Radar Assembly with Test Access Opening for Reworkable Manufacturing
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Solution Overview
Problem
Conventional radar structures face challenges in cost-effective manufacturing due to difficulties in disassembling and replacing defective components, leading to increased costs and waste, and require testing the entire assembly which complicates the process.
Innovation Solution
A radar structure comprising a radome, circuit board, and shielding cover with an opening region for direct electrical connection, allowing pre-assembly testing and component replacement, reducing manufacturing costs and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire radar structure is assembled before testing, then the transmission testing can be conducted on the complete assembly, but the manufacturing cost increases and time is wasted when defects are found
Solution Approach 1:
The patent divides the radar structure into separable modules: the circuit board assembly (CBA) with the antenna and radome, and the encapsulation cover. This segmentation allows the CBA to be tested independently before final assembly, so that if defects are found, only the CBA needs to be disassembled and reworked rather than the entire sealed unit. The separable design enables staged testing that saves time and resources.
Solution Approach 2:
The patent implements preliminary testing of the circuit board assembly before it is permanently enclosed in the encapsulation cover. By conducting transmission and reception capability tests on the CBA while it is still accessible and not yet sealed, the system allows for early detection of defects. This preliminary action prevents wasted time and materials that would result from discovering defects after final assembly.
2Reliability
If the entire radar structure is assembled before testing, then the complete system performance can be evaluated, but the manufacturing cost increases due to scrapping entire units
Solution Approach 1:
The patent segments the radar into a testable circuit board assembly and an encapsulation cover. This segmentation enables cost-effective manufacturing by allowing defects to be identified and corrected in the CBA stage, avoiding the need to scrap entire assembled units. The separable design means that only the defective CBA components need to be replaced, not the entire radar structure.
Solution Approach 2:
The patent performs preliminary testing and validation of the circuit board assembly before final encapsulation. This preliminary action enables early detection of manufacturing defects, allowing for corrective measures to be taken on individual components rather than requiring scrapping of complete assembled units, thereby reducing manufacturing costs.
3Strength
If the radome and circuit board are tightly assembled, then the structural integrity is improved, but the disassembly becomes difficult and component replacement becomes impossible
Solution Approach 1:
The patent divides the radar structure into separable segments: the circuit board assembly (including radome and circuit board) and the encapsulation cover. The connection between these segments uses detachable fastening structures that provide sufficient structural integrity during operation but allow for easy disassembly when testing or repair is needed. This segmentation resolves the contradiction between strong assembly and easy disassembly.
Solution Approach 2:
The patent employs dynamic fastening structures that can transition between a tightly connected state for structural integrity and a separated state for accessibility. The encapsulation cover and circuit board assembly are designed with detachable connections that maintain strong structural integrity during normal operation but can be easily separated using simple fastening mechanisms, enabling both strong assembly and easy disassembly.
4Reliability
If conventional testing methods are used on the complete assembly, then the entire system can be tested, but the testing process becomes complex and time-consuming
Solution Approach 1:
The patent segments the testing process into two stages: first testing the circuit board assembly independently for transmission and reception capabilities, then testing the complete assembly after encapsulation. This segmented approach simplifies the testing process by breaking it into manageable stages, reducing the complexity of setup and measurement while ensuring comprehensive testing coverage.
Solution Approach 2:
The patent performs preliminary testing of the circuit board assembly before final encapsulation. This preliminary testing action simplifies the overall testing process by identifying and addressing potential issues early when the CBA is accessible, avoiding the need for complex disassembly and retesting operations later. The two-stage testing approach reduces overall testing complexity while maintaining completeness.
Data Source
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AI summary
A radar includes a radome (1), a circuit board (2), a shielding cover (3), and an encapsulation cover (4). The radome (1) includes a receiving space (S) and a wave transmitting face (11). The circuit board (2) is received in the receiving space (S). The circuit board (2) includes a first surface having an antenna area (21) and facing the wave transmitting face (11). The circuit board (2) further includes a second surface having a connection region (23). The shielding cover (3) is disposed over the second surface of the circuit board (2) and includes an opening region (31) aligned with the connection region (23). The encapsulation cover (4) includes at least one connecting element (41) which is electrically connected to the connection region (23) via the opening region (31). At least one testing element (51) is aligned with and electrically connected to the connection region (23) via the opening region (31) to perform a radar test. Thus, this process reduces manufacturing costs and improves testing and reprocessing efficiency.