight assembly is installed on the other side of bearing seat. High -precision spherical cambered surface can be scraped through rotating scraper. The utility model discloses ingenious structure design, and the expensive whole steel mould is replaced for the cement master mould of on -the -spot making, and the mould manufacturing cost is reduced significantly, and the processing period is shortened, and the forming precision of cambered surface is guaranteed, and a new solution is provided for the manufacture of large -scale spherical antenna cover.

Description

Technical Field

[0001] This utility model relates to the field of composite material mold manufacturing technology, and in particular to a tooling for manufacturing a large spherical radome arc surface mold. Background Technology

[0002] Large spherical radomes are critical components in satellite communication, radio astronomy, and radar systems, protecting the internal precision antennas from environmental damage. To ensure structural safety in strong winds and maintain optimal aerodynamics and electromagnetic wave transmission performance, a spherical or dome shape is the most classic and optimized design. These large spherical radomes are typically assembled from multiple curved composite material panels, and manufacturing the high-precision composite material molds required for these panels is a key technical challenge in this field. Currently, the master molds for manufacturing such large spherical arc surfaces traditionally rely on integral steel molds. While this process offers high precision, it suffers from several insurmountable drawbacks: firstly, the material and machining costs of large steel molds are extremely high; secondly, the design, processing, and completion cycle is very long, severely hindering project progress. To reduce costs and shorten the cycle, the industry is exploring master mold manufacturing methods based on cement-based substrates. However, when scraping and molding large, high-precision spherical arc surfaces, there is a general lack of dedicated and reliable tooling. Existing simplistic scraping methods often lack a definitive axis of rotation for the scraper, and the scraper's cutting edge itself is not a precise arc centered on that axis. This results in the scraper's cutting edge not moving on a standard spherical surface during operation, leading to poor precision and low profile in the final cement arc surface, which fails to meet the stringent requirements of composite material molds for the master mold. Furthermore, when scraping large arc surfaces, the tooling generally lacks effective balancing and height adjustment mechanisms, further impacting molding quality and ease of operation.

[0003] Therefore, there is an urgent need in this field for a special tooling and method that is low in cost, quick to manufacture, and can guarantee from a structural principle that the scraping trajectory is a standard spherical surface. Utility Model Content

[0004] A tooling for manufacturing a large spherical radome arc surface mold includes a base, a fixed seat, a rotating shaft, a bearing seat, a scraper, a positioning block, and a counterweight assembly. The fixed seat is fixedly mounted on the base. The rotating shaft is vertically arranged and its lower end is adjustablely connected to the fixed seat. The bearing seat is fitted onto the rotating shaft and can rotate around the rotating shaft. The scraper is fixedly connected to one side of the bearing seat, and its free end bottom edge forms a scraping edge. The outline of the scraping edge is an arc, and the center of the arc is located on the axis of the rotating shaft, so that when the bearing seat rotates, the scraper can scrape out a spherical arc surface. The counterweight assembly is fixedly connected to the bearing seat on the opposite side of the scraper, and is used to balance the gravitational torque of the scraper when it is working.

[0005] The lower end of the rotating shaft is screwed into the fixed seat via a threaded connection. The initial height of the rotating shaft is adjusted by changing the screwing depth, and it is locked in place by a round nut.

[0006] The bearing housing is an integrally formed structure with a rectangular main body and a mounting hole in the middle. The bearing housing has outwardly extending wing plates on both sides. One wing plate is used to install the scraper, and the other wing plate is used to install the counterweight assembly.

[0007] A positioning block is provided on each of the left and right wing plates of the bearing housing; wherein the positioning block on the left wing plate is used to install and position the counterweight plate assembly, and the positioning block on the right wing plate is used to install and position the scraper.

[0008] The scraper is engaged with the positioning block by at least two positioning pins to achieve precise positioning relative to the bearing seat; the scraper is connected to the positioning block by at least two screws to press and fix it to the bearing seat.

[0009] The scraper is welded with angle steel reinforcing ribs and has weight reduction holes and lifting holes.

[0010] The locating pins and screws are arranged diagonally symmetrically on the connecting surfaces.

[0011] The locating pin and the screw are both concentrated at the connection interface between the scraper and the bearing seat, and are located in the area of ​​the interface closest to the axis of the rotating shaft.

[0012] The scraper is made of stainless steel.

[0013] The counterweight assembly includes a counterweight plate and a counterweight block. The counterweight plate has a through hole for mounting the counterweight block. The right connecting end of the counterweight plate is positioned and connected to the left wing plate of the bearing seat through a positioning block.

[0014] The base includes a square tube welded frame and a bottom plate; the bottom plate is fixed to the bottom of the square tube welded frame; the square tube welded frame is provided with several reinforcing ribs on the outside, and a cover is welded to the upper surface of the frame; the lower end of the fixing seat is fixedly installed on the cover.

[0015] The bearing housing is fitted onto the rotating shaft by deep groove ball bearings installed at its upper and lower ends; the upper and lower ends of the mounting holes of the bearing housing are respectively provided with an upper cover plate and a lower cover plate, and the deep groove ball bearings are pressed between the upper cover plate and the lower cover plate to achieve axial positioning and sealing.

[0016] The inner ring of the deep groove ball bearing is interference-fitted with the shaft, while the outer ring is clearance-fitted or transition-fitted with the bearing housing bore.

[0017] The shaft is made of 45 steel.

[0018] Beneficial effects: 1. High forming precision and reliable quality: This invention features a scraper blade configured as a precise arc centered on the axis of rotation, ensuring a standard spherical trajectory during scraper rotation. This fundamentally guarantees extremely high contour accuracy and surface quality in the final cement master mold and composite material mold, fully meeting the manufacturing requirements of high-end radomes. 2. Significantly reduced manufacturing costs: This invention utilizes a clever tooling structure to transform the manufacturing of steel molds, which relies heavily on high-cost machining, into a master mold manufacturing method for on-site cement scraping. This eliminates substantial material and machining costs, significantly reducing the overall manufacturing cost of the mold compared to traditional steel molds.

[0019] 2. Significantly shortened production cycle: This utility model has a simple structure and is easy to install, enabling rapid on-site manufacturing of molds. It eliminates the lengthy design, programming, and machining cycle of steel molds, greatly shortening the total project cycle from design to finished product and significantly improving production efficiency.

[0020] 3. Convenient operation and flexible adjustment: The unique adjustable connection design between the rotating shaft and the fixed base of this utility model allows the initial height of the scraper to be easily fine-tuned, flexibly adapting to different mold arc depth requirements.

[0021] The counterweight balancing system effectively balances the weight of the scraper by utilizing the lever principle, making the drive rotation easy and effortless, while ensuring the stability of the system during scraping and further improving the flatness of the formed surface.

[0022] The scraper achieves rapid and accurate installation and repeated positioning through a connection method that separates positioning and locking, effectively controlling assembly errors and ensuring molding accuracy.

[0023] 4. Robust and durable structure: The base of this utility model adopts an internally reinforced welded frame structure, the rotating shaft is made of high-strength material, and standard bearings are selected for key rotating parts with optimized fit, so that the entire tooling has sufficient strength, rigidity and wear resistance, and can ensure long-term stable operation in harsh on-site construction environments. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the overall structure of this utility model; Figure 2 This is a schematic diagram of the bearing housing structure of this utility model.

[0025] In the diagram: 1. Base; 101. Reinforcing rib; 102. Cover; 103. Square tube welded frame; 2. Fixed seat; 3. Rotating shaft; 4. Bearing seat; 401. Wing plate; 5. Deep groove ball bearing; 6. Scraper; 601. Angle steel reinforcing rib; 602. Weight reduction hole; 603. Lifting hole; 7. Counterweight plate; 8. Screw; 9. Locating pin; 10. Round nut; 11. Counterweight block; 12. Locating block; 13. Upper cover plate; 14. Lower cover plate. Detailed Implementation

[0026] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0027] like Figure 1 and Figure 2The tooling shown is for fabricating a large spherical radome curved surface mold, including a base 1, a fixed seat 2, a rotating shaft 3, a bearing seat 4, a scraper 6, a positioning block 12, and a counterweight assembly. The base 1 serves as the foundation of the entire tooling and is fixed to a concrete base with anchor bolts to ensure overall stability. The fixed seat 2 is fixedly installed on the center of the upper surface of the base 1 by welding or bolting. The rotating shaft 3 is vertically positioned and its lower end is adjustablely connected to the fixed seat 2, providing the rotational reference axis for the entire tooling. The bearing seat 4 is fitted onto the rotating shaft 3, allowing the bearing... The bearing seat 4 can rotate smoothly 360 degrees around the rotating shaft 3; the scraper 6 is fixedly connected to one side of the bearing seat 4, and the bottom edge of its free end forms a scraping edge. The outline of the scraping edge is an arc, and the outline of the scraping edge is formed by laser cutting or other precision machining methods. The center of the arc is located on the axis of the rotating shaft 3, so that when the bearing seat 4 rotates, the scraper 6 will eventually scrape out a standard spherical arc surface; the counterweight assembly is fixedly connected to the bearing seat 4 on the other side opposite to the scraper 6, and is used to balance the gravitational torque of the scraper 6 when it is working.

[0028] Furthermore, such as Figure 2 As shown, the lower end of the rotating shaft 3 is screwed into the fixed seat 2 via a threaded connection and locked in place by a round nut 10. The lower end of the rotating shaft 3 is machined with an external thread, and the fixed seat 2 is machined with an internal threaded hole in the center. The rotating shaft 3 is installed by screwing into the threaded hole. By precisely adjusting the screwing depth of the rotating shaft 3, the initial height of the rotating shaft 3 can be finely adjusted, thereby controlling the arc surface reference height of the formed cement mold. After adjustment, the round nut 10 is used to lock it in place to prevent the rotating shaft from loosening under force.

[0029] Furthermore, the bearing seat 4 is an integrally formed structure, with a rectangular main body and a mounting hole in the middle. The bearing seat 4 has outwardly extending wing plates 401 on both the left and right sides, with one wing plate 401 used to install the scraper 6 and the other wing plate 401 used to install the counterweight assembly.

[0030] Furthermore, a positioning block 12 is provided on each of the left and right wing plates of the bearing seat 4; wherein the positioning block 12 on the left wing plate 401 is used to install and position the counterweight assembly, and the positioning block 12 on the right wing plate 401 is used to install and position the scraper 6.

[0031] Furthermore, the scraper 6 engages with the positioning block 12 via at least two positioning pins 9 to achieve precise positioning relative to the bearing seat 4, ensuring that its arc center coincides with the axis of the rotating shaft 3; the scraper 6 is connected to the positioning block 12 via at least two screws 8, thereby pressing and fixing it onto the bearing seat 4. This structure of positioning pins and screws ensures the repeatability and reliability of scraper installation.

[0032] Furthermore, such as Figure 1 As shown, in order to ensure the structural rigidity of the scraper 6 when scraping large molds and to reduce its weight, angle steel reinforcing ribs 601 are welded to the back of the stainless steel scraper 6. At the same time, weight reduction holes 602 and lifting holes 603 are opened on the plate to facilitate production and handling.

[0033] Furthermore, the positioning pin 9 and the screw 8 are arranged diagonally symmetrically on the connecting surface, resulting in uniform force distribution and better stability.

[0034] Furthermore, the positioning pin 9 and the screw 8 are both concentrated at the connection interface between the scraper 6 and the bearing seat 4, and are located in the area of ​​the interface closest to the axis of the rotating shaft 3.

[0035] Furthermore, the scraper 6 is made of stainless steel to ensure its rigidity and wear resistance.

[0036] Furthermore, the counterweight assembly is located on the opposite side of the scraper 6, forming a lever system together with the scraper 6. Further, the counterweight assembly includes a counterweight plate 7 and counterweight blocks 11. The counterweight plate 7 has through holes. Based on the weight and center of gravity of the scraper 6, a corresponding number of counterweight blocks 11, such as cast iron blocks, are installed on the counterweight plate 7. This utilizes the lever principle to balance the gravitational torque of the scraper 6, achieving a balance of the gravitational torque on the scraper 6. This ensures that the tooling is in a good balanced state during operation, requiring only a small force from the operator to drive its smooth rotation. Simultaneously, it ensures the high stability of the scraper during rotation, thereby ensuring a high degree of flatness on the scraped cement arc surface. The right connecting end of the counterweight plate 7 is positioned and connected to the left wing plate of the bearing seat 4 via a positioning block 12.

[0037] Furthermore, the base 1 includes a square tube welded frame 103 and a bottom plate; the bottom plate is fixed to the bottom of the square tube welded frame; to enhance the rigidity and stability of the base, several reinforcing ribs 101 are provided on the outside of the square tube welded frame, and a cover 102 is welded to the upper surface of the square tube welded frame 103, forming a flat working platform, and the lower end of the fixed seat 2 is fixedly installed on this cover 102. Specifically, square steel tubes are welded into a sturdy rectangular frame, the bottom plate is welded to the bottom of the frame, and the reinforcing ribs 101 are welded to the outside of the frame, together forming a support structure with extremely high rigidity and not easily deformed.

[0038] The bottom plate of the base 1 is designed based on the rotation radius from the farthest end of the scraper 6 to the center of the rotating shaft 3, so as to provide sufficient support area for the entire tooling and thus ensure the stability of the tooling throughout the scraping process. The lower end of the fixed seat 2 is fixedly installed on the cover 102.

[0039] Furthermore, the bearing housing 4 is fitted onto the rotating shaft 3 by deep groove ball bearings 5 ​​installed at its upper and lower ends; an upper cover plate 13 and a lower cover plate 14 are respectively provided at the upper and lower ends of the mounting hole of the bearing housing 4, and the deep groove ball bearings 5 ​​are pressed between the upper cover plate 13 and the lower cover plate 14 to achieve axial positioning and sealing.

[0040] Furthermore, the inner ring of the deep groove ball bearing 5 is interference-fitted with the shaft 3, while its outer ring is clearance-fitted or transition-fitted with the bearing housing 4's seat hole to compensate for installation alignment errors and accommodate the deformation of the shaft 3 under heavy loads, while also facilitating on-site assembly and maintenance.

[0041] Furthermore, the rotating shaft 3 is a moving and load-bearing component of the tooling, and its strength and rigidity are required to be high. Therefore, in this embodiment, it is preferably made of 45 steel.

[0042] Furthermore, the working principle of this utility model is as follows: When specifically manufacturing the curved cement mold, this tooling is placed above a pre-prepared concrete base. By calculating and adding appropriate counterweights 11 to the counterweight plate 7, the lower edge of the scraper 6 is adjusted to the designed height. The drive bearing seat 4 slowly and uniformly rotates 360 degrees around the central axis of the rotating shaft 3. The rotating scraper 6 scrapes the concrete poured below, forming a smooth and precise spherical curved surface base. After the concrete has cured, the final mold for producing composite material radomes can be manufactured on this high-precision cement master mold through subsequent surface treatment, application of release agent, and gel coat processes.

[0043] Where there is no conflict, those skilled in the art can combine the relevant technical features in the above examples according to the actual situation to achieve the corresponding technical effects. Specific details of the various combinations will not be elaborated here.

[0044] It should be noted that all directional indicators (such as up, down, left, right, front, back, etc.) in this utility model embodiment are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicator will also change accordingly.

[0045] Furthermore, the use of terms such as "first" and "second" in this utility model is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features.

[0046] The above description is merely a preferred embodiment of the present invention. The present invention is not limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. Any simple modifications, equivalent variations, and alterations made to the above embodiments based on the technical essence of the present invention shall still fall within the scope of the present invention.

Claims

1. A tooling for manufacturing a large spherical radome arc surface mold, characterized in that: The system includes a base (1), a fixed seat (2), a rotating shaft (3), a bearing seat (4), a scraper (6), a positioning block (12), and a counterweight assembly. The fixed seat (2) is fixedly installed on the base (1). The rotating shaft (3) is vertically arranged and its lower end is adjustablely connected to the fixed seat (2). The bearing seat (4) is fitted onto the rotating shaft (3) and can rotate around the rotating shaft (3). The scraper (6) is fixedly connected to one side of the bearing seat (4), and its free end bottom edge forms a scraping edge. The outline of the scraping edge is an arc, and the center of the arc is located on the axis of the rotating shaft (3), so that when the bearing seat (4) rotates, the scraper (6) can scrape out a spherical arc surface. The counterweight assembly is fixedly connected to the bearing seat (4) on the other side opposite to the scraper (6) and is used to balance the gravitational torque when the scraper (6) is working.

2. The tooling for manufacturing a large spherical radome arc surface mold according to claim 1, characterized in that: The lower end of the rotating shaft (3) is screwed into the fixed seat (2) by a threaded connection. The initial height of the rotating shaft (3) is adjusted by changing the screwing depth, and it is locked and fixed by a round nut (10).

3. The tooling for manufacturing a large spherical radome arc surface mold according to claim 1, characterized in that: The bearing seat (4) is an integrally formed structure. Its main body is rectangular and has a mounting hole in the middle. The bearing seat (4) has outwardly extending wing plates (401) on the left and right sides. One wing plate (401) is used to install the scraper (6), and the other wing plate (401) is used to install the counterweight assembly.

4. The tooling for manufacturing a large spherical radome arc surface mold according to claim 3, characterized in that: A positioning block (12) is provided on each of the left and right wing plates (401) of the bearing housing (4); wherein the positioning block (12) on the left wing plate (401) is used to install and position the counterweight assembly, and the positioning block (12) on the right wing plate (401) is used to install and position the scraper (6).

5. The tooling for manufacturing a large spherical radome arc surface mold according to claim 4, characterized in that: The scraper (6) is engaged with the positioning block (12) by at least two positioning pins (9) to achieve precise positioning relative to the bearing seat (4); the scraper (6) is connected to the positioning block (12) by at least two screws (8) to press and fix it on the bearing seat (4).

6. The tooling for manufacturing a large spherical radome arc surface mold according to claim 4, characterized in that: The scraper (6) is welded with angle steel reinforcing ribs (601) and has weight reduction holes (602) and lifting holes (603).

7. The tooling for manufacturing a large spherical radome arc surface mold according to claim 5, characterized in that: The locating pin (9) and the screw (8) are arranged diagonally symmetrically on the connecting surface.

8. The tooling for manufacturing a large spherical radome arc surface mold according to claim 7, characterized in that: The positioning pin (9) and the screw (8) are both concentrated at the connection interface between the scraper (6) and the bearing seat (4), and are located in the area of ​​the interface closest to the axis of the rotating shaft (3).

9. The tooling for manufacturing a large spherical radome arc surface mold according to claim 8, characterized in that: The scraper (6) is made of stainless steel.

10. The tooling for manufacturing a large spherical radome arc surface mold according to claim 3, characterized in that: The counterweight assembly includes a counterweight plate (7) and a counterweight block (11). The counterweight plate (7) has a through hole for mounting the counterweight block (11). The right side connection end of the counterweight plate (7) is positioned and connected to the left side wing plate of the bearing seat (4) through a positioning block (12).

11. The tooling for manufacturing a large spherical radome arc surface mold according to claim 1, characterized in that: The base (1) includes a square tube welded frame (103) and a bottom plate; the bottom plate is fixed to the bottom of the square tube welded frame; the square tube welded frame (103) is provided with a number of reinforcing ribs (101) on the outside, and a cover (102) is welded to the upper surface of the square tube welded frame (103); the lower end of the fixing seat (2) is fixedly installed on the cover (102).

12. The tooling for manufacturing a large spherical radome arc surface mold according to claim 1, characterized in that: The bearing housing (4) is fitted onto the rotating shaft (3) by deep groove ball bearings (5) installed at its upper and lower ends; the upper and lower ends of the mounting holes of the bearing housing (4) are respectively provided with an upper cover plate (13) and a lower cover plate (14), and the deep groove ball bearing (5) is pressed between the upper cover plate (13) and the lower cover plate (14) to achieve axial positioning and sealing.

13. The tooling for manufacturing a large spherical radome arc surface mold according to claim 12, characterized in that: The inner ring of the deep groove ball bearing (5) is interference-fitted with the shaft (3), and its outer ring is clearance-fitted or transition-fitted with the seat hole of the bearing housing (4).

14. The tooling for manufacturing a large spherical radome arc surface mold according to claim 1, characterized in that: The shaft (3) is made of 45 steel.

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