CN115070243A - Welding method for reliable welding of dual-polarized microstrip antenna - Google Patents
Welding method for reliable welding of dual-polarized microstrip antenna Download PDFInfo
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- CN115070243A CN115070243A CN202210703431.9A CN202210703431A CN115070243A CN 115070243 A CN115070243 A CN 115070243A CN 202210703431 A CN202210703431 A CN 202210703431A CN 115070243 A CN115070243 A CN 115070243A
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- 238000003466 welding Methods 0.000 title claims abstract description 151
- 238000000034 method Methods 0.000 title claims abstract description 68
- 238000013461 design Methods 0.000 claims abstract description 40
- 239000000463 material Substances 0.000 claims abstract description 21
- 238000009826 distribution Methods 0.000 claims abstract description 8
- 238000004088 simulation Methods 0.000 claims description 38
- 238000004458 analytical method Methods 0.000 claims description 24
- 238000011156 evaluation Methods 0.000 claims description 23
- 238000004364 calculation method Methods 0.000 claims description 9
- 238000005094 computer simulation Methods 0.000 claims description 4
- 238000012937 correction Methods 0.000 claims description 3
- 238000005336 cracking Methods 0.000 claims description 3
- 230000009977 dual effect Effects 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- 229910000679 solder Inorganic materials 0.000 abstract description 9
- 238000012360 testing method Methods 0.000 abstract description 8
- 238000012544 monitoring process Methods 0.000 abstract description 3
- 230000035882 stress Effects 0.000 description 14
- 238000010586 diagram Methods 0.000 description 6
- CSDREXVUYHZDNP-UHFFFAOYSA-N alumanylidynesilicon Chemical compound [Al].[Si] CSDREXVUYHZDNP-UHFFFAOYSA-N 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 229910000838 Al alloy Inorganic materials 0.000 description 2
- 238000001514 detection method Methods 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 238000003801 milling Methods 0.000 description 2
- 238000005457 optimization Methods 0.000 description 2
- 230000035515 penetration Effects 0.000 description 2
- 239000002210 silicon-based material Substances 0.000 description 2
- 238000005476 soldering Methods 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- 230000008646 thermal stress Effects 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
- 229910000676 Si alloy Inorganic materials 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 230000002452 interceptive effect Effects 0.000 description 1
- 230000002427 irreversible effect Effects 0.000 description 1
- LQBJWKCYZGMFEV-UHFFFAOYSA-N lead tin Chemical compound [Sn].[Pb] LQBJWKCYZGMFEV-UHFFFAOYSA-N 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000000059 patterning Methods 0.000 description 1
- 238000011056 performance test Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 238000005493 welding type Methods 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
Abstract
The invention discloses a welding method for reliable welding of a dual-polarized microstrip antenna, which can realize prediction of welding reliability in a design stage, greatly reduce the fault probability of welding a physical sample and improve the design quality. Meanwhile, the temperature in the welding process, and the stress, strain and deformation values and distribution of the microstrip plate, the structural plate and the connector can be observed in real time, the conditions that stress data cannot be obtained and temperature monitoring points are few due to limited test in a closed space are remedied, and data reference can be provided for later-stage improved process design. In addition, the design method provided by the invention is suitable for the process design of the complex antenna unit, is not influenced by the shape of a test piece, the diversity of materials and the type of solder, and can be applied to the design of various micro-strip antenna units such as missile-borne, satellite-borne and airborne antennas.
Description
Technical Field
The invention relates to the technical field of dual-polarized microstrip antenna welding, in particular to a welding method for reliably welding a dual-polarized microstrip antenna.
Background
Compared with the traditional waveguide antenna, the microstrip antenna has the advantages of small volume, light weight, easiness in realizing the conformal effect with the surface of a carrier and the integration with an active device and a circuit, wide application prospect in military and civil fields, narrow bandwidth, low power of a single microstrip antenna and the like, and limits the application of the microstrip antenna technology. With the development of microstrip antenna technology and the increasing application demand, other antenna design modes are derived, wherein dual-polarized microstrip antennas are the most important antennas, the defects of the microstrip antennas are overcome by the antenna, two non-interfering orthogonally polarized electromagnetic waves can be transmitted simultaneously, a pair of orthogonally polarized ports are used as a receiving end and a transmitting end respectively, and the performance of the antenna is greatly improved.
The dual-polarized microstrip antenna generally comprises components such as a microstrip plate, a connector, a structural member and the like, and the electrical property of the whole antenna array surface is directly influenced by the shape after welding. The dual-polarized microstrip antenna often has the characteristics of large welding breadth, multiple material systems, complex welding relation and the like, and more than two types of welding materials can be involved in one antenna structure, so that the welding implementation difficulty is high, and the welding quality is difficult to ensure. The traditional microstrip antenna welding process design mainly refers to specifications and experiences and verifies the reliability of the process design through welding of a physical sample piece. For the design of the dual-polarized microstrip antenna, which is compact in structure, multiple in welding surface, various in materials and high in requirement on accuracy of the shape after welding, a corresponding prediction method for reliability of a welding process is lacked, so that reliable antenna products can be obtained only by multiple times of physical sample welding and process optimization, the number of design iterations is increased, and the development period is prolonged.
Disclosure of Invention
In order to solve the technical problems in the background technology, the invention provides a welding method for reliably welding a dual-polarized microstrip antenna.
The invention provides a welding method for reliably welding a dual-polarized microstrip antenna, which comprises the following steps of:
s1, performing initial design of a welding process according to the design structure of the dual-polarized microstrip antenna;
s2, carrying out simulation modeling according to the structure, process design and actual implementation conditions of welding of the dual-polarized microstrip antenna;
s3, carrying out temperature field simulation analysis, stress field and deformation analysis by using the simulation model;
s4, carrying out simulation model rationality evaluation, and carrying out model correction according to the analysis result in S3;
s5, performing preliminary evaluation on welding reliability;
s6, optimizing the welding process and performing iterative simulation evaluation;
and S7, welding the antenna physical sample piece, and detecting the welding quality of the physical sample piece.
Preferably, the method further comprises S8, and when the welding quality of the physical sample meets the preset requirement, the physical sample is subjected to an electrical property test.
Preferably, when the welding quality of the physical sample does not meet the preset requirement, returning to the step S6, and optimizing the welding process through simulation until the welded quality of the physical sample meets the requirement.
Preferably, in S3, the temperature field simulation analysis specifically includes: and acquiring the temperature value of the dual-polarized microstrip antenna through temperature calculation according to the corresponding temperature boundary loaded by the heating furnace body.
Preferably, in S4, the performing the simulation model rationality evaluation specifically includes: and self-evaluating the simulation model according to the distribution conditions of the stress and deformation calculation results, wherein the self-evaluation comprises unit grids and relevant parameters of boundary conditions.
Preferably, in S5, the performing of the preliminary evaluation of the welding reliability specifically includes one or more of the reliability evaluation criteria of no structural damage, no plastic deformation of the mounting board, a warp of the micro-strip board of less than 0.75%, and no cracking of the welding spot.
Preferably, in S6, the optimizing the welding process and performing the iterative simulation evaluation specifically includes: and optimizing the aspects of material selection, temperature curve setting and tooling.
Preferably, in S3, before the temperature field simulation analysis is performed using the simulation model described above, a finite element model is built from the three-dimensional design model.
Preferably, stress and deformation analysis of the antenna element is performed based on the temperature field analysis result.
According to the welding method for reliably welding the dual-polarized microstrip antenna, the welding reliability can be predicted in the design stage, the fault probability of welding a physical sample piece is greatly reduced, and the design quality is improved. Meanwhile, the temperature in the welding process, and the stress, strain and deformation values and distribution of the microstrip plate, the structural plate and the connector can be observed in real time, the conditions that stress data cannot be obtained and temperature monitoring points are few due to limited test in a closed space are remedied, and data reference can be provided for later-stage improved process design. In addition, the design method provided by the invention is suitable for the process design of the complex antenna unit, is not influenced by the shape of a test piece, the diversity of materials and the type of solder, and can be applied to the design of various microstrip antenna units such as missile-borne, satellite-borne, airborne and the like.
Drawings
Fig. 1 is a schematic structural diagram of an antenna unit in an embodiment of a welding method for reliably welding a dual-polarized microstrip antenna according to the present invention.
Fig. 2 is a deformation curve diagram of an antenna unit mounting plate obtained by an initial welding process simulation in the first embodiment of the welding method for reliably welding the dual-polarized microstrip antenna provided by the invention.
Fig. 3 is a deformation curve diagram of an antenna unit mounting plate obtained by simulation of an optimized welding process in the first embodiment of the welding method for reliably welding the dual-polarized microstrip antenna provided by the invention.
Fig. 4 is a schematic structural diagram of an antenna unit in a second embodiment of the welding method for reliably welding the dual-polarized microstrip antenna according to the present invention.
Detailed Description
As shown in fig. 1 to 4, fig. 1 is a schematic structural diagram of an antenna unit in a first embodiment of a welding method for reliable welding of a dual-polarized microstrip antenna provided by the present invention, fig. 2 is a deformation curve graph of an antenna unit mounting plate obtained by an initial welding process simulation in a first embodiment of a welding method for reliable welding of a dual-polarized microstrip antenna provided by the present invention, fig. 3 is a deformation curve graph of an antenna unit mounting plate obtained by a welding process simulation after optimization in a first embodiment of a welding method for reliable welding of a dual-polarized microstrip antenna provided by the present invention, and fig. 4 is a schematic structural diagram of an antenna unit in a second embodiment of a welding method for reliable welding of a dual-polarized microstrip antenna provided by the present invention.
The invention provides a welding method for reliably welding a dual-polarized microstrip antenna, which comprises the following steps of:
s1, performing initial design of a welding process according to the design structure of the dual-polarized microstrip antenna;
s2, carrying out simulation modeling according to the structure, process design and actual implementation conditions of welding of the dual-polarized microstrip antenna;
s3, carrying out temperature field simulation analysis, stress field and deformation analysis by using the simulation model;
specifically, before the temperature field simulation analysis is performed by using the simulation model, a finite element model is established according to the three-dimensional design model. Wherein, the temperature field simulation analysis specifically comprises: and acquiring the temperature value of the dual-polarized microstrip antenna through temperature calculation according to the corresponding temperature boundary loaded by the heating furnace body. Further, stress and deformation analysis of the antenna unit is performed based on the temperature field analysis result.
S4, carrying out simulation model rationality evaluation, and carrying out model correction according to the analysis result in S3;
specifically, the performing of the simulation model rationality evaluation specifically includes: and self-evaluating the simulation model according to the distribution conditions of the stress and deformation calculation results, wherein the self-evaluation comprises unit grids and relevant parameters of boundary conditions.
S5, performing preliminary evaluation on welding reliability;
specifically, the preliminary evaluation of the welding reliability is carried out by one or more of the reliability evaluation standards of no structural damage, no plastic deformation of the mounting plate, a warp degree of the microstrip board lower than 0.75%, and no cracking of the welding spot.
S6, optimizing the welding process and performing iterative simulation evaluation;
specifically, the optimizing the welding process and performing the iterative simulation evaluation specifically includes: and optimizing the aspects of material selection, temperature curve setting and tooling.
And S7, welding the antenna physical sample piece, and detecting the welding quality of the physical sample piece.
The welding method for reliably welding the dual-polarized microstrip antenna further comprises S8, and when the welding quality of the physical sample meets the preset requirement, the physical sample is subjected to an electrical performance test.
In a specific embodiment, when the welding quality of the physical sample does not meet the preset requirement, returning to the step S6, and optimizing the welding process through simulation until the post-welding quality of the physical sample meets the requirement.
In this embodiment, the proposed welding method for reliable welding of the dual-polarized microstrip antenna can realize prediction of welding reliability in a design stage, greatly reduce the failure probability of welding a physical sample, and improve the design quality. Meanwhile, the temperature in the welding process, and the stress, strain and deformation values and distribution of the microstrip plate, the structural plate and the connector can be observed in real time, the conditions that stress data cannot be obtained and temperature monitoring points are few due to limited test in a closed space are remedied, and data reference can be provided for later-stage improved process design. In addition, the design method provided by the invention is suitable for the process design of the complex antenna unit, is not influenced by the shape of a test piece, the diversity of materials and the type of solder, and can be applied to the design of various micro-strip antenna units such as missile-borne, satellite-borne and airborne antennas.
The following describes the welding method for reliably welding the dual-polarized microstrip antenna of the present embodiment in two embodiments.
Example one
As shown in fig. 1, the welding implementation of the present embodiment mainly relates to the dual polarized antenna elements. The antenna unit consists of a microstrip board 1, a microstrip board 2, a radio frequency connector 3 and a mounting board 4.
The microstrip plate 1 and the microstrip plate 2 are both multilayer junctionsThe structure is manufactured by the steps of drilling, perforating, patterning, pressing, milling and the like on a substrate material, the substrate is made into a multilayer board by selecting a domestic substitute material CF294, and the thermal expansion coefficient is 1.3(X)/1.5(Y)/3 (Z). times.10 -5 and/K. The mounting plate is made of aluminum alloy (5A06AL) and is processed and formed, and the thermal expansion coefficient of the material is 2.3 multiplied by 10 < -5 >/K. When the antenna unit is welded, welding between the microstrip plate 1 and the mounting plate 4, welding between the microstrip plate 2 and the mounting plate 4, welding between the radio frequency connector 3 and the microstrip plate 2 need to be considered at the same time, welding forming needs to be carried out at one time, a welding medium is a tin-lead soldering lug (Sn63Pb37), a large number of welding objects are needed, and welding difficulty is high. The welding needs to be positioned by means of a tool 5, the material is stainless steel, and the thermal expansion coefficient is 1.5 multiplied by 10 -5 And the tool is connected with the mounting plate 5 through screws.
The welding is carried out by convection reflow soldering, and the welding temperature is set to 210 ℃. Firstly, establishing a finite element model according to a three-dimensional design model and calculating a temperature field, wherein the convective heat transfer coefficient is 26W/m 2 K, the temperature calculation shows that the integral temperature uniformity is good when the antenna unit is welded, and the temperature difference is lower than 1 ℃. And secondly, analyzing the stress and deformation of the antenna unit based on the temperature field analysis result, and displaying that the post-welding thermal stress on the antenna unit mounting plate exceeds the yield strength of the antenna unit mounting plate by the calculation result, wherein the maximum deformation is 0.3mm (shown in figure 2), which indicates that the structural member of the antenna unit has irreversible plastic deformation and does not meet the design requirement. Thirdly, optimizing the welding process, replacing the antenna unit mounting plate material with aluminum-silicon alloy with the thermal expansion coefficient of 1.6 multiplied by 10 -5 And the material has better rigidity and strength performance. The calculation shows that the thermal stress of the aluminum-silicon material mounting plate is lower than the yield strength of the aluminum-silicon material mounting plate, the deformation of the mounting plate is reduced to 0.1mm (shown in figure 3), no plastic deformation occurs in the welding process, and the stress and the deformation of the microstrip plate and the solder meet the requirements. And fourthly, welding the physical sample piece according to the optimized welding process. And finally, detecting. The post-welding detection shows that the antenna unit structure is not damaged, the mounting plate is not subjected to plastic deformation, the warping degree of the microstrip board is less than 0.2% and less than 0.75%, and the solder penetration rate is more than 95% and more than 85%. The indexes such as antenna unit power, standing wave and the like are qualified through physical electric measurement, and the rapid prediction dual-polarization microstrip antenna welding performance provided by the invention is verifiedThe design method of reliability is effective.
Example two
As shown in fig. 4, the present embodiment relates to a dual-polarized antenna, the size of the antenna is 500mm (length) x 240mm (width), and the welding difficulty is large due to the large welding breadth of the microstrip board. The welding implementation mainly relates to the distribution of materials such as a microstrip board, a connector, a mounting board and the like and the multi-temperature gradient welding.
The dual-polarized antenna unit is composed of a column microstrip plate 11, a row microstrip plate 12, a reflecting plate 13, a boss 14, a connector 15 and a mounting plate 16. The column microstrip plate 11 and the row microstrip plate 12 are multilayer plates made of domestic material CF294, the boss 14 and the mounting plate 16 are formed by numerical control milling, the material is 5A06, and the reflecting plate 13 is connected with the mounting plate 14 through screws. The manufacturing process of the antenna needs two types of solders with high melting point and low melting point, so a distributed welding mode is adopted. And the micro-strip plate and the boss, the connector and the micro-strip are welded by Sn63Pb37 solder, and the boss and the mounting plate are welded by Sn50In50 solder and are welded In a reflow furnace.
Firstly, analyzing the welding reliability of the high-melting-point welding material. And carrying out simulation modeling and temperature field and stress field analysis according to the antenna three-dimensional design model. The welding temperature in the furnace is set to 210 ℃, and the convective heat transfer coefficient is taken to be 26W/m 2 K, measured by temperature, shows that the temperature difference between the row and column micro-strip plates is not higher than 9 ℃ during welding. And (3) deformation analysis of the micro-strip plate after welding is carried out based on the temperature distribution condition, and all parts are not damaged after welding, so that the micro-strip plate is small in deformation. And secondly, analyzing the welding reliability of the low-melting-point welding material. The welding temperature is set to 145 ℃, modeling and simulation are carried out, the temperature stress after welding is lower than the yield strength of materials of all parts of the welding, the welding spot is not damaged, and the structure of the antenna unit is not damaged. And thirdly, welding the physical sample piece. Finally, through detection, the antenna welding quality is good, the solder penetration rate of the welding position of the microstrip plate reaches 90%, and the warping rate of the microstrip plate is 0.3% to less than 0.75%. The electrical property test indexes also meet the design requirements.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be considered as the technical solutions and the inventive concepts of the present invention within the technical scope of the present invention.
Claims (9)
1. A welding method for reliably welding a dual-polarized microstrip antenna is characterized by comprising the following steps:
s1, carrying out initial design of the welding process according to the design structure of the dual-polarized microstrip antenna;
s2, carrying out simulation modeling according to the structure, process design and actual implementation conditions of welding of the dual-polarized microstrip antenna;
s3, carrying out temperature field simulation analysis, stress field and deformation analysis by using the simulation model;
s4, carrying out simulation model rationality evaluation, and carrying out model correction according to the analysis result in S3;
s5, performing preliminary assessment on welding reliability;
s6, optimizing the welding process and performing iterative simulation evaluation;
and S7, welding the antenna physical sample piece, and detecting the welding quality of the physical sample piece.
2. The welding method for reliable welding of dual-polarized microstrip antenna according to claim 1, further comprising S8, wherein when the welding quality of the physical sample meets the preset requirement, the physical sample is tested for electrical performance.
3. The welding method for reliable welding of the dual-polarized microstrip antenna according to claim 1 or 2, wherein when the welding quality of the physical sample does not meet the preset requirements, the welding process is returned to S6 and optimized through simulation until the welded quality of the physical sample meets the requirements.
4. The welding method for reliable welding of dual-polarized microstrip antenna according to claim 1, wherein in S3, said temperature field simulation analysis specifically comprises: and acquiring the temperature value of the dual-polarized microstrip antenna through temperature calculation according to the corresponding temperature boundary loaded by the heating furnace body.
5. The welding method for reliable welding of dual polarized microstrip antenna according to claim 1, wherein in S4 said performing simulation model plausibility evaluation specifically is: and self-evaluating the simulation model according to the distribution conditions of the stress and deformation calculation results, wherein the self-evaluation comprises unit grids and relevant parameters of boundary conditions.
6. The method of claim 1, wherein in step S5, the preliminary evaluation of the reliability of the welding is performed by one or more of the following evaluation criteria, namely, no structural damage, no plastic deformation of the mounting board, a warpage of the microstrip board of less than 0.75%, and no cracking of the welding point.
7. The welding method for reliable welding of a dual-polarized microstrip antenna according to claim 1, wherein in S6, the optimizing the welding process and performing the iterative simulation evaluation specifically comprises: and optimizing the aspects of material selection, temperature curve setting and tooling.
8. The method for reliably welding a dual polarized microstrip antenna according to claim 1 wherein at S3, a finite element model is created from a three dimensional design model prior to temperature field simulation analysis using said simulation model.
9. The method of claim 8 wherein the stress and distortion analysis of the antenna elements is performed based on the temperature field analysis.
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