Comprehensive Design Flow of a 61GHz Radar Frontend with ... · with CST Studio Suite and Altium...

Comprehensive Design Flow of a 61GHz Radar Frontend with CST Studio Suite and Altium Designer

Gabor Vinci – Lead Research Engineer, R&D Industrial Division

Gabor Vinci – InnoSenT GmbH - CST European User Conference 2014 - Berlin

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1. Introduction

2. Product Development Phases & Tools

4. Geometry, Layout & Numerical 3D EM Simulation

3. Development Process – Design Flow

5. Data Format Exchange and Workflow

6. Data Import/Export from/to Tools

7. Complete Model Full-3D Simulation

8. EM-relevant Mechanics - Example

9. Conclusion

Overview


3

Introduction


InnoSenT radar sensors Advanced technology for a wide area of applications

distance, speed and position of moving or stationary objects / people

24, 61 and 77 GHz Radar frontends and Systems Mostly based on planar PCB Technology

High level of Integration

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Product Development Phases and Tools

Product Development

& Design

Thermal Simulation

CST Mpysics

Studio

System & Circuit Simulation

Agilent ADS, LT Spice

Analytic System & Signals Simulation

MATLAB

Geometry & Layouting

Altium Designer

3D-EM Simulation CST Microwave

Studio


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Product Development Phases and Tools

Product Development

& Design

Thermal Simulation

CST Mpysics

Studio

System & Circuit Simulation

Agilent ADS, LT Spice

Analytic System & Signals Simulation

MATLAB

Geometry & Layouting

Altium Designer

3D-EM Simulation CST Microwave

Studio


6

Development Process – Design Flow

Analytical System Simulation (MATLAB)

Low-level Hardware System & Circuit Simulation (Agilent ADS)

Analytical Circuit Simulation (LT Spice)

3D-EM Simulation (CST Microwave Studio)

Thermal Simulation (CST Mphysics Studio)

Analytical System Design (handmade functional block diagram)

Product Idea Customer Requests and Specifications

Layouting / Routing (Altium Designer)

LF RF LF


Finalized Design

Mechanical (Solid Works)

Analytical

System Design

Analytical

Circuit Design

Geometry, Layout Numerical 3D EM Simulation

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Development Process – Design Flow

Analytical System Simulation (MATLAB)

Low-level Hardware System & Circuit Simulation (Agilent ADS)

Analytical Circuit Simulation (LT Spice)

3D-EM Simulation (CST Microwave Studio)

Thermal Simulation (CST Mphysics Studio)

Analytical System Design (Handmade Functional block diagram)

Product Idea Customer Requests and Specifications

Layouting / Routing (Altium Designer)

LF


Finalized Design

Mechanical (Solid Works)

Analytical

System Design

Analytical

Circuit Design

Geometry, Layout Numerical 3D EM Simulation

RF LF

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Geometry, Layout & Numerical 3D EM Simulation


CST Microwave Studio

• Design of RF circuit elements • Verification of link-budget • Complex geometry construction • Influence of material tolerances • Influence of geometrical tolerances • Integration of mechanical data

• Optimization process

Mechanical Design (Solid Works)

System requirements

Altium Designer • Circuit diagram & netlist

• Integration of RF circuit elements

• Merging of RF and LF circuit design

• Design-rule check

• Routing

• Multilayer design

• Mechanical overlay

Finalized Design

9

Data Format Exchange and Workflow


CST Microwave Studio 2013.06

CST PCB Studio 2013.06

Altium Designer 14.1.5 (Build 30772)

Solid Works Premium 2012 x 64 SP5.0

ODB++ Data Archive

3D Model Internal

Link

PCB Dummy IDF (EMN)

Single component geometries DXF Layers

Mechanics SAT V-19

Mechanics SAT V-19

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Basic DXF geometries with primitives of the microwave planar structures Several structures can be merged in sub-units as well.

• Design of RF circuits

• True 3D-EM simulation • Verification of link-budget

• Yield analysis • Material tolerances • Optimization process

• Influence and Interaction

• Circuit diagram

• Complete routing process

• Multilayer PCB design • Definition of components

• Definition of net-lists

• Solder masks, paste-layers

• Design-rule check

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ODB++ Data Archive

PCB Dummy IDF (EMN)

• Whole system is exported as an ODB++ archive and imported back in the CST Studio Suite with the help of the PCB Studio module.

• Mechanical PCB dummy is generated in Altium and exported as IDF

(EMN) file for the Mechanical Design Team.

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3D Model Internal

Link

• A fully detailed 3D model is generated and passed to CST MWS. 3D Models of components are embedded in the ODB++ archive.

• Mechanical data is transferred to CST MWS as SAT File.

• Mechanical data can be transferred back to Solid Works.

Mechanics SAT V-19

Mechanics SAT V-19

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DXF Export from CST Microwave Studio


Pick points to define layers

Export DXF

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DXF Export from CST Microwave Studio


DXF layers highlighted. Multilayer export.

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DXF import in Altium Designer


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ODB++ Export from Altium Designer


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ODB++ Import in CST PCB Studio


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From PCB Studio to Microwave Studio


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Imported Model in CST Microwave Studio


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Complete Model Full-3D Simulation


• Influence of geometrical tolerances

• Integration of mechanical data

• Optimization process

• Design of RF circuit elements

• Complex geometry construction

• Influence of material tolerances

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Dielectric Lens Antenna Design


Lens Diameter: 40 mm

50 mm

50 mm

26.5 mm

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Mechanical data from 3D-EM specific geometries can be transferred back to Solid Works for integration with other mechanical features.

Mechanics SAT V-19

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Conclusion


Design Iterations Goal Optimization

Hardware Prototype With (nearly) no iterations

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Conclusion


Thank you for your attention

Comprehensive Design Flow of a 61GHz Radar Frontend with ... · with CST Studio Suite and Altium...

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