Electrostatic formed membrane reflector antenna is a new type of antennas. Its reflective surface accuracy is its important performance index. It is necessary to study shape errors existing in forming of membrane reflector. Firstly, shape errors were classified into principle errors and manufacturing errors, manufacturing errors were divided into mosaic errors, paste errors and boundary errors. Then, reflector forming simulation was realized based on the finite element method to obtain principle errors. Mosaic errors were presented numerically through rotation and radical translation of film surface design position. Paste bars were approximately equivalent to cable elements, different cable stresses were set to simulate paste errors. Boundary errors were presented with skirt boundary cable force errors. Based on the above mentioned errors, the reflector’s cutting layout optimization model was proposed. Ring number, cutting number per ring and voltage were taken as variables to be optimized, the shape precision of membrane reflector was taken as the objective to be optimized, and the positivity and uniformity of membrane stress were taken as constraints. A technique combining the gradient method and the genetic algorithm was proposed to solve this optimization model including continuous and discrete variables with high non-linearity. The validity of the optimization model was verified with a numerical example of a 0.55m membrane reflector antenna model.
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