Cavity Filter Resonant Bar Mounting for Tolerance-Tuned Assembly
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Solution Overview
Problem
The challenge lies in the precise manufacturing of resonators within a cavity filter, requiring them to be within a narrow design tolerance range for frequency tuning, which complicates the manufacturing process and increases costs.
Innovation Solution
A cavity filter design incorporating a resonant bar boss with a tolerance management stopper part that allows for adjustable resonant bar insertion and fixation, enabling extended design tolerance and reducing the need for post-processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the resonator is manufactured within a narrow design tolerance range, then the frequency tuning design can be performed accurately, but the manufacturing complexity and cost increase
Solution Approach 1:
The resonator is designed to be movable within the cavity rather than fixed during manufacturing. The resonator can be adjusted to different positions to achieve the desired frequency tuning, transforming a static manufacturing tolerance problem into a dynamic adjustment problem. This allows the resonator to be positioned precisely at runtime without requiring extremely tight manufacturing tolerances.
Solution Approach 2:
The cavity structure is pre-designed with specific geometric features and mounting arrangements that guide the resonator into the correct position. The preliminary design of the cavity includes reference surfaces and mounting structures that automatically position the resonator with sufficient accuracy, reducing the need for post-manufacturing adjustments and lowering manufacturing complexity.
2Manufacturing precision
If the resonator is manufactured within a narrow design tolerance range, then the frequency tuning design can be performed accurately, but the production cost increases
Solution Approach 1:
By allowing the resonator to be moved and adjusted after manufacturing, the system eliminates the need for expensive precision manufacturing processes. The resonator can be manufactured with standard tolerances and then positioned accurately through mechanical adjustment mechanisms, significantly reducing production costs while maintaining frequency tuning accuracy.
Solution Approach 2:
The system changes the approach from controlling manufacturing parameters (tolerances) to controlling positional parameters (adjustment range and precision). This parameter shift allows the use of lower-cost manufacturing processes while achieving the same functional outcome through mechanical adjustment and repositioning of the resonator.
3Productivity
If the resonator is made thinner to improve production yield, then the manufacturing efficiency increases, but the resonator becomes more difficult to manufacture within tolerance
Solution Approach 1:
Thinner resonators are designed with movable mounting structures that allow for post-manufacturing position adjustment. This dynamic positioning capability compensates for the reduced manufacturing precision inherent in thinner components, enabling high production yield while maintaining the required frequency tuning accuracy through mechanical adjustment rather than relying solely on manufacturing tolerance.
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 design enhances manufacturing flexibility, reduces production costs, and allows for thinner resonant bars, improving production yield and efficiency.
Implementation Method 1
a resonator consisting of a resonant post (or a resonant bar), etc., that is, a conductor, is provided within a box structure formed of a metallic conductor and the RF filter transmits only a characteristic frequency of an ultra high frequency by resonance because only an electromagnetic field having a unique frequency is present in the cavity
Data Source
AI summary
The present invention relates to a cavity filter for an antenna, specifically to a cavity filter comprising: a filter body having a plurality of cavities which are open at one side and are divided by a partition wall; a resonance bar installed at each of the plurality of cavities; a resonance bar boss into which a part of the resonance bar is inserted and which is provided such that the resonance bar is installed at the cavity; and a tolerance management stopper part which is disposed between an inner peripheral surface of the resonance bar boss and an outer peripheral surface of the resonance bar to perform stop-and-moving functions in an insertion direction of the resonance bar in designing the tolerance of the cavity, thereby providing the advantage of improving a production yield of an entire product.