The design and manufacturing of the X-band waveguide dual-directional coupler require a strict process flow. The project ensures the precision of the coupling holes and the reliability of the closed cavity through part disassembly, positioning step design, dimension chain optimization, and welding processes. The coupler consists of main waveguide, secondary waveguide, cover plate, matching block, etc., with an operating frequency of 9~11GHz. The key lies in the machining precision of the coupling holes and the reliability of the connections.
The technical challenges are to ensure the precision of the coupling holes and to achieve a reliable vacuum brazing connection. The environmental adaptability requires a temperature range of -40~+50°C and the ability to withstand vibration, shock, mold, and salt spray. The matching block requires high precision in distance from the inner cavity, using a two-step welding process involving electron beam welding and vacuum brazing.
The process plan includes waveguide assembly welding and integrated coupling body machining. The integrated machining plan was chosen, ensuring the accurate positioning of the matching block through positioning steps and dowels, followed by electron beam welding and vacuum brazing. The machining formation, positioning, and welding process design have been carefully calculated and optimized to ensure product electrical performance and the rationality of the manufacturing process.
In conclusion, the plan provides a reference for the manufacturing of similar directional couplers, reducing the number of parts, clarifying positioning relationships, ensuring main precision, and meeting telecommunications and environmental adaptability requirements.
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