What are the advantages of self-locking tuning screws in the field of communication equipment?
The application of self-locking tuning screws in the field of communication equipment (such as base station antennas, RF filters, satellite communication terminals, and 5G/6G core network equipment, etc.) focuses on solving the contradiction between "high-precision tuning requirements" and "stability in complex working conditions", and its advantages can be developed from the core demands of communication equipment (signal accuracy, operational reliability, maintenance convenience and environmental adaptability), as follows:
1. Ensure the accuracy of RF signals: meet the "micron" tuning requirements of communication equipment.
The core function of communication equipment is to transmit/receive RF signals. The frequency, phase and gain of signals need to be accurately calibrated by tuning components (such as filters, power splitters and antenna elements), and self-locking tuning screws are the key carriers to realize this calibration. The advantages are as follows:
The tuning accuracy reaches micron level. Matching RF parameters requires that the RF parameters of communication equipment (such as filter bandwidth and antenna standing wave ratio) require extremely high accuracy of mechanical tuning (usually 0.001 mm ~ 0.01 mm). Self-locking tuning screw can achieve "stable and controllable tuning displacement per turn" through precise thread processing (pitch error ≤0.005mm/100mm) and coaxiality control (≤0.003mm) (for example, M2×0.25 fine thread, each turn displacement accurately corresponds to 0.25mm, and fine adjustment of 0.1μm level can be achieved with subdivision drive mechanism), so as to ensure that RF signal parameters are calibrated to the "optimal interval".
The self-locking function locks the tuning state to avoid signal drift. The tuning parameters of communication equipment (such as antenna beam angle and filter center frequency) need to be stable for a long time. If the screws are loosened after tuning, the parameters will drift (for example, when the temperature changes and the equipment vibrates, ordinary screws are prone to "micro-displacement"). Self-locking tuning screw can realize "automatic locking position after tuning" through crushing thread, coating self-locking or structural self-locking design (such as serrated anti-loosening thread)-its loosening torque is usually ≥ 80% of the pre-tightening torque (such as the pre-tightening torque of M3 screw is 0.6N・m, and the loosening torque is ≥ 0.48 nm), which can effectively resist vibration in equipment operation (such as low-frequency vibration of base station antenna under the action of wind) and temperature cycle (-).
Second, improve the reliability of equipment operation: adapt to the demand of "long-term trouble-free" of communication equipment.
Communication equipment (especially base stations and satellite terminals) are mostly deployed outdoors, at high altitude or in remote areas, with high maintenance costs and strict requirements for the "trouble-free operation life" of components (usually ≥10 years). The advantages of self-locking tuning screws are as follows:
Anti-vibration/impact to avoid mechanical failure. Outdoor base stations and vehicle-mounted communication equipment will bear vibration for a long time (for example, the base station beside the road is affected by vehicle vibration, and the vehicle-mounted terminal is affected by road bumps). Ordinary screws are prone to dislocation of tuning components due to "vibration loosening" and even cause equipment downtime. The self-locking structure of the self-locking tuning screw (such as "interference fit" formed by local thread crushing) can greatly improve the anti-vibration performance. According to the GB/T 10431.1 standard, under the vibration environment of 10-2000Hz and 200 m/s acceleration, its position offset is ≤0.002mm, which is much lower than that of ordinary screws (the offset is usually ≥0.01mm), ensuring the long-term maintenance of the tuning assembly.
Anti-environmental corrosion can prolong the service life of equipment. Communication equipment often faces corrosive environments such as outdoor humidity, salt spray (coastal areas), industrial dust, etc. If the screws are corroded, the tuning will be stuck (unable to be calibrated later) or the structure will fail. Self-locking tuning screws mostly adopt corrosion-resistant materials and special surface treatment for communication scenes;
Materials: 316 stainless steel (salt spray resistance is better than 304, neutral salt spray test is more than 100 hours without corrosion) and titanium alloy (acid and alkali corrosion resistance, suitable for industrial pollution areas);
Surface treatment: With "passivation+solid lubrication coating" (such as MoS₂ coating, which can prevent corrosion and reduce tuning friction) or "Ni-P alloy plating" (salt spray resistance ≥72 hours), it can be used in outdoor harsh environment for a long time to avoid premature scrapping of equipment due to screw corrosion.
Third, simplify equipment assembly and maintenance: reduce the "manpower/time cost" of communication engineering.
Both "efficiency" and "convenience" should be taken into account in the production and assembly of communication equipment (such as batch assembly of base stations) and later maintenance (such as parameter calibration of base stations in remote areas). The design of self-locking tuning screws can significantly optimize this process:
There is no need for additional anti-loosening parts in assembly, which simplifies the process. After the communication equipment is tuned, ordinary screws need to be additionally equipped with check washer (such as spring washer and stop washer) or coated with thread glue to prevent loosening, which not only increases the number of parts (increases the cost), but also may affect the tuning accuracy due to the thickness of washer and uneven application of thread glue. The self-locking tuning screw has its own "integrated self-locking function", so it can be assembled directly without additional anti-loosening measures after tuning in place. Taking the assembly of base station filter as an example, a single device can reduce the assembly steps by 30% (saving washer installation and screw glue curing time), and improve the mass production efficiency.
During maintenance, "tuning-locking" is completed in one step, which reduces the difficulty of operation and maintenance. Communication equipment needs to calibrate the RF parameters regularly (for example, every 1-2 years) (if the beam of the base station antenna deviates due to wind and sun, it needs to be re-tuned). The "tuning-self-locking" integrated design of the self-locking tuning screw allows the operation and maintenance personnel to directly rotate and tune through special tools (such as Allen wrench and precision screwdriver), and automatically lock the screw when it is in place, without repeatedly checking whether it is loose or whether it needs to be coated with thread glue, especially in hard-to-reach scenes such as high-altitude base stations and mountain satellite terminals, which can shorten the single maintenance time (from the traditional 30 minutes per set to 10 minutes per set)
Fourth, the trend of "miniaturization/integration" of compatible communication equipment
With the development of 5G/6G equipment to miniaturization and high-density integration (for example, the internal space of micro-base stations and millimeter-wave terminals is only 1/5 of that of traditional equipment), the requirements for "compact size" and "light weight" of components are raised, and the advantages of self-locking tuning screws are as follows:
Compact structure, self-locking tuning screws suitable for miniaturized cavities can be designed as "miniaturized specifications" (such as M1.6×0.35 and M2×0.25), the minimum head diameter can be 2mm, the rod length can be customized as required (5mm~20mm), and they can be embedded in miniaturized cavities of communication equipment (for example, the cavity size of RF module of 5G micro-base station is only 30mm×20mm), and there is no need to reserve extra space for locking parts.
Lightweight design, reducing equipment load For "lightweight and sensitive" scenes such as satellite communication terminals and unmanned airborne communication equipment, the self-locking tuning screws can be made of lightweight materials such as titanium alloy and high-strength engineering plastics (such as PEEK) (the density of titanium alloy is only 4.5g/cm³, which is much lower than that of stainless steel's 7.9g/cm³), while ensuring the strength and accuracy, the overall weight of the equipment can be reduced (the weight of a single satellite terminal can be reduced by 5%~10%).
Five, reduce the whole life cycle cost: from production to operation and maintenance of "reducing costs and increasing efficiency"
The communication industry is sensitive to cost control. Although the unit price of self-locking tuning screws is higher than that of ordinary screws, from the perspective of "full life cycle" (production-operation and maintenance-scrapping), the total cost can be significantly reduced:
Production end: save the procedures of purchasing locking parts and coating thread glue, and reduce the spare parts inventory and assembly time (for example, when the base station is mass-produced, a single machine can save 2-3 assembly steps, and the annual production capacity can be increased by 10%-15%);
Operation and maintenance end: avoid "secondary tuning" and "equipment fault maintenance" caused by loose screws (for example, the signal of a base station in a certain area is interrupted due to loose common screws, and the cost of single maintenance exceeds 10,000 yuan, while the self-locking screws can reduce the occurrence rate of such faults by more than 90%);
Scrap end: Corrosion-resistant materials (such as 316 stainless steel and titanium alloy) can be recycled, which reduces the waste of resources and conforms to the trend of "green and low carbon" in the communication industry.
summary
The core advantage of self-locking tuning screw in the field of communication equipment is to combine high-precision tuning, long-term stability, environmental adaptability and cost controllability, and perfectly match the core demands of communication equipment for high signal accuracy, reliable operation, convenient maintenance and miniaturization integration. Especially under the background of the popularization of 5G/6G technology and the development of communication equipment to "high frequency band (millimeter wave), high density (micro base station) and wide coverage (outdoor/satellite)", its application scenarios will be further expanded and become a key basic component to ensure communication quality.
