Large-scale High-precision Vehicle Radar Antenna Manufacturing Technology Research

A new type of radar was developed using a cosecant shaped reflector antenna, which had a large diameter size and high surface precision. Its production was a big issue. This paper putted forward a complete set of technology solutions for the developed antenna. The solution could meet the precision requirement, and had high production efficiency, low cost. Using this scheme, we had successfully completed the antenna production. The antenna reflector precision and electrical properties were tested, and the results showed that all the indexes had reached the design requirements.This paper viewed the current antenna manufacturing situation, pointed out the difficulties and deficiencies of the conventional manufacture mode in the skeleton forming, welding stress treatment, rib installation, web forming and precision testing, and introduced the research topics in the paper.The antenna structure and technological characteristics were carefully analyzed around the skeleton manufacturing, reflective surface detection, rib forming and installation, web types and the way of laying. The complete solutions were provided to overcome the disadvantages of the conventional methods. Focusing on the skeleton forming and the specific process of reflector alignment, we completed the antenna manufacturing, and the measuring results showed that the developed antenna reached the requirements of design.The combination of universal fixture and graphic template adopted in this paper avoided the high investment and the long cycle production of large special tooling. The welding process of two inert gas protection presented here had controlled the welding quality effectively. The VSR technology solved the problem of the aging treatment of welded structures. The double theodolite measuring system solved the high precision alignment and the test issues of rib and web.The practice proved that the manufacturing scheme is effective and feasible with less investment and efficiency. It provided a good reference for other large pieces of the structure with high precision welding and assembling.