Broadband Calibration Sensor Head for Unified Antenna Alignment

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing antenna alignment systems require separate mechanical and electrical fixtures, leading to increased downtime, mounting skew errors, and measurement inaccuracies due to the need for multiple setups.

Innovation Solution

A calibration sensor head integrating a laser and interferometer in a single device for simultaneous mechanical and electrical alignment of antenna elements, utilizing a laser for coarse positioning and an interferometer for fine electrical positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If separate mechanical and electrical fixtures are used for antenna alignment, then mechanical positioning and electrical positioning can be performed independently, but this leads to increased downtime, mounting skew errors, and measurement inaccuracies

Engineering Contradiction:

Improveindependent positioning operationsVSAvoidalignment downtime

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent combines separate mechanical and electrical alignment fixtures into a single integrated alignment device. The mechanical positioning component and electrical positioning component are merged into one unified structure that can perform both functions simultaneously, eliminating the need for separate setups and reducing alignment downtime while maintaining operational independence through modular sub-components.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If separate mechanical and electrical fixtures are used for antenna alignment, then each fixture can be optimized for its specific function, but this results in mounting skew errors and measurement inaccuracies

Engineering Contradiction:

Improvefunction-specific optimizationVSAvoidalignment accuracy

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

By merging mechanical and electrical fixtures into a single integrated device with a common reference frame, the patent eliminates mounting skew errors that occur when separate fixtures are used. The integrated design ensures that both positioning functions share the same mechanical baseline, thereby maintaining function-specific optimization while achieving superior alignment accuracy.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated alignment device is segmented into distinct mechanical and electrical positioning modules, each optimized for its specific function. These modules are arranged within a unified structure that provides a common reference frame, allowing each segment to perform its specialized function while contributing to overall measurement precision through their coordinated integration.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If multiple separate alignment setups are required, then comprehensive alignment coverage is achieved, but this increases device complexity and setup time

Engineering Contradiction:

Improvealignment coverageVSAvoidnumber of fixtures

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent consolidates multiple separate alignment fixtures into a single integrated device that provides comprehensive alignment coverage. The unified structure incorporates both mechanical and electrical positioning capabilities, reducing the total number of fixtures required while maintaining the versatility to perform complete antenna alignment procedures.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated alignment device is designed with multi-functionality, serving both mechanical positioning and electrical positioning functions within a single apparatus. This universal design eliminates the need for multiple specialized fixtures, reducing device complexity while maintaining comprehensive alignment coverage through its ability to perform multiple alignment tasks.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Reduces measurement errors and saves time and costs by consolidating alignment processes, ensuring precise and efficient alignment of antenna elements on a hemispherical surface.

Implementation Method 1

a laser configured to generate a laser beam for coarse mechanical positioning of the antenna element

Methodology Applied

Scientific EffectLaser: Laser

Implementation Method 2

an interferometer having a plurality of antennas configured to receive signals from the antenna element for fine electrical positioning of the antenna element

Methodology Applied

Scientific EffectInterference: Interference

Data Source

PatentUS20250314485A1Broadband calibration sensor head

Publication Date: 2025.10.09 RAYTHEON CO

AI summary

An apparatus for testing an antenna element of an antenna array includes a laser configured to generate a laser beam for coarse mechanical positioning of the antenna element. The apparatus also includes an interferometer having a plurality of antennas configured to receive signals from the antenna element for fine electrical positioning of the antenna element, where the laser and the interferometer are collocated. The apparatus further includes a controller configured to control positioning of the laser and the interferometer based on information associated with the laser beam received by the controller and the signals received from the antenna element.