90 Product focus | Antennas Lastly, while one might assume antennas for GCSs are a solved technology, with stationary broadcast and reception for fixed ground systems having existed for over a century, new forms of tracking antenna are coming out with the ability to more precisely maintain directional links with UAVs. Innovations include installing specialised tracking modules on UAVs that feed real-time position and attitude data back to the tracking antenna assembly, regardless of autopilot and GCS selections, and also the integration of new electric motors and ESCs that enable the antennas to pan and tilt with fast reaction times, maintaining coverage even in highly dynamic operations. Smart search patterns and similar behaviours embedded into tracking antenna software can also enable the recovery of lost links, thereby preventing the loss of a mission or vehicle. The design process Following copious discussions on platform anatomy, mission specifics, environmental considerations, frequency requirements and so on, a Request for Information or similar document can be formed, summarising the customer’s needs and specifications in a way that informs a new antenna’s initial design concept, whether it be a blank sheet design or the modification of an existing antenna. From our research, we surmise that at least a small majority of new antennas in this industry are customisations of existing designs to reduce SWaP-C parameters and be better suited to uncrewed vehicle requirements, as some manufacturers are now doing with designs unveiled not so long ago. Further technical dialogue, along with judicious simulation of the antenna’s electromagnetic, electrical and mechanical properties in industrystandard software such as CST can formalise these high-level requirements into an effective blueprint for antenna engineers to prototype something with adherence to exact technical specifications, performance criteria and matters crucial to regulatory compliance. What follows prototyping can vary between production houses. Some will begin rounds of in-house testing and validation; others will initially pass the first prototype to the customer for them to test and validate against their specific use-case scenarios as a first source of vital data to inform design adjustments on subsequent iterations of the prototype. Once sufficiently optimised, a first article antenna – designed not only for all the vehicle, mission and environment parameters but also for manufacture – can be produced, and put through qualification tests to verify that it meets all standards and will perform to spec in its intended environment. Some antenna companies will henceforth retain that first article antenna to serve as a reference point for subsequent production units to conform to. Production lines Regardless of the mixture of manual versus automated processes, antenna manufacturing requires extremely tight quality control (QC) at every stage to ensure consistency of produced batches with the first article in their form and performance. Hence, a variety of organisational software programs are leveraged by antenna makers for the earliest stages of production, encompassing the planning and processing of new orders, and the acquisition, inspection and characterisation of material inventories. Antenna production lines can be right-sized for high-volume throughput of thousands of units per week, or lower volumes of 25-50 per week, and run the gamut of manufacturing machinery seen across the industry. CNC mills and lathes can be vital for consistent and controlled production of complex antenna elements, as well as housings, and also for tools, jigs and fixtures. Some manufacturers will even bring a flat-bed mill in-house to produce their own PCBs for antennas, internal networks, filters or radios. While PCBs produced in this way are unlikely to match the consistency of traditionally fabricated boards, such capability can be a godsend for rapid June/July 2024 | Uncrewed Systems Technology Thorough testing for pattern, gain and environmental ruggedness are all key to ensuring antennas function optimally in the field (Image courtesy of Videosys Broadcast)
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