Passive Microwave Products. Facts - Products - Applications

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Alfred Mosley
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1 Passive Microwave Products Facts - Products - Applications

High technology for the global satellite market 1.

clear European market leader. On its 60,000m² premises in Backnang, Germany, 1,200 employees develop, assemble, integrate, and test systems and equipment for telecommunication via satellite.

The Applications page 14 Our product offerings encompass highly reliable equipment as for example the travelling wave tube amplifiers, multiplexers, waveguide switches, and modulators, which along

Therefore, we offer the complete communication technology necessary to disseminate television signals via satellite to each household on ground.

The future global communication infrastructure has to support security-related real time applications with ubiquitous coverage.

2 High technology for the global satellite market 1. The Motive page 4 Over the course of five decades, Tesat-Spacecom has developed in-depth expertise in manufacturing of payload equipment for communication satellites and has established itself as a clear European market leader. On its 60,000m² premises in Backnang, Germany, 1,200 employees develop, assemble, integrate, and test systems and equipment for telecommunication via satellite. To date, more than 700 space projects have been completed. The accumulated in-orbit lifetime heritage exceeds 250 million hours. 2. The Developments PAge 6 3. The Products PAge 8 4. The Applications page 14 Our product offerings encompass highly reliable equipment as for example the travelling wave tube amplifiers, multiplexers, waveguide switches, and modulators, which along with complete systems are delivered to all leading satellite manufacturers worldwide. Therefore, we offer the complete communication technology necessary to disseminate television signals via satellite to each household on ground. More than half of all communication satellites The World of Tesat-Spacecom in orbit operate with Tesat equipment on board. The future global communication infrastructure has to support security-related real time applications with ubiquitous coverage. This will only be viable with most advanced communication systems operating in space. Tesat has successfully developed the key element for this space infrastructure, the optical broadband Laser Communication Terminal (LCT). Using lasers, such terminals can transmit data and imagery between satellites and from satellites to ground at unprecedented data rates. We at Tesat have demonstrated for the first time the operational capabilities of such broadband LCTs in space. Given our competitive position in the commercial satellite market and our top quality standards, Tesat products are today the first choice for various satellitebased systems operated by several governments worldwide for security and defense related applications. 5. The Mission PAge Amplifier Products Passive Microwave Products Communication Systems Datalink Products Laser Products Parts Agency

Why use Tesat s Passive Microwave Products? Tesat has extensive experience in the field of designing satellite filters in accordance with individual customer requirements.

The Motive 1Why Use Tesat s Passive Microwave Products?

3 Why use Tesat s Passive Microwave Products? Tesat has extensive experience in the field of designing satellite filters in accordance with individual customer requirements. Expertise and competence are merged in the operational division of Passive Microwave Products to ensure highly efficient performance at all times. The Motive 1Why Use Tesat s Passive Microwave Products? A multitude of Input and Output Multiplexers and Filters from L- to Ka-Band have been designed, manufactured, qualified and successfully launched in various programs for the past five decades. Based on our experience in supplying Passive Products, Tesat has established production lines for a wide range of products such as IMUXes, OMUXes, Components and Waveguide Switches. These lines are supported by a customer interface, a design & an analysis team and an outstanding manufacturing & test facility. Our customers benefit from the following qualities: A customer interface ensuring continuous communication flow and project tracking An engineering team supporting concurrent engineering approach for payload layout and system design By using state-of-the-art design and simulation tools, short design iterations with excellent product performance can be finished in time Thanks to an extended portfolio ranging from simple components to complex assemblies a complete Payload equipment can be provided A well-established subcontractor management and long-term supplier relationship support high-quality piece parts machining in time In-house Parts Agency ensures high quality of procurement Products are assembled and tested in the Passive Microwave Facility, with dedicated value streams for Components, Waveguide Switches, IMUXes and OMUXes Manufacturing processes such as surface treatment are accommodated in-house to provide a continuous assembly flow 5

The Developments The engineering and manufacturing of Passive Products can be traced back to 1971, when a small team of engineers set out on the long way to become a satellite

Design was calculated by simple formula and finalised using cut-and-try approach.

Today Tesat has a multiphysic simulation platform to synthesize and simulate 24-channel OMUXes or IMUXes including all parameters like temperature drift, RF performance, power

The continuous improvement of quality, assembly, test and engineering is merged in a dedicated 6-floor building for Passive Products.

4 The Developments The engineering and manufacturing of Passive Products can be traced back to 1971, when a small team of engineers set out on the long way to become a satellite equipment supplier. The Developments Tesat s Extensive Experience The first unit was delivered for the Intelsat IV program in Design was calculated by simple formula and finalised using cut-and-try approach. Simulation tools, based on field theory, were developed and continuously extended over the last decades. Today Tesat has a multiphysic simulation platform to synthesize and simulate 24-channel OMUXes or IMUXes including all parameters like temperature drift, RF performance, power loss and CAD file configuration. Assembly and test of Passive Products is another sector that was built up. The continuous improvement of quality, assembly, test and engineering is merged in a dedicated 6-floor building for Passive Products. The concentration, providing the advantage of short routes, has generated a spirit of pioneering and commitment to our customer. A Customer Interface Team is the first technical contact to provide payload design support. The team is supported by a strong group with microwave engineering background. To manage the growing business in the last couple of years, the entire team has been trained in six-sigma design and manufacturing methodology. This is supporting our mission: Transforming ideas into high-quality products. 7

The Products Tesat supplies all Passive Products between receive and transmit antenna which a customer needs to build up

The product spectrum is branched into IMUXes, OMUXes, Switches and Components.

Due to forward-looking stock policy for parts, a good delivery time and a high producibility can be ensured.

OMUXes are designed and produced in different technologies to meet customer demands.

high power-handling capability in Ku- and Ka-Band.

To reduce footprint and integration effort on the Payload, Tesat is providing assemblies with three or more layers.

Waveguide Switches are a key component for redundancy and configuration concepts.

Sequential and random access actuators for changing switch branching can be provided for Payloads.

5 The Products Tesat supplies all Passive Products between receive and transmit antenna which a customer needs to build up a Payload. Many products have a long heritage in orbit or are qualified by a dedicated program. The product spectrum is branched into IMUXes, OMUXes, Switches and Components. The Products IMUXes - OMUXes - Switches - Components IMUXes feature excellent RF performance and temperature stability. Due to forward-looking stock policy for parts, a good delivery time and a high producibility can be ensured. A proven concept of modularity opens up the benefit of flexibility to provide customer-specific IMUX configurations. OMUXes are designed and produced in different technologies to meet customer demands. The classical OMUX technology based on Invar filter is complemented with the upcoming Aluminum technology to provide high power-handling capability in Ku- and Ka-Band. Diplexers are combining output signals of OMUXes to increase the number of channels per antenna. To reduce footprint and integration effort on the Payload, Tesat is providing assemblies with three or more layers. These highly integrated subunits can be configured and designed to customer specifications. Waveguide Switches are a key component for redundancy and configuration concepts. These switches have a high reliability and excellent RF performance. Sequential and random access actuators for changing switch branching can be provided for Payloads. The product spectrum was increased in continuously responding to market request for Tesat to offer all frequency bands from 3 to 40 GHz. Components such as Couplers, Loads or Circulators are designed and manufactured from 3 to 40 GHz. These products have a high producibility and some follow ESA guidelines of manufacturing. For high-power components such as Loads and Circulators, a dedicated test setup is available to ensure a systematic screening process. IMUXes OMUXes Switches 9

Input Multiplexers and Multiplexer Assemblies An Input Multiplexer (IMUX) allots the broadband incoming signals to individual channels.

They are also available as Input Multiplexer Assemblies including Switches, Low-Pass Filters, Hybrids, Circulators, Isolators, etc.

Tesat has an excellent heritage in designing and manufacturing Microwave Output Multiplexers. The most common technology for X-, Ku-, Ka-Band are Dielectric Channel Filters.

IMUX assemblies up to 24 channels follow a common integration approach. The modular design approach is the basis of this flexible architecture.

For lower frequencies like L-, S- and C-Band, a coaxial resonator technology for channel filters is the common approach.

6 Input Multiplexers and Multiplexer Assemblies An Input Multiplexer (IMUX) allots the broadband incoming signals to individual channels. Highly demanding electrical performance requirements have to be met by the Input Multiplexer. They are also available as Input Multiplexer Assemblies including Switches, Low-Pass Filters, Hybrids, Circulators, Isolators, etc. Output Multiplexers and Multiplexer Assemblies Output Multiplexers combine power signals emitted from the Power Amplifier to feed the antenna network. Tesat has an excellent heritage in designing and manufacturing Microwave Output Multiplexers. The most common technology for X-, Ku-, Ka-Band are Dielectric Channel Filters. Typically, these filters have 8 to 10 poles to shape the required transmit characteristic. The vertical integration provides a small footprint and optimal connector access from the top. IMUX assemblies up to 24 channels follow a common integration approach. The modular design approach is the basis of this flexible architecture. Following heritage guideline, configurations can be adapted to customer demands. For lower frequencies like L-, S- and C-Band, a coaxial resonator technology for channel filters is the common approach. These filters are following the successful vertical integration concept to provide optimal connector access. Especially the C-Band units have an outstanding small footprint and low mass. The modular concept can be extended up to 26 filters. The flexible architecture can be adapted to customer demands. Special Ka- Band RF performance challenges can be realized using Waveguide Channel Filters with 8 to 12 poles. To reduce the footprint, a two- or three-layer assembly with heritage is available. Classical Invar technology for the channel filters has the longest heritage and is still dominating the market. Thanks to Invar, very low temperature drift can be provided. Power handling is increased by special design features like copper stripes and a highly sophisticated assembly technique. The most complex part is the manifold which collects all signals. In order to achieve the best possible RF performance, this part is manufactured from one single block of raw material. OMUXes are built with cylindrical cavity filter up to 24 channels on one manifold or in halfshell technology up to 10 channels. Both technologies have an excellent market penetration. For lower frequency bands, the cavity is loaded with dielectric to reduce the overall size. Up to 14 channels can be combined on manifold. The aluminum technology introduced is the baseline to reduce weight and to increase the output power of Output Multiplexers. Low-loss microwave modes are combined with temperature compensation measured to improve temperature stability. As a result of this technology merge, these OMUXes represent a premier space technology

Waveguide Switches Tesat is manufacturing and supplying Waveguide Switches operating in the frequency range from 4 to 40 GHz for redundancy matrices and Payloads.

These units significantly reduce payload integration time and are thus in strong demand. Another benefit is the improved overall RF-performance of the payload.

Following this design approach, Tesat can provide a wide spectrum of configurations to support various types of satellite payload architecture.

The Waveguide Switches can handle very high RF power. All waveguide interfaces are covered by windows to protect the sensitive RF section.

Thanks to this, switch performance and position will not change over life time and ensure full functionality after high vibration and shock levels.

7 Waveguide Switches Tesat is manufacturing and supplying Waveguide Switches operating in the frequency range from 4 to 40 GHz for redundancy matrices and Payloads. Assemblies In Assemblies, many units such as OMUXes, IMUXes, Switches, Circulators, Couplers and Loads are combined to Super Units called Output- or Input Assemblies. These units significantly reduce payload integration time and are thus in strong demand. Another benefit is the improved overall RF-performance of the payload. The modular switch concept is based on three building blocks: RF section, Actuator and Interface. Following this design approach, Tesat can provide a wide spectrum of configurations to support various types of satellite payload architecture. For the RF section, C- and R-Type Switches are designed in the frequency range from 3 to 40 GHz. The excellent RF performance is ensured by integrated design features. The Waveguide Switches can handle very high RF power. All waveguide interfaces are covered by windows to protect the sensitive RF section. To change switch position, the RF section can be combined with a sequential or random access Actuator. The different switch positions are locked by magnetic latching. Thanks to this, switch performance and position will not change over life time and ensure full functionality after high vibration and shock levels. The interface can be equipped with a 9- or 15-pin connector. The switch position is indicated by reed switches. They can provide a resistance or open closure telemetry. Footprint and weight is reduced by introduction of multiple switches in one block. The story of designing such superunits started several years ago, following the demand to increase functionality on payload with equal footprint. For such units Tesat has developed a dedicated technology to lay out multiple floor approaches. The on-site experts for electrical design, layout and environmental analysis work hand in hand to shape the units to best performance vs. small footprint, low mass and RF characteristic. Nowadays multiplexers, switches, circulators, loads and switches are merging together to overcome yesterday s concepts. Tesat is designing and manufacturing nearly all units, which supports the optimum alignment of subunits and interfaces. Tesat provides these assemblies from L-band up to 30 GHz. For such units in particular, the TVac test capability was expanded in 2015, which reflects market success and customer demand. established & proved Benefits: Reduced payload integration time because output sections are realized with few units only Improved overall RF payload performance due to step-by-step tuning process Increased integration density on payload due to multi-floor approach, more functionality per square foot 12 13

Passive Components for Space Applications These products include High-Performance Circulators, Couplers, Power Combiners & Transitions for L-, S-, C-, Ku- & Ka-Band.

For this dynamically increasing business, Tesat has built up a dedicated assembly-/test-team.

The introduction of six-sigma process monitoring indicates early process deviations and is driving the process feedback loop in production.

This product group has a modular technology and process platform. This means integrity of technology and process versus frequency bands is established.

8 Passive Components for Space Applications These products include High-Performance Circulators, Couplers, Power Combiners & Transitions for L-, S-, C-, Ku- & Ka-Band. The Applications Components for Space Applications Tesat has enhanced its array of products in the past couple of years to cover the full product spectrum. For this dynamically increasing business, Tesat has built up a dedicated assembly-/test-team. Most of the products take the ESA Parts recommendation as guideline to ensure quality and RF-performance. The introduction of six-sigma process monitoring indicates early process deviations and is driving the process feedback loop in production. The in-process power screening on Circulators and Loads is verifying process integrity. Screening test is run on automatic power test stations to sustain smooth production flow. This product group has a modular technology and process platform. This means integrity of technology and process versus frequency bands is established. The benefits for our customer are cross-frequency heritage and excellent quality. RF performance is state-of-the-art and fitted to the other products such as IMUXes, OMUXes or Waveguide Switches. The transformation of market expectation has arrived in this product area, too. On the one side components have become more and more a part of integrated assemblies and on the other side components functions are merged to more functionality at lower cost, e.g. Filters with Couplers, Circulators with Loads and so forth. 15

Based on heritage discover the future Tesat has established a close partnership and cooperation with six universities to ensure scientific support for our pioneering.

Finally many students find an interesting engineering position at Tesat for their first industrial placement.

In the last decade, Tesat has had a successful cooperation with DLR and ESA in designing new products and placing them on the market.

In recent years, Tesat has extended the high power capability of OMUXes with the new generation of Aluminum OMUX technology.

9 Based on heritage discover the future Tesat has established a close partnership and cooperation with six universities to ensure scientific support for our pioneering. The positive outcome of this interchange is a continuous flow of new ideas and innovative thoughts. Finally many students find an interesting engineering position at Tesat for their first industrial placement. The Mission 5Roadmap of Programs Joint projects with universities cover the area of improving simulation tools, pioneering future technology or research of new products. In the last decade, Tesat has had a successful cooperation with DLR and ESA in designing new products and placing them on the market. This is a key contribution in the satellite equipment engineering and research process. Improving customer benefit is the driving force for many innovations. In recent years, Tesat has extended the high power capability of OMUXes with the new generation of Aluminum OMUX technology. The power handling of every channel has been increased to more than 300 W and up to 12 channels on one manifold. Another benefit is the mass reduction by 50% compared with state-of-the-art technology. The new generation of C-Band OMUXes can be provided with waveguide or coaxial interfaces. The circulator integration approach with the OMUX is reducing the footprint for payload integration on the one side and improves the RF performance on the other. The modular concept can be configured for an optimum solution for medium- and high-power applications. A key point of this concept is that the upcoming ALM production revolution is already considered in the design. For the IMUX in the input section, Tesat continues the successful vertical integration approach introduced in Ku- and Ka-Band. As a result of this arrangement, mass and footprint is kept low, providing excellent RF performance. Introduction of multi-manifold OMUXes in all frequency bands in the last couple of years illustrates our innovation capability, and the rapid market penetration is a result of brisk customer demand. In cooperation with universities, Tesat is pioneering on the next generation of flexible Inand Output Networks. 17

1971 Filter for Intelsat 1996 C-Band OMUX

Technology 2013 High Power Low Loss Ka-Band

Switch Switch 2011 3-Position Random Access

Roadmap of Programs 1997 Waveguide Ka-Band

8-Channel Ku-Band OMUX with 130W/Channel

Dielectric IMUX in Ku-Band 2008 Dielectric

V-Band 2009 24-Channel Ku-Band OMUX More

10 1971 Filter for Intelsat 1996 C-Band OMUX 1980 TV Sat 4-Channel OMUX 450W 2004 Low-weight Sequential Access Waveguide Switch Channel Ka-Band OMUX 2015 ALM Technology 2013 High Power Low Loss Ka-Band OMUX 1997 Sequential Access Waveguide R-Switch and 2-Position Random Access C-Switch 2016 L-Band Waveguide Waveguid Switch Switch Position Random Access of Waveguide R-Switch 2017 Flexible Payload Roadmap of Programs 1997 Waveguide Ka-Band IMUX 1987 DFS Ka-Band 20/30GHz Diplexer Channel Ku-Band OMUX with 130W/Channel Channel OMUX with 230W/Channel 2007 Dielectric IMUX in Ku-Band 2008 Dielectric IMUX in X-Band Positiun Random Access 4-Position of Waveguide R-Switch 2012 Multi-Manifold OMUX 2012 Complex 30GHz IMUX Assemblies 2014 C-Band OMUX & IMUX 2013 Ka-Band 12-Channel OMUX with 300W 2018 Q- & V-Band Channel Ku-Band OMUX More than 100 flight programs accomplished The Tesat-Spacecom Passive Microwave Products Division 18 19

Datalink Products Facts - Products - Applications

Datalink Products Facts - Products - Applications link Products Facts - Products - Applications High technology for the global satellite market Over the course of five decades, Tesat-Spacecom has developed in-depth expertise in manufacturing of payload