Modular Radar Array Architecture for Scalable Thermal Management
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Solution Overview
Problem
Existing phased array architectures require costly and time-consuming redesign of cooling, power, and signal distribution systems to resize arrays, limiting scalability and increasing operational temperatures due to heat dissipation challenges.
Innovation Solution
A modular radar array design where identical radar modules receive coolant, power, and control signals in parallel, allowing for scalable array sizes by simply adding modules, with a chassis that acts as a heat sink and a thermal conductive radiator panel to manage heat and prevent ice accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If phased array antennas are resized to change operational parameters, then performance can be optimized for different missions, but the cooling, power, and signal distribution systems require costly and time-consuming redesign
Solution Approach 1:
The phased array antenna is divided into multiple identical modular subarrays, each containing its own T/R modules, phase shifters, and cooling channels. These modules can be independently configured and assembled to create arrays of different sizes without requiring redesign of the cooling or power distribution systems.
Solution Approach 2:
The modular subarray design creates universal building blocks that can be used across different array configurations. Each module serves multiple functions including signal processing, phase control, and self-cooling, allowing the same hardware to adapt to various operational requirements without modification.
2Ease of operation
If active circuits are used in phased array antennas, then functionality and control are improved, but heat dissipation becomes a critical challenge requiring extensive cooling infrastructure
Solution Approach 1:
The cooling channels are integrated directly into the substrate structure that supports the active T/R modules and phase shifters. This merging of cooling infrastructure with the functional circuit board eliminates the need for separate cooling systems while providing efficient heat removal from active components.
Solution Approach 2:
The substrate serves as an intermediary between the active circuits and the cooling fluid. The substrate conducts heat away from the T/R modules and phase shifters to the integrated cooling channels, where thermal management fluid removes the heat, thereby protecting sensitive electronic components.
3Reliability
If traditional phased array designs are used, then initial performance is achieved, but scalability to larger arrays is limited by the need to redesign entire systems
Solution Approach 1:
The array is segmented into identical, interchangeable subarray modules that maintain consistent electrical and thermal characteristics. This segmentation allows linear scaling of array aperture by simply adding more modules while preserving the performance characteristics of individual elements.
Solution Approach 2:
The modular subarray design allows smaller functional units to be nested or combined to form larger arrays. Multiple subarrays can be arranged in various configurations (linear, planar, three-dimensional) to achieve different aperture sizes and beamforming capabilities while using the same basic building blocks.
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
Enables scalable radar array sizes from two to thirty-two feet and beyond, efficiently managing heat dissipation and preventing ice accumulation, thus improving performance and reducing redesign costs and time.
Implementation Method 1
a thermal conductive layer configured to facilitate a transfer of heat to the radome
Implementation Method 2
a chassis having channels configured to receive a coolant
Data Source
AI summary
In one aspect, a radar array assembly includes two or more vertical stiffeners each having bores with threads and a first radar module. The first radar module includes radar transmit and receive (T/R) modules and a chassis having channels configured to receive a coolant. The chassis includes shelves having ribs. The ribs have channels configured to receive the coolant and the ribs form slots to receive circuit cards disposed in parallel. The circuit cards include the T/R modules. The chassis also includes set screws attached to opposing sides of the chassis. The set screws have bores to accept fasteners to engage the threads on a corresponding one of the two or more vertical stiffeners. The first radar module is configured to operate as a stand-alone radar array.