Abstract
The cementing manufacturing process of ferrite phase shifters has the defect that cementing strength is insufficient and fractures always appear. A detection method of these defects was studied utilizing the multi-sensors Prognostic and Health Management (PHM) theory. Aiming at these process defects, the reasons that lead to defects are analyzed in this paper. In the meanwhile, the key process parameters were determined and Differential Scanning Calorimetry (DSC) tests during the cure process of resin cementing were carried out. At the same time, in order to get data on changing cementing strength, multiple-group cementing process tests of different key process parameters were designed and conducted. A relational model of cementing strength and cure temperature, time and pressure was established, by combining data of DSC and process tests as well as based on the Avrami formula. Through sensitivity analysis for three process parameters, the on-line detection decision criterion and the process parameters which have obvious impact on cementing strength were determined. A PHM system with multiple temperature and pressure sensors was established on this basis, and then, on-line detection, diagnosis and control for ferrite phase shifter cementing process defects were realized. It was verified by subsequent process that the on-line detection system improved the reliability of the ferrite phase shifter cementing process and reduced the incidence of insufficient cementing strength defects.
Highlights
Curing pressure has an impact on the thickness of the adhesive, but the thickness is only about 0.02 mm, so the fluctuations of adhesive thickness are so small that its influence can be ignored, so the main process parameters related to cementing strength in the ferrite phase shifter cementing process are curing temperature, curing time and curing pressure
We determined the process parameters which have a stronger effect on cementing strength, by sensitivity analysis of curing time, curing temperature and curing pressure
An indirect on-line non-destructive testing method for undetected defects will be studied
Summary
The ferrite phase shifter cementing process is a procedure that bonds microwave dielectric rods and ferrite bars in order while meeting specific requirements of size and strength. That is the reason for the insufficienWt ibthoonudticnognsitdrernigngthf.actors such as device failure and the operational environment, cementing Wstrietnhgotuht cisonresliadtedrintgo fcaecmtoernstisnugchmaastedrieavlsi,cejofianitludriemaenndsiothn,e coupreinragtipornoacleessn,veirtco.nTmheenyt,ccaenmbeenting strengsuthmims raerliazteeddatsofoclelmowesn:ting materials, joint dimension, curing process, etc. They can be summarized as fol(l1o)wsC: ementing materials: different adhesives present different properties. Curing pressure has an impact on the thickness of the adhesive, but the thickness is only about 0.02 mm, so the fluctuations of adhesive thickness are so small that its influence can be ignored, so the main process parameters related to cementing strength in the ferrite phase shifter cementing process are curing temperature, curing time and curing pressure
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