Mechanical Engineering Design

Structure

The Generation 1 structure weighed 220 lbs, had stability issues, and was very difficult to transport. The goal for Generation 2 is to provide a better platform for the electrical engineers to interface with. This will be acheived by cutting weight, enhancing mobility, and improving rigidity. It was decided that the use of modular extruded aluminum (80/20) would best meet the needs of the project. The "open-ended" nature of this product allowed the team to make adjustments throughout the life of the project.

Horn Holders

Functional requirements dictate that there be 20 different antenna horns -- all of which have to be correctly aimed within a 1ft circle at a distance of 20ft away. The previous design did not allow for any adjustment in the rotation of the antennas. The new design allows for 3 degrees of freedom for each horn: one translational (inwards/outwards from the center of the structure) and two rotational (elevation and azimuth). Additionally, each horn is mounted with identical hardware and can be easily removed or modified independently of one another.

Antenna Alignment

3D Printed parts were created to fasten to the antenna horns during calibration. Once the brackets were attached to the horn, they would be laser-calibrated within a 1ft diameter circle.

Radar Reflectors

To better support product testing, the ME Team designed supplemental hardware. The radar reflectors were used in order to provide data in a test scenario. The structure will be set up, and the radar reflectors placed at the predetermined distance of 20ft. Any radar waves emitted from the antenna array would reflect off of the half-cube aluminum reflector.

RF Panels

Because any emmitted RF would reflect back after making contact with metal, any metal objects in the testing room would cause interference in the readings. As a solution, RF absorbent material was used as a backdrop to the target, the radar reflectors.