CN101673880B - Method for manufacturing antenna reflecting surface with aluminum skin honeycomb sandwich structure - Google Patents

Method for manufacturing antenna reflecting surface with aluminum skin honeycomb sandwich structure Download PDF

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Publication number
CN101673880B
CN101673880B CN200910075751A CN200910075751A CN101673880B CN 101673880 B CN101673880 B CN 101673880B CN 200910075751 A CN200910075751 A CN 200910075751A CN 200910075751 A CN200910075751 A CN 200910075751A CN 101673880 B CN101673880 B CN 101673880B
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edge sealing
inside panel
fitting
reflecting surface
built
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CN101673880A (en
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金超
李金良
王海东
宁晓磊
郭海鹰
张万才
陈宏辉
贺彩霞
党元兰
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CETC 54 Research Institute
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Abstract

The invention discloses a method for manufacturing an antenna reflecting surface with an aluminum skin honeycomb sandwich structure, which relates to a technology for manufacturing the antenna reflecting surface in the fields of satellite communication, radio measurement and control, deep space exploration, large radio telescopes and the like. The method adopts a high-precision enveloping mold for realizing the stretch forming of an inner skin and an outer skin, imposes the negative pressure through sealing and a vacuum device, presses and attaches the two layers of the skins, a honeycomb and other separating components on the mold, carries out adhesive curing and molding to form a whole by a bonding agent, and forms a high-precision aluminum skin honeycomb sandwich antenna reflecting surface unit after releasing vacuum negative pressure. The method has the advantages of high precision, light weight, great rigidness, great strength, simple processing technology, stable and reliable performances, low manufacturing cost, easy realization of production environment, mass production and the like, thereby being particular applicable to manufacturing the high-precision antenna reflecting surfaces above ka frequency band and Q frequency band.

Description

A kind of manufacturing approach of antenna reflecting surface with aluminum skin honeycomb sandwich structure
Technical field
The present invention relates to the manufacturing approach of a kind of antenna reflecting surface with aluminum skin honeycomb sandwich structure in the fields such as satellite communication, radio observing and controlling, survey of deep space, large-scale radio telescope.Be specially adapted to be operated in the reflecting surface batch manufacturing technology of the high-precision antenna panel more than Ka frequency range and the Q frequency range.
Background technology
Along with developing rapidly of communication, observation and control technology; Working frequency range is increasingly high; Precision to antenna reflective face is had higher requirement; Big-and-middle-sized antenna main reflector all is that tens even thousands of monolithic reflectings surface formations are arranged, and the precision of monolithic antenna reflective face is the basis of antenna main reflector precision.Mostly the manufacturing of antenna reflective face at present is the manufacturing process of continuity aircraft skin; Its monolithic reflecting surface generally adopts earlier behind drawing and forming on the stretching die; The process program of riveting molding on envelope riveting clamping tool again, there are shortcomings such as riveted joint stress is big, distortion is wayward in it, and reflector precision is low.
Chinese patent numbers 200510012407.7, name are called that to disclose a kind of honeycomb core material thickness in " a kind of method for manufacturing high-precision antenna reflector " patent be 3 to 10 millimeters antenna reflective face manufacturing approach, and the fatal shortcoming of 3 to 10 millimeters its aerial panels that bring of thickness of the honeycomb core material in this manufacturing approach is:
1. in the course of processing, exist stress deformation more outstanding, support frame panel low precision.The support frame panel is on support frame face riveted joint type frame, a Z section bar muscle beam and a support bone curved slab to be come moulding through riveted joint, in forming process, has riveted joint stress, causes the accuracy of manufacture poor.Simultaneously, the support frame panel rigidity is bigger, and skin curved panel thickness has only 0.5 millimeter, and rigidity is very poor, and covering rigidity is unbalance about causing at aluminium honeycomb place, is unfavorable for realizing high accuracy.
2. aluminium honeycomb core material thickness is less than normal.The honeycomb core material maximum ga(u)ge is 10 millimeters; Determined that the rigidity of comb core is very poor; Can't play the effect of enhanced rigidity; The cushioning effect of the honeycomb core material of mentioning in this invention relies on the retractility of honeycomb to remedy the gap such as height such as not grade between support frame panel and the skin curved panel, on practical applications, can't realize.
3. this invented technology cost is high, and except that having made skin surface stretching module tire, a support bone surface stretching module tire, this panel also will be made multiple mould tires such as Z section bar muscle beam stretch bending mould tire, support frame face riveted joint type frame; Increased manufacturing cost; Also have complex process, the process-cycle is long, and wayward operation is many; Be difficult to realize high accuracy, can't realize producing in batches shortcomings such as high accuracy panel.
Summary of the invention
The manufacturing approach that the objective of the invention is to avoid the weak point in the above-mentioned background technology and the antenna reflecting surface with aluminum skin honeycomb sandwich structure that a kind of precision is high, in light weight, bending stiffness is big, specific strength is big, specific stiffness is big is provided, and the antenna reflective face of the inventive method manufacturing has the precision height, rigidity is big, processing technology is simple, stable and reliable for performance, cheap for manufacturing cost, production environment is easy to realize, can produce, have characteristics such as practical value in batches.
The objective of the invention is to realize like this, the present invention includes step:
1. set up inside panel curved surface 1 Mathematical Modeling, according to the inside panel drawing die 2 of Mathematical Modeling design reflectivity face unit;
2. adopt aluminum alloy plate materials through quenching technical, on inside panel drawing die 2, adopt drawing process to constitute inside panel 3;
3. the concave curved surface with inside panel 3 is a datum level, moves 30 to 50 millimeters along normal convex surface direction and obtains exterior skin curved surface 4;
4. according to exterior skin curved surface 4, the exterior skin drawing die 5 of design reflectivity face unit;
5. adopt aluminum alloy plate materials through quenching technical, on exterior skin drawing die 5, adopt drawing process to constitute exterior skin 6;
6. according to the edge sealing curved surface of Mathematical Modeling design reflectivity face unit, adopt aluminum alloy plate materials to constitute edge sealing 7 through mechanical processing technique;
7. the edge sealing 7 according to Mathematical Modeling and reflecting surface unit designs edge sealing frocks 8;
8. according to Mathematical Modeling design corner dress built-in fitting 9-1, connection built-in fitting 9-2, adopt aluminum alloy plate materials to constitute angle dress built-in fitting 9-1, connect built-in fitting 9-2 through mechanical processing technique;
9. according to the overall dimension of exterior skin 6, adopt aluminum honeycomb material to constitute aluminium honeycomb core material 10 interlayers through mechanical processing technique;
10. on inside panel drawing die 2, inside panel 3 is pasted the mould location place, vacuumize through vacuum plant and make inside panel 3 subsides moulds; Edge sealing frock 8 is installed on the inside panel drawing die 2 through screw; Equal adhesive coating on inside panel 3 convex surfaces, edge sealing 7 medial surfaces, exterior skin 6 concave curved surfaces; Edge sealing 7 is placed on inside panel 3 convex surfaces, and the medial surface of the lateral surface of edge sealing 7 and edge sealing frock 8 fits tightly, and edge sealing 7 is positioned on inside panel 3 convex surfaces; Aluminium honeycomb core material 10, angle dress built-in fitting 9-1, connection built-in fitting 9-2 are placed on inside panel 3 convex surfaces; The concave curved surface of exterior skin 6 is placed in edge sealing 7, aluminium honeycomb core material 10, angle dress built-in fitting 9-1, connects on the surface of built-in fitting 9-2;
is on inside panel drawing die 2; Inside panel 3 after settling, exterior skin 6, edge sealing 7, edge sealing frock 8, angle dress built-in fitting 9-1, connection built-in fitting 9-2, aluminium honeycomb core material 10 are sealed in the vacuum bag, adopt the bonding curing of negative pressure of vacuum technology to constitute reflecting surface unit 15;
removes edge sealing frock 8 with the reflecting surface unit after the bonding curing 15; Apply sealant and constitute sealant 14 at edge sealing 7 and inside panel 3, exterior skin 6 bonding seam crossings, accomplish antenna reflecting surface with aluminum skin honeycomb sandwich structure unit 15 and make.
The inside panel 3 of antenna reflecting surface with aluminum skin honeycomb sandwich structure of the present invention unit 15 or the thickness of exterior skin 6 are 0.5 to 1.5 millimeter; The sheet metal thickness of edge sealing 7 is 0.5 millimeter to 1.0 millimeters; The sheet metal thickness of built-in fitting 9 is 0.5 to 5 millimeter; The thickness of aluminium honeycomb core material 10 is 30 to 50 millimeters.
The present invention compares with background technology has following advantage:
1. the present invention has overcome the deficiency of conventional fabrication processes; Adopted ripe mould tire stretching covering and aluminium honeycomb core material adhesive structure form, in the high accuracy antenna reflecting surface with aluminum skin honeycomb sandwich structure 15 that is shaped, inside panel 3, exterior skin 6 and aluminium honeycomb core material 10 are through the bonding formation of adhesive rigidity in light weight, high, a integral body that reliability is high; The work reflecting surface of making not only precision is high; Rigidity is big, and reliability is high, and in light weight; Cost is low, adapts to the reflector antenna of various forms and bore.
2. the present invention has overcome the deficiency of conventional fabrication processes; Eliminated internal stress to greatest extent; Be not employed in the staking process on the riveting clamping tool, removed riveting dress stress, inside panel 3 all adopts aluminum alloy plate materials on high accuracy mould tire, to stretch with exterior skin 6 and forms; Plastic deformation has taken place in aluminum alloy plate materials in technical process, has eliminated that aluminum alloy plate materials becomes not deployable parabola or hyperboloid by the plane and the internal stress and the resilience stress that produce.
3. the edge sealing 7 of the present invention's design, angle dress built-in fitting 9-1, connection built-in fitting 9-2 have effectively increased the intensity of antenna reflective face, have improved the reliability of antenna reflective face, and angle dress built-in fitting 9-1 has increased adhesive strength in the reflecting surface unit; Play anti-effect of peeling off; In the connector Position Design of reflecting surface and back of the body frame be connected built-in fitting 9-2, improved the intensity of stressed position, edge sealing 7 interosculates with sealant 14; Increase the sealing of antenna reflective face, improved product useful life.
4. the present invention realizes the stretch forming of covering and the bonding shaping of covering and aluminium honeycomb core material through high-precision envelope mould, seals and applies negative pressure of vacuum through vacuum bag, and making separation assemblies such as inside panel 3, exterior skin 6, comb core 10, edge sealing 7, built-in fitting 9 is an integral body by the bonding agent solidification by cement; Constitute antenna reflective face, realize that reflecting surface is shaped under little rigidity, finalize the design under the big rigidity; The work reflecting surface of making not only precision is high, and rigidity is big, and reliability is high; And in light weight, cost is low, and operational sequence is simple; Environment is easy to realize, is fit to very much produce in batches, has the engineering application value.
Description of drawings
Fig. 1 is the manufacturing process flow diagram of most preferred embodiment of the present invention.
Among Fig. 1: 1 is that inside panel curved surface, 2 is that inside panel drawing die, 3 is that inside panel, 4 is that exterior skin curved surface, 5 is that exterior skin drawing die, 6 is that exterior skin, 7 is that edge sealing, 8 is that edge sealing frock, 9-1 are that built-in fitting is adorned at the angle, 9-2 is that connection built-in fitting, 10 is that aluminium honeycomb core material, 15 is the antenna reflective face unit.
Embodiment
With reference to Fig. 1, most preferred embodiment of the present invention is as shown in Figure 1, comprises the following steps:
1. set up inside panel curved surface 1 Mathematical Modeling, according to the inside panel drawing die 2 of Mathematical Modeling design reflectivity face unit.Antenna inside panel curved surface 1 can be arbitrary curved surface, generally is assemblied to form by being divided into the adjustment of multiple less reflecting surface unit, adopts same drawing die manufacturing with a kind of reflecting surface unit.Embodiment inside panel drawing die 2 adopts cast iron materials, and the surface becomes the enveloping surface of high accuracy inside panel through digital control processing, like Fig. 1-1.
2. adopt aluminum alloy plate materials through quenching technical, on inside panel drawing die 2, adopt drawing process to constitute inside panel 3.Inside panel 3 is reflecting surface unit of antenna reflective face, and thickness is 0.5 millimeter to 1.5 millimeters, and embodiment inside panel 3 adopts the aluminum alloy plate materials of 1 millimeters thick after quenching, and is drawn into inside panel 3, and its surface adopts phosphoric acid to handle, like Fig. 1-2.
3. the concave curved surface with inside panel 3 is a datum level, moves 30 to 50 millimeters along normal convex surface direction and obtains exterior skin curved surface 4, and embodiment exterior skin curved surface 4 moves 50 millimeters along normal convex surface direction, like Fig. 1-3.
4. according to exterior skin curved surface 4, the exterior skin drawing die 5 of design reflectivity face unit.This mould can be resin glue sand mo(u)ld tool, uses wooden carcass, and the top layer is an epoxy resin; Adopting model to scrape type is made; Have precision high, be easy to regular maintenance, can effectively reduce advantage such as cost of manufacture, embodiment exterior skin drawing die 5 is a resin glue sand mo(u)ld tool, like Fig. 1-4.
5. adopt aluminum alloy plate materials through quenching technical, on exterior skin drawing die 5, adopt drawing process to constitute exterior skin 6.Exterior skin 6 is inoperative reflectings surface of antenna reflective face, and thickness is 0.5 millimeter to 1.5 millimeters, and embodiment exterior skin 6 adopts the aluminum alloy plate materials of 1 millimeters thick after quenching, and is drawn into exterior skin 6, and its surface adopts phosphoric acid to handle, like Fig. 1-5.
6. according to the edge sealing curved surface of Mathematical Modeling design reflectivity face unit, adopt aluminum alloy plate materials to constitute edge sealing 7 through mechanical processing technique.Edge sealing 7 can adopt the material identical with covering, also can adopt materials such as rustproof aluminum alloy, and edge sealing 7 sheet metal thicknesses are 0.5 millimeter to 1.0 millimeters, and effect is that the reflecting surface unit is sealed, and increases the useful life of reflecting surface unit.Embodiment edge sealing 7 adopts the aluminum alloy plate materials of 1 millimeters thick, is made through digital control processing, and the surface adopts phosphoric acid to handle, like Fig. 1-6.
7. the edge sealing 7 according to Mathematical Modeling and reflecting surface unit designs edge sealing frocks 8.Edge sealing frock 8 had both played the positioning action of edge sealing 7, also played the aluminium honeycomb core material compressed effect in forming process that prevents, embodiment edge sealing frock 8 adopts the cast aluminium material, is made through digital control processing, like Fig. 1-7.
8. according to Mathematical Modeling design corner dress built-in fitting 9-1, connection built-in fitting 9-2, adopt aluminum alloy plate materials to constitute angle dress built-in fitting 9-1, connect built-in fitting 9-2 through mechanical processing technique.Angle dress built-in fitting 9-1 is placed in four bights of reflecting surface unit, in the reflecting surface unit, has increased adhesive strength, plays anti-effect of peeling off; In the connector Position Design of exterior skin 6 connection built-in fitting 9-2; Improved the intensity of stressed position; The sheet metal thickness of built-in fitting 9 is 0.5 to 5 millimeter, and embodiment angle dress built-in fitting 9-1 adopts the aluminum alloy plate materials of 1 millimeters thick to be processed into the built-in fitting of pentagonal configuration, connects built-in fitting 9-2 and adopts the aluminum alloy plate materials of 3 millimeters thick to be processed into the built-in fitting of " worker " word structure; Its surface all adopts phosphoric acid to handle, like Fig. 1-8.
9. according to the overall dimension of exterior skin 6, adopt aluminum honeycomb material to constitute aluminium honeycomb core material 10 interlayers through mechanical processing technique.The thickness of aluminium honeycomb core material has determined the rigidity of reflecting surface unit, and high rigidity is to realize high-precision essential condition, and the thickness of aluminium honeycomb core material is 30 to 50 millimeters; Embodiment aluminium honeycomb core material 10 is 0.05 millimeter for aluminum foil thickness; The hole lattice length of side is 5 millimeters, and honeycomb thickness is 50 millimeters, like Fig. 1-9.
10. on inside panel drawing die 2, inside panel 3 is pasted the mould location place, vacuumize through vacuum plant and make inside panel 3 subsides moulds; Edge sealing frock 8 is installed on the inside panel drawing die 2 through screw; Adhesive coating constitutes adhesive linkage 11 on inside panel 3 convex surfaces, and adhesive coating constitutes adhesive coating formation adhesive linkage 13 on adhesive linkage 12, exterior skin 6 concave curved surfaces on edge sealing 7 medial surfaces; Edge sealing 7 is placed on inside panel 3 convex surfaces, and the medial surface of the lateral surface of edge sealing 7 and edge sealing frock 8 fits tightly, and edge sealing 7 is positioned on inside panel 3 convex surfaces; Aluminium honeycomb core material 10, angle dress built-in fitting 9-1, connection built-in fitting 9-2 are placed on inside panel 3 convex surfaces; The concave curved surface of exterior skin 6 is placed in edge sealing 7, aluminium honeycomb core material 10, angle dress built-in fitting 9-1, connects on the built-in fitting 9-2 surface; The embodiment adhesive adopts J-133B (AE II) type glue to carry out bonding; Thickness of adhibited layer is 0.3 millimeter; The thickness of adhesive linkage has guaranteed the adhesive strength of each parts, like Fig. 1-10.
is on inside panel drawing die 2; Inside panel 3 after settling, exterior skin 6, edge sealing 7, edge sealing frock 8, angle dress built-in fitting 9-1, connection built-in fitting 9-2, aluminium honeycomb core material 10 are sealed in the vacuum bag, adopt the bonding curing of negative pressure of vacuum technology to constitute reflecting surface unit 15.The embodiment adhesive is through solidifying, and reaches to discharge negative pressure of vacuum after setting intensity, realizes that the reflecting surface unit is shaped under little rigidity, finalizes the design under the big rigidity.
removes edge sealing frock 8 with the reflecting surface unit after the bonding curing 15; Apply sealant and constitute sealant 14 at edge sealing 7 and inside panel 3, exterior skin 6 bonding seam crossings, accomplish the antenna reflective face unit 15 of aluminum skin honeycomb sandwich structure and make.Embodiment applies HM108A4 type sealant and constitutes sealant 14 at edge sealing 7 and inside panel 3, exterior skin 6 bonding seam crossings; Prevent entering reflecting surface destruction adhesive strengths such as steam; Can improve product useful life; To be sealed dose with the adhesive full solidification after, accomplish the manufacturing of high accuracy antenna reflecting surface with aluminum skin honeycomb sandwich structure unit 15, like Fig. 1-11.
The artificial same applicant of the invention of inventor of the present invention and Chinese patent 200510012407.7; The biggest characteristic difference mainly is the parameter change of honeycomb interlayer gauge between two inventions; The minimum thickness of honeycomb interlayer of the present invention is 30 millimeters; And the maximum ga(u)ge of 200510012407.7 patent honeycomb interlayers is 10 millimeters; The deficiency that the too thin manufacturing high accuracy of its honeycomb interlayer thickness reflecting surface is caused has been set forth in background technology; This patent can not be as practical applications, so the patent of invention that the inventor of this 200510012407.7 patent has applied for again that Chinese patent number is 200610012581.6, name is called " a kind of method for manufacturing high-precision antenna reflector that does not have honeycomb interlayer " realizes the manufacturing of high accuracy panel.The present invention brings up to the thickness of honeycomb interlayer more than 30 millimeters; Overcome the patent No. and be deficiency and a difficult problem that 200510012407.7 invention can't realize practical applications; Obtained unexpected effect, on engineering, obtained to use widely, in commercial achieving success.

Claims (2)

1. the manufacturing approach of an antenna reflecting surface with aluminum skin honeycomb sandwich structure comprises step:
1. set up inside panel curved surface (1) Mathematical Modeling, according to the inside panel drawing die (2) of Mathematical Modeling design reflectivity face unit;
2. adopt aluminum alloy plate materials through quenching technical, go up at inside panel drawing die (2) and adopt drawing process to constitute inside panel (3);
3. the concave curved surface with inside panel (3) is a datum level, moves 30 to 50 millimeters along normal convex surface direction and obtains exterior skin curved surface (4);
4. according to exterior skin curved surface (4), the exterior skin drawing die (5) of design reflectivity face unit;
5. adopt aluminum alloy plate materials through quenching technical, go up at exterior skin drawing die (5) and adopt drawing process to constitute exterior skin (6);
It is characterized in that this method also comprises step:
6. according to the edge sealing curved surface of Mathematical Modeling design reflectivity face unit, adopt aluminum alloy plate materials to constitute edge sealing (7) through mechanical processing technique;
7. the edge sealing (7) according to Mathematical Modeling and reflecting surface unit designs edge sealing frock (8);
8. according to Mathematical Modeling design corner dress built-in fitting (9-1), connection built-in fitting (9-2), adopt aluminum alloy plate materials to constitute angle dress built-in fitting (9-1), connect built-in fitting (9-2) through mechanical processing technique;
9. according to the overall dimension of exterior skin (6), adopt aluminum honeycomb material to constitute aluminium honeycomb core material (10) interlayer through mechanical processing technique; The thickness of aluminium honeycomb core material (10) is 30 to 50 millimeters;
10. on inside panel drawing die (2), inside panel (3) is pasted the mould location place, vacuumize through vacuum plant and make inside panel (3) subsides mould; Edge sealing frock (8) is installed on the inside panel drawing die (2) through screw; Equal adhesive coating on inside panel (3) convex surface, edge sealing (7) medial surface, exterior skin (6) concave curved surface; Edge sealing (7) is placed on inside panel (3) convex surface, and the medial surface of the lateral surface of edge sealing (7) and edge sealing frock (8) fits tightly, and edge sealing (7) is positioned on inside panel (3) convex surface; Aluminium honeycomb core material (10), angle dress built-in fitting (9-1), connection built-in fitting (9-2) are placed on inside panel (3) convex surface; The concave curved surface of exterior skin (6) is placed in edge sealing (7), aluminium honeycomb core material (10), angle dress built-in fitting (9-1), connects on the surface of built-in fitting (9-2);
is on inside panel drawing die (2); Inside panel (3) after settling, exterior skin (6), edge sealing (7), edge sealing frock (8), angle dress built-in fitting (9-1), connection built-in fitting (9-2), aluminium honeycomb core material (10) are sealed in the vacuum bag, adopt the bonding curing of negative pressure of vacuum technology to constitute reflecting surface unit (15);
removes edge sealing frock (8) with the reflecting surface unit (15) after the bonding curing; Apply sealant and constitute sealant (14) at edge sealing (7) and inside panel (3), the bonding seam crossing of exterior skin (6), accomplish antenna reflecting surface with aluminum skin honeycomb sandwich structure unit (15) and make.
2. the manufacturing approach of a kind of antenna reflecting surface with aluminum skin honeycomb sandwich structure according to claim 1, it is characterized in that: the inside panel (3) of antenna reflecting surface with aluminum skin honeycomb sandwich structure unit (15) or the thickness of exterior skin (6) are 0.5 to 1.5 millimeter; The sheet metal thickness of edge sealing (7) is 0.5 millimeter to 1.0 millimeters; The sheet metal thickness of built-in fitting (9) is 0.5 to 5 millimeter.
CN200910075751A 2009-10-21 2009-10-21 Method for manufacturing antenna reflecting surface with aluminum skin honeycomb sandwich structure Active CN101673880B (en)

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