Pillbox Window Collar Alignment for Stable Waveguide Welding
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Solution Overview
Problem
The existing sealing structures for pillbox windows, particularly those using Tig welding, are labor-intensive and time-consuming, leading to variations that adversely affect the electrical characteristics of electron tubes and accelerator tubes.
Innovation Solution
A pillbox window design incorporating a rotation regulation jig and torque application jig to precisely align and fix welding collars, ensuring accurate rotation and torque application during the welding process, thereby stabilizing the high-frequency transmission ratio (VSWR) and preventing misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Tig welding is used to seal waveguide tubes, then sealing reliability is improved, but assembly time and labor intensity increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-assembling the waveguide tubes with welding collars and performing alignment adjustments before the actual welding process. The collars are positioned and aligned in advance, allowing the welding to proceed without time-consuming adjustments during the welding operation itself, thus reducing total assembly time while maintaining sealing reliability.
Solution Approach 2:
The patent replaces manual measurement and alignment tools with a specialized fixture system that mechanically constrains and positions the welding collars. This fixture-based mechanical system eliminates the need for repeated measurements with levels and other instruments, significantly reducing assembly time while ensuring consistent alignment quality for reliable sealing.
2Manufacturing precision
If manual measurement and control methods are used during welding, then alignment precision can be achieved, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent introduces a specialized alignment fixture as an intermediary tool between the welding collars and the welding process. This fixture serves as a mediator that automatically maintains the correct angular relationship and position of the collars, eliminating the need for operators to perform complex manual measurements and calculations, thus improving ease of manufacture while maintaining alignment precision.
Solution Approach 2:
The patent changes the approach from controlling alignment through multiple measurement parameters (using levels and measurement instruments) to controlling alignment through a single geometric constraint system. The fixture defines the angular relationship through its physical geometry rather than through repeated measurements, simplifying the manufacturing process while maintaining precision.
3Adaptability or versatility
If welding collars are allowed to rotate during welding, then assembly flexibility is maintained, but misalignment occurs affecting electrical characteristics
Solution Approach 1:
The patent applies dynamics by designing a fixture system that provides controlled rigidity during welding while allowing for initial positioning adjustments. The fixture maintains the correct angular relationship throughout the welding process, preventing rotation, but allows operators to position components correctly before welding begins, thus balancing adaptability with precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the assembly process, reduces misalignment errors to less than 1°, and maintains the high-frequency transmission ratio within ±0.01 of the designed value, stabilizing the electrical characteristics and quality of the connected cavity.
Implementation Method 1
both the one welding collar and the other welding collar comprise holes formed in an entire portion along the circumferential direction, and a rotation regulation jig which fits into the holes of the one welding collar and the other welding collar
Implementation Method 2
there is a sealing structure made by Tig welding. In this welding process, waveguide tubes to be welded together are each provided with a welding collar, and the welding collars are fixed to each other by Tig welding
Implementation Method 3
The circular waveguide tube has a dielectric hermetic window (ceramic window) in its inner space, and the dielectric hermetic window compartmentalizes the introduction side and the lead-out side from each other
Data Source
AI summary
According to one embodiment, an introduction-side rectangular waveguide tube and a lead-out-side rectangular waveguide tube are each connected to a circular connection plate connected to an end surface of the circular waveguide tube, and at least one connection plate includes, in an outer circumference thereof, the other welding collar welded to the one welding collar, and both the one welding collar and the other welding collar include grooves or holes for a rotation regulation jig to regulate rotation in a circumferential direction, and an entire portion along the circumferential direction including the grooves or holes is welded and fixed thereto.