Waveguide Bend Assembly With Cavity Flanges

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Solution Overview

Problem

Conventional waveguide assemblies require complex and costly soldering or brazing processes for assembly, necessitating specialized skills and equipment, and are often transported and stored as fused units, which can be cumbersome and prone to damage.

Innovation Solution

The waveguide assembly features longitudinal features on the tubular portions that allow for easy cutting and reconfiguration using simple tools, enabling assembly with screws and flanges, eliminating the need for fusion techniques and allowing for disassembly and reassembly as needed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If soldering or brazing processes are used to assemble waveguide components, then the joint strength and reliability are improved, but the manufacturing complexity and cost increase, and specialized skills and equipment are required

Engineering Contradiction:

Improvejoint strengthVSAvoidassembly process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The waveguide assembly is divided into separate modular components (straight waveguide sections and bend sections) that can be independently manufactured and assembled. Each section has standardized flange interfaces with cavity portions that receive attachment fasteners, allowing the components to be segmented yet reliably connected through mechanical fastening rather than fusion processes

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Attachment fasteners serve as intermediary elements that connect the waveguide components. These fasteners engage with the cavity portions in the flanges to provide a reliable mechanical connection, replacing the need for soldering or brazing while maintaining joint strength and reliability

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If waveguide units are transported and stored as fused units, then the structural integrity is maintained, but the transportation and storage become cumbersome and the units are prone to damage

Engineering Contradiction:

Improvestructural integrityVSAvoidtransportation and storage ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The waveguide system is segmented into separate, modular components that can be transported and stored independently. The straight sections and bend sections can be moved separately, reducing the bulk and weight compared to transporting complete fused assemblies, while the standardized flange interfaces ensure reliable reassembly at the installation site

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flange interfaces with cavity portions and attachment features are pre-configured on each component during manufacturing. This preliminary preparation of connection interfaces allows for quick and reliable assembly at the installation site, maintaining structural integrity without requiring complex field welding or brazing operations

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If specialized skills and equipment are required for waveguide assembly, then the manufacturing precision and reliability are improved, but the manufacturing cost and time increase

Engineering Contradiction:

Improveassembly precisionVSAvoidmanufacturing accessibility

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The waveguide components are designed with self-aligning flange interfaces that feature cavity portions and standardized attachment points. These built-in guiding features automatically align components during assembly, eliminating the need for specialized alignment skills or equipment while ensuring manufacturing precision through the standardized interface geometry

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The flange interfaces are designed as universal connectors that can accommodate various waveguide configurations (straight sections, bends, different orientations). This universal interface design allows the same attachment mechanism to work across different assembly scenarios, reducing the need for specialized skills and equipment while maintaining precision through standardized dimensions and tolerances

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10090570B2Waveguide bend assembly having waveguide flanges with cavity portions therein for attaching the waveguide bend to straight waveguides

Publication Date: 2018.10.02 AVIAT U S

AI summary

Various embodiments provide for waveguide assemblies which may be utilized in wireless communication systems. Various embodiments may allow for waveguide assemblies to be assembled using tools and methodologies that are simpler than the conventional alternatives. Some embodiments provide for a waveguide assembly that comprises a straight tubular portion configured to be shortened, using simple techniques and tools, in order to fit into a waveguide assembly. For instance, for some embodiments, the waveguide assembly may be configured such that the straight portion can be shortened, at a cross section of the portion, using a basic cutting tool, such a hacksaw. In some embodiments, the straight portion may be further configured such that regardless of whether the straight tubular portion is shortened, the waveguide assembly remains capable of coupling to flanges, which facilitate coupling the straight tubular portion to connectable assemblies, such as other waveguide assemblies, radio equipment, or antennas.