CN111509399A - Method for manufacturing integral large-area subreflector - Google Patents
Method for manufacturing integral large-area subreflector Download PDFInfo
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- CN111509399A CN111509399A CN202010353409.7A CN202010353409A CN111509399A CN 111509399 A CN111509399 A CN 111509399A CN 202010353409 A CN202010353409 A CN 202010353409A CN 111509399 A CN111509399 A CN 111509399A
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q15/00—Devices for reflection, refraction, diffraction or polarisation of waves radiated from an antenna, e.g. quasi-optical devices
- H01Q15/14—Reflecting surfaces; Equivalent structures
- H01Q15/141—Apparatus or processes specially adapted for manufacturing reflecting surfaces
- H01Q15/142—Apparatus or processes specially adapted for manufacturing reflecting surfaces using insulating material for supporting the reflecting surface
- H01Q15/144—Apparatus or processes specially adapted for manufacturing reflecting surfaces using insulating material for supporting the reflecting surface with a honeycomb, cellular or foamed sandwich structure
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q15/00—Devices for reflection, refraction, diffraction or polarisation of waves radiated from an antenna, e.g. quasi-optical devices
- H01Q15/14—Reflecting surfaces; Equivalent structures
- H01Q15/16—Reflecting surfaces; Equivalent structures curved in two dimensions, e.g. paraboloidal
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q19/00—Combinations of primary active antenna elements and units with secondary devices, e.g. with quasi-optical devices, for giving the antenna a desired directional characteristic
- H01Q19/10—Combinations of primary active antenna elements and units with secondary devices, e.g. with quasi-optical devices, for giving the antenna a desired directional characteristic using reflecting surfaces
- H01Q19/12—Combinations of primary active antenna elements and units with secondary devices, e.g. with quasi-optical devices, for giving the antenna a desired directional characteristic using reflecting surfaces wherein the surfaces are concave
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Abstract
The invention discloses a method for manufacturing an integral large-area subreflector, belonging to the technical field of precision machining. The method mainly comprises the main steps of preparing an auxiliary reflecting surface blank, roughly machining the auxiliary reflecting surface, reinforcing the blank, finely machining the auxiliary reflecting surface, measuring, coating and the like. The method of the invention realizes the integral manufacture of the large-area subreflector, effectively ensures the precision of the curved surface, improves the structural rigidity, reduces the deformation of the subreflector in use, has strong operability and is an important improvement on the prior art.
Description
Technical Field
The invention belongs to the technical field of antenna preparation, and particularly relates to a manufacturing method of an integral large-area subreflector.
Background
With the development of radio astronomy science and technology and the steady promotion of aerospace projects such as deep space exploration and the like in China, the matched large-caliber radio telescope antenna plays an increasingly important role in the space. Which is an important and widely used form of antenna. Reflective surface antennas come in many forms, such as cassegrain antennas, grignard antennas, ring focus antennas, and the like. Basically, the reflector antenna has three core structures of a main reflector, an auxiliary reflector and a feed source, and in use, electromagnetic wave signals are collected by the main reflector and reflected to the auxiliary reflector, and then are reflected to the feed source by the metal surface of the auxiliary reflector and received. In the process, the sub-reflecting surface plays a key role, and the shape precision and the surface quality of the sub-reflecting surface directly influence the performance of the antenna.
The caliber size of the main and auxiliary reflecting surfaces of the radio telescope approximately accords with the direct proportion relation of 10:1, for example, the caliber of the auxiliary reflecting surface of a 65-meter astronomical telescope in Shanghai is more than 6 meters, and the caliber of the auxiliary reflecting surface of a 40-meter antenna in Thailand is more than 3 meters. The larger the aperture, the larger the size of the sub-reflecting surface and the larger the weight. Since the sub-reflector is generally flip-chip mounted on the top of the antenna, the lighter the weight the better in order to achieve precise and complicated motion control. Therefore, in the manufacture of the large-area auxiliary reflecting surface, the shape precision of the auxiliary reflecting surface is required to be met, and the product quality is strictly controlled, so that the manufacture difficulty is greatly increased.
Some large-scale antenna subreflectors adopt a block combination mode. This approach requires the addition of a set of mechanisms to connect and adjust the individual segments, not only is weight not easily controlled but also results in loss of accuracy. There are also monolithic fabrication processes that employ composite materials. Generally, the precision of the composite material product is limited by the precision of the mold, namely the precision of the product is smaller than that of the mold, and the mold is machined by a metal material in a numerical control mode. The sub-reflecting surface of the integral metal processing is directly processed in a numerical control mode, which indicates that the precision of the composite material product is smaller than that of the product manufactured in the integral metal processing mode under the general condition.
Chinese patent publication No. CN103560331A discloses a large-caliber high-precision subreflector and a method for manufacturing the same, which mainly includes a top panel, an inner ring panel and an outer ring panel, wherein the inner ring panel is integrally formed by a spinning method, and the outer ring panel is formed by a drawing method. The method is suitable for the large-caliber high-precision auxiliary reflecting surface, the processing cost is low, the production efficiency is high, but the method belongs to a split type assembling method, and the precision is limited.
Disclosure of Invention
In order to solve the technical problems mentioned in the background technology, the invention provides a manufacturing method of an integral large-area subreflector, which can be used for integrally manufacturing and molding the large-area subreflector and has the characteristics of high precision, light weight and high reliability.
Based on the above purpose, the technical scheme provided by the invention is as follows:
a method for manufacturing an integral large-area subreflector comprises the following steps:
s1, drawing an ideal curved surface configuration of the front surface of the auxiliary reflecting surface, and casting an auxiliary reflecting surface blank according to the ideal curved surface configuration, wherein the front surface of the auxiliary reflecting surface blank is a cambered surface corresponding to the front surface of the auxiliary reflecting surface, the back surface of the auxiliary reflecting surface blank is a concave cavity, and the thickness of the auxiliary reflecting surface blank is two times to five times of the ideal curved surface configuration;
s2, machining a secondary surface by taking the cambered surface of the secondary reflection surface blank as a precision surface 1 and taking the concave cavity of the secondary reflection surface blank as the secondary surface, so as to form a back cavity 2 and a connecting cylinder 3 in the center of the back cavity;
s3, adding a foaming agent 6 into a back cavity space outside the connecting cylinder, then putting the sub-reflecting surface blank into a heat preservation furnace 5 in a back cavity upward posture, setting the furnace temperature at 50-70 ℃, preserving the heat for 3-5 hours, and taking out;
s4, cutting off the foaming agent higher than the opening surface of the back cavity, then installing a sealing cover plate 7 on the opening surface of the back cavity outside the connecting cylinder, and arranging a connecting piece for fixing the auxiliary reflecting surface on the antenna on the end surface of the connecting cylinder;
and S5, processing the precision surface to enable the curvature of the precision surface to be equal to the curvature of the ideal curved surface configuration.
Further, the following steps are included between step S2 and step S3: the method comprises the steps of presetting a plurality of concentric circular lines by taking the center of an subreflector blank as a circle center, enabling the distances between the adjacent circular lines to be equal, presetting a plurality of radial lines by taking the center of the subreflector blank as a starting point, enabling included angles between the adjacent radial lines to be equal, taking the intersection points of the radial lines and the circular lines as measurement point positions, and arranging a thickness measuring hole at each measurement point position.
Further, the specific process of step S5 is to process the precision surface of the subreflector blank multiple times, and measure the hole depth of each thickness measurement hole after each processing until the configuration of the precision surface conforms to the configuration of the ideal curved surface.
Further, in step S2, the sub-reflector blank needs to be subjected to a stress relief process, in which a heat treatment or a high-frequency vibration is used as a stress relief method.
As can be seen from the above description, the technical scheme of the invention has the beneficial effects that:
1. the technical scheme provided by the invention realizes the integral manufacture of the large-area subreflector, effectively ensures the curved surface precision and has strong operability.
2. The invention adopts a foaming and cover plate mode to effectively improve the structural rigidity and reduce the deformation of the auxiliary reflecting surface in use.
3. The method provided by the invention has certain universality and is not directed to a structural form.
4. The reasonable structure of the subreflector is designed. The large integral type subreflector is required to be uniform and reasonable in structure. The design and manufacture of the processing tool should be considered in the design process. The tool mainly comprises two types, namely a turning tool and a machining tool. The overturning tool is designed and manufactured depending on the use and installation positions of the auxiliary reflecting surfaces. The large-area metal aluminum alloy secondary surface has the weight of hundreds of kilograms or even tons, cannot be lifted by manpower, and can be lifted and turned over only by a crane or a chain block or other equipment. The processing tool is a clamping tool for precisely processing the front and back surfaces of the subreflector. By adopting the method, the precise processing of the heavy and minor surfaces can be realized.
5. In the embodiment, the selected sub-reflecting surface is in a Cassegrain antenna form and has a circularly symmetric structure, the maximum diameter of the sub-reflecting surface is 4 meters, the height of the sub-reflecting surface is 1 meter, and the sub-reflecting surface has a larger curved surface area and a larger volume. The designed sub-reflecting surface is shown in figures 1 and 2, the front surface is provided with a smooth precision surface 1, the back surface is provided with longitudinal and transverse reinforcing ribs which are distributed in a crossed manner to form an open back cavity 2, and the top in the middle of the back cavity is provided with a connecting cylinder surface 3. The structure has reasonable design, stable shape and high manufacturability;
drawings
Fig. 1 is a schematic view of the structure of a sub-reflecting surface in the embodiment of the present invention.
Fig. 2 is a structural perspective view of a sub-reflecting surface in an embodiment of the present invention.
FIG. 3 is a schematic illustration of a cast blank of a subreflector in an embodiment of the invention.
Fig. 4 is a schematic diagram of a foaming packaging process in an embodiment of the invention.
Fig. 5 is a schematic structural diagram of a finished product after processing is completed in the embodiment of the invention.
Description of reference numerals: the device comprises a precision surface 1, a back cavity 2, a connecting cylinder 3, a clamping plate 4, a holding furnace 5, a foaming agent 6 and a sealing cover plate 7.
Detailed Description
In order to facilitate understanding of the technical solutions of the present patent by those skilled in the art, and to make the technical objects, technical solutions and advantages of the present patent more apparent and fully support the scope of the claims, the technical solutions of the present patent are described in detail in the following embodiments.
A method for manufacturing an integral large-area subreflector comprises the following steps:
s1, drawing an ideal curved surface configuration of the front surface of the auxiliary reflecting surface, and casting an auxiliary reflecting surface blank according to the ideal curved surface configuration, wherein the front surface of the auxiliary reflecting surface blank is a cambered surface corresponding to the front surface of the auxiliary reflecting surface, the back surface of the auxiliary reflecting surface blank is a concave cavity, and the thickness of the auxiliary reflecting surface blank is two times to five times of the ideal curved surface configuration;
the method comprises the following specific steps:
preferentially preparing a turning tool and a processing tool, wherein the turning tool is designed and manufactured by depending on the use and installation position of the auxiliary reflecting surface. In the embodiment, the selected auxiliary surface has the weight of about one ton, and cannot be lifted manually, and the auxiliary surface can be turned only by turning the tool with the help of force. The processing tool is a supporting and clamping tool for processing the front and back surfaces of the subreflector,
casting aluminum alloy sub-reflecting surface blank. The post processing clamp plate 4 is reserved in a casting mode in the casting process, and is shown in figure 3. After casting, the whole blank is subjected to solid solution treatment, so that the strength of the material is improved.
S2, machining a secondary surface by taking the cambered surface of the secondary reflection surface blank as a precision surface 1 and taking the concave cavity of the secondary reflection surface blank as the secondary surface, so as to form a back cavity 2 and a connecting cylinder 3 in the center of the back cavity;
the method comprises the following specific steps:
the method comprises the steps of presetting a plurality of concentric circular lines by taking the center of an subreflector blank as a circle center, enabling the distances between the adjacent circular lines to be equal, presetting a plurality of radial lines by taking the center of the subreflector blank as a starting point, enabling included angles between the adjacent radial lines to be equal, taking the intersection points of the radial lines and the circular lines as measurement point positions, and arranging a thickness measuring hole at each measurement point position.
Roughly machining an auxiliary reflecting surface, wherein the front surface of an auxiliary reflecting surface blank is an arc surface corresponding to the front surface of the auxiliary reflecting surface, and the back surface of the auxiliary reflecting surface blank is a concave cavity, and machining secondary surfaces to form a back cavity and a connecting cylinder at the center of the back cavity; during processing, the connecting cylinder surface 3 and the back cavity are firstly processed. The plane serves as a size positioning reference for the whole sub-reflecting surface processing. All need to be left with proper allowance after rough machining.
After the processing is finished:
heat treatment destressing or high frequency vibration destressing. The method is carried out according to the parameters of the common cast aluminum alloy so as to remove the machining stress generated by rough machining.
And (5) finely machining the back cavity. And (4) processing the back cavity 2 of the auxiliary reflecting surface in place, comparing the ideal curved surface configuration, and removing all reserved thicknesses.
S3, adding a foaming agent 6 into a back cavity space outside the connecting cylinder, then putting the sub-reflecting surface blank into a heat preservation furnace 5 in a back cavity upward posture, setting the furnace temperature at 50-70 ℃, preserving the heat for 3-5 hours, and taking out;
the method comprises the following specific steps:
after the cavity structure 2 is processed in the back direction, the workpiece is turned over through the tool, and the precision surface 1 is processed. The machining needs to remove about 1/3 of the remaining margin, and excessive machining cannot be performed. The thickness of the curved surface needs to be detected in real time during processing, the processing is controlled, and the auxiliary reflecting surface blank is processed to ensure that the curvature of the auxiliary reflecting surface is equal to the configuration curvature of an ideal curved surface.
The method comprises the following specific steps:
the workpiece is vertically suspended through a turnover tool, and a high-pressure water gun is used for being matched with a deoiling agent and clear water to repeatedly wash the workpiece so as to remove oil stains. Turning over the back cavity 2 to the upper part, directly transferring the mixture into a heat preservation furnace 5, and pouring a foaming agent 6 which is mixed and uniformly stirred according to requirements into the back cavity 2 after drying, as shown in figure 4. Starting a heat preservation furnace after foaming is basically completed, setting the furnace temperature to be 50-70 ℃, preserving the heat for 3-5 hours, and taking out;
s4, cutting off the foaming agent higher than the opening surface of the back cavity, then installing a sealing cover plate 7 on the opening surface of the back cavity outside the connecting cylinder, and arranging a connecting piece for fixing the auxiliary reflecting surface on the antenna on the end surface of the connecting cylinder;
so that the foaming agent can fully react and expand. And (4) after foaming is finished. And (3) moving out of the heat preservation furnace, finishing the appearance of the foam, cutting off the foaming agent higher than the opening surface of the back cavity, then installing a sealing cover plate on the opening surface of the back cavity outside the connecting cylinder, arranging a connecting piece for fixing the auxiliary reflecting surface on the antenna on the end surface of the connecting cylinder to form a waterproof filling effect, and then installing and sealing a sealing cover plate 7. The sealing cover plate 7 is made of a 1.5mm hard aluminum thin plate. After the connection is finished, the seal cover plate 7 and the processing workpiece and the exposed part connected by each bolt are sealed by the south large-704 silicon rubber, so that the waterproof effect is achieved.
And S5, processing the precision surface to enable the curvature of the precision surface to be equal to the curvature of the ideal curved surface configuration.
And overturning the auxiliary reflecting surface to the curved surface upwards by utilizing an overturning tool. And meanwhile, the connecting cylinder surface 3 and the processing clamping plate 4 are fixed on a large numerical control machine tool, the precision surface of the subreflector blank is processed for multiple times, and the hole depth of each thickness measuring hole is measured after each processing is finished until the configuration of the precision surface conforms to the ideal curved surface configuration.
The curvature of the precision surface is equal to the curvature of the ideal curved surface configuration, and the machining clamp plate 4 is mechanically removed after machining is finished.
And S6, detecting, namely measuring the precision of the precision surface 1 by using a photogrammetric system, and performing coating protection after the precision is qualified, thereby finishing manufacturing.
In a word, the method greatly improves the feasibility of manufacturing the large-area antenna subreflector, changes the traditional split combination or airborne splicing mode, improves the manufacturing precision, ensures the manufacturing quality and is an important improvement on the prior art.
It should be understood that the above description of the embodiments of the present patent is only an exemplary description for facilitating the understanding of the patent scheme by the person skilled in the art, and does not imply that the scope of protection of the patent is only limited to these examples, and that the person skilled in the art can obtain more embodiments by combining technical features, replacing some technical features, adding more technical features, and the like to the various embodiments listed in the patent without any inventive effort on the premise of fully understanding the patent scheme, and therefore, the new embodiments are also within the scope of protection of the patent.
Furthermore, for the purpose of simplifying this description, this patent may not list some common embodiments, which will occur to those skilled in the art after understanding the present patent, and obviously, these embodiments should be included in the scope of the patent protection.
Any embodiment falling within the scope of the claims of the present patent is within the scope of the present patent, in combination with the interpretation of the claims by the specification.
Claims (4)
1. A method for manufacturing an integral large-area subreflector is characterized by comprising the following steps:
s1, drawing an ideal curved surface configuration of the front surface of the auxiliary reflecting surface, and casting an auxiliary reflecting surface blank according to the ideal curved surface configuration, wherein the front surface of the auxiliary reflecting surface blank is a cambered surface corresponding to the front surface of the auxiliary reflecting surface, the back surface of the auxiliary reflecting surface blank is a concave cavity, and the thickness of the auxiliary reflecting surface blank is two times to five times of the ideal curved surface configuration;
s2, machining a secondary surface by taking the cambered surface of the secondary reflection surface blank as a precision surface (1) and taking the concave cavity of the secondary reflection surface blank as a secondary surface, so as to form a back cavity (2) and a connecting cylinder (3) at the center of the back cavity;
s3, adding a foaming agent (6) into a back cavity space outside the connecting cylinder, then putting the sub-reflecting surface blank into a heat preservation furnace (5) in a back cavity upward posture, setting the furnace temperature to be 50-70 ℃, preserving the heat for 3-5 hours, and taking out;
s4, cutting off the foaming agent higher than the back cavity opening surface, then installing a sealing cover plate (7) on the back cavity opening surface outside the connecting cylinder, and arranging a connecting piece for fixing the sub-reflecting surface on the antenna on the end surface of the connecting cylinder;
and S5, processing the precision surface to enable the curvature of the precision surface to be equal to the curvature of the ideal curved surface configuration.
2. The method of claim 1, further comprising the following steps between step S2 and step S3:
the method comprises the steps of presetting a plurality of concentric circular lines by taking the center of an subreflector blank as a circle center, enabling the distances between the adjacent circular lines to be equal, presetting a plurality of radial lines by taking the center of the subreflector blank as a starting point, enabling included angles between the adjacent radial lines to be equal, taking the intersection points of the radial lines and the circular lines as measurement point positions, and arranging a thickness measuring hole at each measurement point position.
3. The method as claimed in claim 2, wherein the step S5 is performed by processing the precision surface of the sub-reflector blank multiple times, and measuring the depth of each thickness measuring hole after each processing until the configuration of the precision surface conforms to the ideal curved surface configuration.
4. The method as claimed in claim 1, wherein in step S2, the sub-reflector blank is further subjected to a stress relieving process, wherein the stress relieving process is performed by heat treatment or high frequency vibration.
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Inventor after: Li Zengke Inventor after: Liang Qian Inventor after: Li Jikang Inventor after: Cao Jiangtao Inventor after: Sun Dongwen Inventor after: Mao Guihai Inventor after: Wu Zhicai Inventor after: Sun Qi Inventor after: Niu Chuanfeng Inventor after: Zhang Wancai Inventor after: Zhao Junhong Inventor before: Cao Jiangtao Inventor before: Li Jikang Inventor before: Sun Dongwen Inventor before: Mao Guihai Inventor before: Wu Zhicai Inventor before: Sun Qi Inventor before: Niu Chuanfeng Inventor before: Zhang Wancai Inventor before: Zhao Junhong Inventor before: Liang Qian |
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