Radio Assembly Selective Filter Unit Repair

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Solution Overview

Problem

Existing radio antenna systems face issues with low first pass production yield due to passive intermodulation (PIM) failures in bullet connectors, requiring multiple cycles of disassembly and reassembly to correct faulty connections, leading to poor yield and increased complexity.

Innovation Solution

A radio assembly design that allows selective detachment of individual filter units by attaching all filter units together as one structural element, enabling the removal of faulty units without disconnecting good branches, maintaining connections between filter units and antenna.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of repair

If all bullet connectors are disconnected for repair, then faulty connections can be accessed and replaced, but the system requires total disassembly and reassembly which increases time loss and reduces productivity

Engineering Contradiction:

Improveaccess to faulty connectorsVSAvoiddisassembly and reassembly time

Core Design Contradiction:

Ease of repairVSLoss of time

Solution Approach 1:

The antenna assembly is segmented into individual antenna branches, each with its own filter unit and bullet connectors. This allows the system to be divided into independent repairable units, so that only the faulty branch needs to be accessed rather than the entire assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The faulty filter unit and its associated bullet connectors are extracted from the assembly for replacement, while the remaining good branches stay connected. This selective extraction avoids the need to disconnect and reconnect all 96 bullet connectors in the system.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of repair

If all bullet connectors are disconnected for repair, then faulty connections can be accessed, but the probability of introducing new PIM failures in previously good connections increases

Engineering Contradiction:

Improveaccess to faulty connectorsVSAvoidPIM performance of good branches

Core Design Contradiction:

Ease of repairVSReliability

Solution Approach 1:

By segmenting the system into independent antenna branches with individual filter units, the repair process isolates the faulty connection to a single branch. This prevents disturbance to the other branches, maintaining their PIM performance without requiring reconnection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The faulty filter unit is extracted and replaced while leaving the good branches permanently connected. This selective replacement approach ensures that previously good connections are not touched, eliminating the risk of introducing new PIM failures in those connections.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of repair

If the entire antenna is disassembled for repair, then all bullet connectors become accessible, but the complexity of the repair process increases and yield decreases

Engineering Contradiction:

Improveaccess to all connectorsVSAvoidrepair process complexity

Core Design Contradiction:

Ease of repairVSDevice complexity

Solution Approach 1:

The antenna assembly is segmented into independent branches, allowing repair personnel to access and repair only the specific faulty branch rather than managing the entire complex assembly of 96 connectors. This reduces repair process complexity significantly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The repair process is localized to only the faulty antenna branch and its associated filter unit. The rest of the system remains untouched and operational, reducing the overall complexity of the repair task from system-wide to component-specific.

Inventive Principle:

Principle #3Local quality

4Reliability

If multiple cycles of disassembly and reassembly are performed, then PIM criteria can be met, but production yield and productivity deteriorate

Engineering Contradiction:

ImprovePIM criterion complianceVSAvoidfirst pass production yield

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Filter units are pre-assembled with their bullet connectors and tested for PIM compliance before integration into the antenna assembly. This preliminary preparation ensures that when units are installed, they meet PIM criteria from the first pass, reducing the need for rework cycles.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Faulty filter units that fail PIM testing are extracted and replaced with pre-tested good units. This targeted replacement approach ensures PIM compliance is achieved in a single repair cycle rather than requiring multiple disassembly and reassembly cycles.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS20260009831A1Radio assembly repairability

Publication Date: 2026.01.08 TELEFONAKTIEBOLAGET LM ERICSSON (PUBL)

AI summary

A method, system and assembly are disclosed. A radio assembly includes at least one radio including a radio board, a plurality of filter units, a plurality of clamp elements, and an antenna unit. A subset of the plurality of filter units remain removably attached to the radio board while the remaining plurality of filter units remain removably attached to the antenna unit and plurality of clamp elements based on whether the second plurality of fastening elements are unfastened from a subset of the plurality of second filter mating elements associated with the subset of the plurality of filter units, the third plurality of fastening elements associated with the subset of the plurality of filter units are unfastened from respective first filter mating elements; and the first plurality of fastening elements associated with the remaining plurality of filter units are unfastened from respective radio mating elements.