Cavity Filter Laser Scanning Pre-Assembly Evaluation
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Solution Overview
Problem
The manufacturing of cavity filters is hindered by the time-consuming tuning process, particularly for complex filters, where many are discarded due to not meeting quality requirements, leading to inefficiencies and material waste.
Innovation Solution
A method utilizing a laser scanning assembly to evaluate the lower filter part's dimensions and shapes against predetermined quality standards before assembly, allowing for accurate verification and adjustment of filter bodies to meet specifications, thereby preventing the assembly of non-conforming filters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual tuning is performed on complex cavity filters, then the filter can be adjusted to meet specifications, but the process takes more than 40 minutes and many filters are discarded due to non-compliance
Solution Approach 1:
The patent applies preliminary action by performing laser scanning and quality evaluation of the filter body before assembly and tuning. The system scans the filter body to collect shape and dimension data, compares it with reference data to determine compliance with quality requirements, and identifies non-conforming filters before they enter the assembly and tuning process. This preliminary quality check prevents time-consuming tuning attempts on filters that will not meet specifications, directly resolving the contradiction between ensuring quality compliance and reducing tuning time.
2Measurement precision
If sample-based mechanical measurement is used to verify filter body quality, then quality requirements can be checked, but the process is time consuming and limited to a small number of samples
Solution Approach 1:
The patent replaces the mechanical measurement system with an optical laser scanning system. Instead of using mechanical contact probes to measure filter body dimensions, the system uses laser scanning to collect shape and dimension data non-contactly. This substitution maintains high measurement precision while dramatically increasing productivity, as the laser scanning process is much faster than manual mechanical measurement and can evaluate all filter bodies in a batch rather than limited samples.
Solution Approach 2:
The patent creates a digital copy of the filter body by scanning it with laser to collect shape and dimension data. This digital replica is then compared with reference data to evaluate compliance with quality requirements. The copying approach allows for rapid, non-contact evaluation of all filter bodies without physical contact or manipulation, resolving the contradiction between measurement precision and evaluation throughput by enabling fast digital analysis of complete batches.
3Reliability
If all filter bodies are evaluated before assembly, then the risk of assembling non-conforming filters is reduced, but the evaluation process must be fast to maintain productivity
Solution Approach 1:
The patent replaces slow mechanical measurement with fast optical laser scanning to enable evaluation of all filter bodies without compromising productivity. The laser scanning system rapidly collects shape and dimension data from each filter body, and the computer system quickly compares this data with reference data to determine compliance. This technological substitution maintains high reliability by evaluating all filter bodies while preserving productivity through the speed of optical measurement compared to mechanical methods.
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
This approach significantly reduces the risk of assembling filters that cannot be properly tuned, saving time and effort by enabling fast evaluation of all filter bodies within a batch, ensuring quality compliance, and allowing for efficient high-volume production by identifying and adjusting non-conforming parts before assembly.
Implementation Method 1
scanning the lower filter part using a laser scanning assembly to collect data relating to shapes and dimensions of the lower filter part
Data Source
AI summary
A method and a system (13) for evaluating a lower filter part (2) of a cavity filter including a bottom plate from which wall portions and at least one resonating element extend in an upward direction, wherein the method comprises: —scanning the lower filter part using a laser scanning assembly (14) to collect data relating to shapes and dimensions of the lower filter part, —comparing the collected data with reference data to determine whether the lower filter part fulfils predetermined quality requirements. A method for manufacturing a cavity filter includes evaluating a filter body of the lower filter part prior to assembling the cavity filter, wherein the step of assembling the cavity filter is only carried out if the filter body fulfils the predetermined quality requirements.