Design And Analysis Of An Automatic Device For High Precision Measuring,Adjusting And Connecting Of Cables

As a core component in mesh reflector antenna,the cable net structure is mainly used to support its reflector in order to make it shape the required curved surface.The accuracy of the cable length and tension determines the performance of the reflector.At present,the manufacturing of the cable net structure is still carried out by artificial method,which can't satisfy the high surface accuracy.Therefore,it is of great significance to develop an automatic crimping equipment which can improve and ensure the precision of cable length and tension for the cable net in antenna reflector.Firstly,the paper summarized the characteristics of the cable net structure and introduced its application status and the development trend.Based on the design requirements and the analysis of the manufacturing procedure of the net,an automatic crimping equipment for the cable net in antenna reflector is designed.The over-all structure of the equipment consists of clamp system,length control system,tension measurement system,tension adjustment system and crimp system.A virtual prototype has been built,and the key components have been designed and selected.Considering the difficulties for high precision measurement of large tension,the paper divided the full scale of tension into several ranges and designed a tension counterbalancing system which can provide a series of standard force.Thus the large tension is consisted of two components: the standard force provided by the counterbalancing system,and the rest,namely the resultant force measured by compliant Mechanism.The paper did a sufficient analysis on the advantages and disadvantages of common connection methods of cable and then aluminum-alloy crimp terminal was selected.Experiments were designed and carried out to study the main influences on pullout force in order to determine the design parameters and crimping process of the crimp terminal.The paper completed the mold design for the terminal and simulated the crimping process.Finally,in mechanical structure checking validation process,the paper completed the theoretical calculation and analysis of the errors of the mechanical structure according to the request of technical index.Thus,the design is proved to be accurate,valid and feasible.