Since the resumption of work, various regions have accelerated the construction process of 5G base stations. In some areas, the planning of 5G base stations is too heavy. The northwest region, which had previously been slow in base station construction, has also announced this year's construction plan. In the construction of 5G base stations, the demand for metal cavity filters and other components is increasing, and the processing of high-quality filter components relies on the mature application of high-performance electric spindles.

Processing requirements for metal cavity filters

1. Efficient processing: 5G metal cavity filter components have a long processing cycle, require a large number of drilling and tapping teeth, and have high requirements for processing efficiency.

2. High precision requirements: The components required for the construction of 5G base stations generally have high added value, and in the field of processing applications, high precision is required for processing.

3. Requirement for high stability: Metal cavity filters have complex structures and are even composed of various curved surfaces, such as 5G base stations being smaller in size than 4G. Its internal structure is more complex, with over 100 internal cavities in each 5G base station, requiring relatively complex processing techniques and requiring long-term processing of high stability spindles.

Efficient processing of high-performance electric spindle empowered filter components

The metal cavity filters and other components of 5G base stations have a large number of cavities and complex structures. In order to achieve faster processing efficiency, higher processing accuracy, and higher product stability, high-performance electric spindles are needed to meet customer needs, solve pain points for filter manufacturers, accelerate production processes, and assist in the construction of 5G base stations.

Based on the characteristics of components such as metal cavity filters, a series of high-performance electric spindles are used to achieve efficient processing of metal cavity filters. Below is a detailed introduction to how electric spindles can leverage their advantages in the process of processing metal cavity filters:

The advantages of high-performance electric spindle machining metal filters are as follows:

01. High efficiency

A. High performance motor

The unique and efficient built-in design provides greater torque output and stunning high-speed effects. One clamping and one precision machining fully reflect the value of the machine tool.

B. High speed

The electric spindle speed can reach 30000rpm, providing sufficient cutting speed to ensure higher surface quality of the metal cavity filter. The higher cutting speed supports faster feed rates and improves machining efficiency; A sufficiently high rotational speed supports the application of small-diameter cutting tools, making the machining range wider.

C. Central outlet

The powerful center water outlet function of the electric spindle greatly improves the machining efficiency and surface machining quality of the workpiece. The cooling of the cutting area can greatly improve the drilling and tapping efficiency of 5G type cavity porous parts, effectively assist in chip removal, and extend tool life.

02. High precision

Combined with HSK double-sided positioning high-precision tool holder interface, the standard detection rod end runout can be less than 5 μ m, and the dynamic balance level can reach G0.4, ensuring high connection stiffness and accuracy of the spindle during high-speed operation, thereby ensuring minimal tool rotation runout and smooth surface of the metal cavity filter components.

03. Long lifespan and high stability

A. Oil air lubrication technology

Support advanced oil air lubrication technology, greatly improving the maximum speed and service life of bearings; The bearing oil air lubrication technology can provide the maximum speed of the bearing on one hand, and on the other hand, it can increase the service life of the bearing by more than 5 times, especially suitable for processing long-term high-speed 5G cavity porous parts.

B. Unique temperature field design

Effectively suppressing the temperature rise of the motor and bearings, keeping the impact of temperature rise within a controllable range, ensuring that the thermal elongation is less than 20 microns, the start-up stability time is less than 15 minutes, and the temperature rise of the electric spindle housing is less than 3 ℃, improving stability and service life.

C. Innovative Pulling Knife Mechanism

1) Ultra long cutting life and high stability of cutting force: Experimental tests of the cutting mechanism show that the cutting life is ≥ 10 million times, which is more than 10 times longer than the traditional disc spring cutting mechanism. The cutting force attenuation is ≤ 10%, and it is stable and reliable.

2) The overall vibration of the machine is ultra-low and the vibration stability is high: compared with the traditional disc spring knife mechanism, the vibration value of the knife mechanism is reduced by 30%; The vibration fluctuation value of the blade mechanism is ≤ 10% throughout its entire lifespan, indicating high vibration stability.

3) Ultra high repeatability and high precision stability: Compared with the traditional disc spring four flap claw puller mechanism, the repeatability and precision of the puller mechanism are ≤ 0.001mm, and the dynamic and static deflection change is ± 0.001mm. At the same time, the rolling friction design of the SPL puller mechanism has the characteristics of high matching accuracy, no stress concentration zone, and low wear, and its excellent performance can fully utilize the greater performance of the puller mechanism.

4) Historical zero failure rate: Since 2016, nearly 100000 spindles have been assembled with a cutting mechanism in bulk, and there have been no abnormalities in the cutting mechanism on the client side.