Sheet Form Inner Connecting Element for Cavity Power Divider Assembly
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Solution Overview
Problem
The assembly of conventional cavity power dividers is complex, inefficient, time-consuming, and costly due to the separate fabrication and machining of components.
Innovation Solution
An inner connecting element in a sheet form is integrated with the cavity power divider, allowing for press-casting of the cavity and connectors as an integral unit, simplifying assembly and reducing costs through direct placement of the connecting element and welding with a cover plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the connecting rod is formed through machining process and cavity and connectors are fabricated separately, then the manufacturing precision and reliability are improved, but the device complexity and assembly time increase
Solution Approach 1:
The cavity and connectors are merged into a single integral component through press-casting technology. This eliminates the need for separate fabrication and assembly of these parts, thereby reducing assembly complexity while maintaining manufacturing precision through controlled casting processes.
Solution Approach 2:
The connecting element is pre-formed with integrated connection structures that include threaded portions and sealing features. This preliminary formation of connection interfaces eliminates the need for post-assembly machining and sealing operations, reducing both assembly time and complexity.
2Adaptability or versatility
If the cavity and connectors are fabricated separately and assembled, then the manufacturing flexibility is improved, but the productivity and assembly efficiency decrease
Solution Approach 1:
By combining the cavity and connectors into one press-casted component, the invention achieves high productivity through single-step manufacturing. The integral structure allows mass production via automated press-casting, significantly improving assembly efficiency while maintaining design flexibility through variable casting parameters.
Solution Approach 2:
The press-casting process enables flexible parameter control (temperature, pressure, mold design) to adapt to different cavity and connector configurations. This maintains manufacturing flexibility while achieving high-volume production capability, resolving the contradiction between flexibility and productivity.
3Strength
If the connecting rod is made through machining process, then the structural strength is improved, but the manufacturing cost and time consumption increase
Solution Approach 1:
The connecting element is pre-formed during the press-casting process with integrated strengthening features such as rib structures and optimized thickness distributions. This eliminates subsequent machining operations while maintaining structural strength, thereby reducing assembly time and manufacturing cost.
Solution Approach 2:
The press-casting process parameters (temperature, pressure, cooling rate) are optimized to produce connecting elements with desired mechanical properties. This allows achievement of required structural strength directly during casting, eliminating time-consuming machining while controlling material properties through parameter adjustment.
Data Source
AI summary
Embodiments of the present disclosure disclose an inner connecting element of a cavity power divider, the cavity power divider and a manufacturing method thereof. Two ends of the inner connecting element of the cavity power divider are respectively an input end and an output end, and the inner connecting element of the cavity power divider is in a sheet form. The cavity power divider comprises a cavity and at least three connectors. The cavity is provided with one connector at an input end thereof and with at least two connectors at an output end thereof. The connecting element is included in the cavity, with the input end and the output end of the connecting element being connected respectively with the connectors at the input end and the output end of the cavity.