Segmented Antenna Reflector Point-to-Point Interconnection
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Solution Overview
Problem
Large reflectors formed from interconnected segments in Earth Station Antennas suffer from shape errors due to cumulative misalignment and warping, affecting portability, repairability, and assembly efficiency.
Innovation Solution
A segmented antenna reflector design with point-to-point interconnections using standardized central, intermediate, and peripheral segments, featuring precise end-face interlocking mechanisms such as cams, latches, and reinforcing ribs, which reduce manufacturing tolerances and allow for easy assembly and repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If large reflectors are formed from multiple interconnected segments, then portability and repairability are improved, but shape accuracy deteriorates due to cumulative misalignment and warping
Solution Approach 1:
The reflector is divided into multiple segments that can be independently manufactured, transported, and assembled. This segmentation enables portability while the patent addresses the shape accuracy issue through precise interconnection mechanisms.
Solution Approach 2:
The patent replaces traditional mechanical alignment methods with a standardized interconnection system using precision-machined mating surfaces, locators, and fasteners that automatically ensure accurate alignment when segments are joined, eliminating cumulative misalignment errors.
2Ease of operation
If more segment interconnections are added, then portability is improved, but assembly complexity increases due to alignment requirements
Solution Approach 1:
Alignment features such as locators and mating surfaces are pre-configured on each segment during manufacturing. This preliminary preparation ensures that during assembly, segments simply need to be connected through these pre-designed interfaces, dramatically reducing assembly complexity despite the number of segments.
Solution Approach 2:
The patent employs standardized interconnection mechanisms that can be used across all segment joints. This universal approach allows the same assembly procedures and components to be reused throughout the structure, reducing the complexity that would otherwise arise from having to design and manage multiple different connection types.
3Ease of manufacture
If traditional surface-to-surface interconnections are used, then assembly is simpler, but shape accuracy deteriorates due to cumulative errors
Solution Approach 1:
The patent extracts the alignment function from the general surface-to-surface contact and concentrates it into specific, precision-machined locators and mating surfaces. This separation allows the majority of the segment surfaces to maintain their reflective function while dedicated features handle the alignment task with high precision.
Data Source
AI summary
An antenna reflector provided with a plurality of segments, each of the segments provided with a plurality of end faces positioned along surfaces of the segments. The end faces of adjacent segments arranged in lateral and radial pairs, the lateral and radial pairs coupled together. At least one of the end faces of the radial pairs and of the lateral pairs extending proud of the respective surfaces, whereby when the radial pairs and the lateral pairs are connected, the adjacent segments contact one another only via the radial and lateral pairs.