Processing Record for Waterproof Navigation Antenna Housing

This processing task aims to produce a batch of waterproof navigation antenna housings for outdoor service robots. The housing requires a high waterproof rating (IP67) and precise dimensions to protect the internal precision navigation antenna from environmental influences. The processing involves precision injection molding, CNC secondary machining, and assembly sealing.

• Selected high-quality ABS+PC engineering plastic granules, supplier: XX Plastics, batch: 20250901.
• Pre-dried the raw material at 80°C±5° for 4 hours to remove moisture.
• Tested material melt flow index and moisture content, conforming to internal standard Q/XXX-2024.

• Used Haitian 280T injection molding machine. Mold temperature set to 80°C, injection pressure 80MPa.
• Molding parameters: Injection phase 1 speed 45%, pressure 60MPa; phase 2 speed 35%, pressure 50MPa; holding pressure 45MPa, time 15s.
• Cooling time 25s, mold temperature controller water temperature set to 25°C.
• Performed first-article inspection every 30 cycles, measuring key dimensions (diameter, height, wall thickness).

• Used Liyz CNC machining center (model VL-660) for precision machining of interface holes and mounting lugs.
• Tool: Φ6mm tungsten steel end mill, spindle speed 8000rpm, feed rate 1800mm/min.
• After machining, used pneumatic CMM (accuracy 0.01mm) to inspect hole position accuracy and flatness.

• Used ultrasonic welder to fuse the upper and lower housings, frequency 20KHz, pressure 3.5Bar, time 0.8s.
• Performed 100% air tightness test on all finished products: using air leak tester, pressure 0.3MPa, hold time 30s, leakage value must be less than 0.5KPa.
• Sampled for waterproof test (IP67 standard): submerged sample in 1 meter deep water for 30 minutes, no moisture ingress inside qualified.

• Performed sandblasting (200 mesh quartz sand) on the housing to enhance texture and remove minor scratches.
• Cleaned with alcohol using lint-free cloth to ensure no oil stain or dust.
• Packed individually in PE bags with foam separation, then placed in dedicated cartons, 20 units per box.

During the initial trial production, parts produced by injection molding machine #3 showed only a 92% pass rate in the air tightness test after ultrasonic welding. Analysis revealed insufficient holding time in the molding parameters caused local shrinkage, affecting the welding surface flatness. After adjusting the holding time to 18s, the pass rate for subsequent batches improved to 99.8%.

Through strict process parameter control and multiple quality inspections, this processing task was successfully completed, producing a total of 2000 qualified waterproof navigation antenna housings. All performance indicators meet the design requirements, providing key component assurance for reliable outdoor robot navigation.