Stacked Waveguide Structure for Precise Radar Antenna Alignment
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Solution Overview
Problem
In millimeter wave radar antenna systems, assembly tolerances due to incorrect alignment of the antenna, waveguide, and circuit board can lead to inaccurate antenna performance.
Innovation Solution
A waveguide design with a lower plate having a first vertical through-hole and an upper plate with a second vertical through-hole and a horizontal groove, allowing for alignment verification during assembly by exposing the launcher on the circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional waveguide structure is used without alignment features, then the manufacturing process is simpler, but alignment tolerance during assembly increases leading to inaccurate antenna performance
Solution Approach 1:
The waveguide structure includes alignment holes and alignment protrusions that enable self-alignment during assembly. The alignment protrusion on the circuit board fits into the alignment hole of the waveguide, allowing the components to automatically position themselves correctly without requiring external alignment tools or complex positioning mechanisms.
Solution Approach 2:
The alignment features (alignment holes and alignment protrusions) are simple, inexpensive structural elements that are integrated into the waveguide and circuit board. These features serve their alignment purpose during assembly and can be considered as single-use alignment aids that do not require complex or expensive alignment mechanisms.
2Manufacturing precision
If alignment features are added to the waveguide, then assembly alignment precision improves, but the device complexity increases
Solution Approach 1:
The waveguide structure is segmented into distinct functional areas: the main waveguide body for signal transmission, and the alignment holes/protrusions for positioning. This segmentation allows the alignment function to be separated from the signal transmission function, enabling simple alignment features to be added without complicating the core waveguide structure.
Solution Approach 2:
The alignment protrusion acts as an intermediary element between the circuit board and the waveguide. It mediates the alignment process by providing a physical interface that guides the relative positioning of the two components, ensuring accurate alignment without requiring complex positioning systems.
3Ease of operation
If the launcher is hidden during assembly, then the waveguide structure is more compact, but alignment verification becomes difficult
Solution Approach 1:
The alignment holes and protrusions are designed to enable preliminary alignment verification before the final assembly is complete. The launcher remains accessible through the alignment hole during the alignment process, allowing operators to verify positioning accuracy before closing or sealing the waveguide structure.
Solution Approach 2:
The design utilizes the vertical dimension by having the launcher extend through the waveguide structure. This allows the launcher to be accessible from the top side of the waveguide while maintaining a compact overall structure, enabling alignment verification without increasing the horizontal footprint or requiring additional external alignment mechanisms.
Data Source
AI summary
Disclosed is a waveguide having a first vertical transfer path formed at a lower plate coupled to a signal processing substrate, and having a horizontal transfer path and a second vertical transfer that are formed at an upper plate coupled to a radar antenna, and thus minimizing tolerance during assembly. The disclosed waveguide is constructed by stacking the upper plate on the upper surface of the lower plate, a first vertical through-hole is formed in the lower plate, a second vertical through-hole and a horizontal groove are formed in the upper plate, and the horizontal groove connects the first vertical through-hole and the second vertical through-hole to form a radio wave transfer path.