Waveguide Assembly Using Elastic Retaining Ring
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Solution Overview
Problem
The existing assembly methods for waveguides, such as screw-nut systems, are inefficient in terms of mass, accessibility, and cost, and pose challenges with disassembly and complex implementation, especially for large-scale satellite payloads requiring thousands of connections, which also compromise RF performance and electromagnetic compatibility.
Innovation Solution
An assembly device using a sheath with annular grooves and reversibly deformable elements, such as springs with inclined turns, to securely connect waveguides without screws, ensuring RF, EMC, and mechanical performance while allowing for disassembly and accessibility, by exerting predefined pressure between the waveguides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screw-nut systems are used to assemble waveguides, then mechanical connection strength is achieved, but assembly time and cost increase significantly
Solution Approach 1:
The invention extracts and removes the screw-nut fastening elements from the waveguide assembly system, replacing them with a direct push-fit connection between waveguides. This eliminates the time-consuming operations of inserting, tightening, and securing multiple screws per joint, while maintaining mechanical strength through the geometric interlocking of the waveguide flanges and the elastic retaining ring that prevents separation.
Solution Approach 2:
The invention substitutes the complex mechanical screw-nut fastening system with a simplified elastic retention mechanism. The elastic retaining ring deforms elastically to engage with grooves in the waveguide flanges, creating a secure mechanical connection through elastic deformation rather than threaded fasteners. This replacement dramatically reduces assembly steps while maintaining connection integrity.
2Strength
If screw-nut systems are used to assemble waveguides, then mechanical connection strength is achieved, but the number of components and cost increase
Solution Approach 1:
The invention merges multiple separate components (screws, nuts, washers, and flanges) into an integrated waveguide structure with built-in attachment features. The waveguide flanges incorporate grooves and protrusions that work together with a single elastic retaining ring to create a secure connection, eliminating the need for multiple discrete fastening components and reducing overall system complexity.
Solution Approach 2:
The waveguide flanges are designed with self-aligning geometric features including grooves and protrusions that automatically guide the connection process. The elastic retaining ring self-adjusts through elastic deformation to engage these features securely, creating a self-service connection system that does not require external fasteners or complex assembly procedures.
3Ease of operation
If clip-on mounting systems are used for existing flanges, then assembly is simplified, but mass and accessibility issues arise
Solution Approach 1:
The elastic retaining ring serves multiple functions simultaneously: it provides mechanical retention to prevent waveguide separation, maintains precise alignment through geometric engagement with grooves, and ensures electrical continuity for RF signal transmission. This multi-functional component replaces the need for separate mounting clips, alignment fixtures, and electrical connectors, reducing overall mass while simplifying assembly.
4Strength
If welding or bonding methods are used to join flanges, then permanent connection is achieved, but disassembly becomes difficult and implementation becomes complex
Solution Approach 1:
The invention introduces dynamic reversibility to the connection system through the elastic retaining ring. The ring's elastic properties allow it to deform during assembly to enable engagement, then maintain a secure permanent-like connection during operation. For disassembly or repair, the ring can be easily deformed again to release the connection, providing reversible connectivity without the permanence and complexity of welding or bonding processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution eliminates the need for screws, reducing assembly time and cost, achieving a 30% weight savings, ensuring uniform contact pressure, and providing enhanced EMC insulation, while allowing for greater waveguide density and easier assembly, with the added benefit of a reinforced shielding system.
Implementation Method 1
two reversibly deformable elements, each being positioned in a first annular groove of the sleeve and positioned in a first annular groove of the first and second waveguides, so as to block in translation along the first axis the first and second waveguides
Implementation Method 2
at least one reversibly deformable element is a spring with inclined coils, so as to exert a predefined pressure between the first and second waveguides
Data Source
Figure 1~3
Figure 4~5
Figure 6~8
AI summary
The invention relates to an assembly comprising a first waveguide (1) and a second waveguide (2) extending longitudinally along a first axis (Z), each having an end (3, 4) comprising a first annular groove (6), the two ends (3, 4) being contiguous along the first axis (Z), and a device for assembling the first waveguide and the second waveguide, in which the assembly device comprises: - a sleeve surrounding the ends of the first and second waveguides, having an inner wall comprising two first annular grooves opposite the first annular grooves of the first and second waveguides, - two reversibly deformable elements, each being positioned in a first annular groove of the sleeve and positioned in a first annular groove of the first and second waveguides, so as to block in translation along the first axis the first and second waveguides.