High Power Handling and DR State of the art Output Multiplexer H.DILLENBOURG*, J.J HERREN*, P.LENOIR**, D.BAILLARGEAT**, S.BILA** *ALCATEL SPACE Toulouse FRANCE, **IRCOM Limoges FRANCE IEEE MTT-S 2005 International Microwave Symposium WMB Filter II : Practical Aspect of Microwave Filter Design and Realization
OUTLINE High power C band DR Output Multiplexer. One of the main ALCATEL filter product state of the art : C band dielectric resonator (DR) OMUX. 1 C Band DR OMUX Technical description 2 Numerical aspects 3 High Power aspects Power Handling PIMP MULTIPACTOR MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 2
INTRODUCTION ALCATEL SPACE has a long experience (>20 years) on filter products OMUX / IMUX / Input and Output filter / DIPLEXER Supplying filters on many program and customer : APT SAT, ARABSAT, EUTELSAT, ENERGIA, INTELSAT, FRENCH AGENCY, GASCOM, NASDA, PANAMSAT, RSCC, SES GLOBAL... MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 3
1 C band DR OMUX Technical Description MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 4
Development and patent in 1996 : new dual mode dielectric resonator (DR) topology Main improvement : high power capabilities allowed by the particular selected resonator geometry. Development of C-Band IMUX and OMUX with consequent reduced dimensions. MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 5
US Patent : Dielectric resonator for a microwave filter, and a filter including such a resonator Number : 5,880,650 / March, 9, 1999 Dual mode resonator Square plate resonator in contact with aluminium cavity housing instead of cylindrical puck resonator. MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 6
The mechanical assembly presents good reproducibility without influencing RF fields : No need of additional mounting elements. Very good thermal conductivity from DR to the aluminium cavity walls : Good power handling capabilities MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 7
Waveguide access High Power handling limitation Tested at 280W without any degradation TNC access Power handling limitation Material T qualification (225 W at 4 GHz & 25 C) Exceptional frequency stabilisation Material characteristics. Low thermal gradient with power thanks to full aluminium design : 36 MHz 4 poles filter with 80W : self heating = 8 C only MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 8
C Band DR filter qualification 6 Poles C Band Omux filter Main characteristics Mass reduction : 30 % High power handling test : Up to 280 W at centre frequency Up to 180 W out of band freq. Multipactor tests : Tested up to 180 W Thermal tests : Tested from 15 to 105 C Mechanical test : 3 axis vibration and shock. Classic Invar filter Dielectric Resonator Filter MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 9
5 channels Qualification Model 1 Com channel with waveguide access Bw = 36 MHz 4 channels with TNC access 3 Com channels with Bw = 36 MHz 1 Beacon channel with Bw = 36 MHz MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 10
Footprint reduction versus Invar technology : -30% MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 11
MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 12
MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 13
Qualification Acceptance Tests Initial Performance Tests at ambient 3 axis Vibration Qualification sine level perpendicular and parallel to the base plate (±20g) Qualification random level perpendicular (25g rms) and parallel (14.1g rms) to the base plate Shock 500 Hz : 200 g 3000 Hz : 2000 g 10000 Hz : 2000 g MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 14
Post Mechanical RF Test High Power Test Test performed at 25 and 85 C baseplate temperature. High power tests at Fc with 85 Watts per TNC channel and 110 W for WG channel. Very good fitting between thermal analysis and thermocouples measurement. MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 15
Multipactor Test and Out Of Band Test Test performed at 25 and 85 C baseplate temperature. Out of band test performed with 85W at worse case out of band frequency (tracking) on one channel and with 85W at center frequency for the other channels. Multipactor test with 170W per TNC channel and 220W for WG channel at 25 and 85 C. EMC Test MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 16
Thermal vacuum Test 8 cycles with RF tests at 25, 0, 65 and 85 C on baseplate. Channel filter temperature = 94 C with a baseplate at 85 C (thermal gradient corresponding to 85 W input power). Temperature + Power test at ambient pressure with 85 and 110 W at Fc. Final Performance Tests at ambient All these tests are successful and the EQM qualification has been declared successful MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 17
2 Numerical Aspects MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 18
Output Multiplexer Synthesis Accurate synthesis method OMUX equivalent circuit : Waveguide : electrical model Te junction : EM model Filters : hybrid LE/EM model Fn Fi F1 WG WG WG Te WG Te WG Te WG MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 19
Filter models Circuit model 4 3 1 2 Full wave model Deviation between circuit model and Full wave model Phase of S11 ( ) 200 100 0-100 -200 Narrow band Circuit model Fullwave model 10,7 10,8 10,9 Frequency (GHz) Mainly due to excitation systems and higher order modes Mixed hybrid LE/EM model Phase of S11 ( ) 200 100 0-100 -200 4 1 Broad band Fullwave model Circuit model 10,5 11.5 12.5 Frequency (GHz) 3 2 MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 20
Hybrid LE/EM model filter Lumped Elements Fundamental mode behaviour Electromagnetism Excitation systems Higher order modes Geometrical parameters,couplings,... Hybrid model S parameters Same accuracy, but faster than full wave analysis MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 21
0 High power C band DR Output Multiplexer. 20 Channel Ku band Omux - Measured Selectivities -10-20 db -30-40 -50-60 -70 Synthesis method validated for X, Ku and Ka bands. 11650 11763 11875 11988 12100 Frequence MHz C band application under development. 12213 12325 12438 12550 MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 22
3 High Power Aspects MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 23
Payload Satellites evolution Number of channels Power per channels Design margin Analysis and qualification tests must be regularly improved to secure equipment MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 24
3 High Power Aspects Power handling MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 25
During the industrial process payload output equipment are fully power handling tested In the OMUX case, all channel filter are feed by the specified power at : Central frequency Out Of Band frequency (maximum dissipated power) MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 26
C band DR OMUX (In Flight heritage) 7 channel DR C Band Omux 60 W : In flight since 1997 9 channel assembly DR C Band Omux (3.4 / 4.2 GHz) 60 W : In flight since 2003 11 channel DR C Band Omux 40W and 110W at 60 C : In flight since 2004 13 channel DR C Band Omux 80W at 85 C : In flight since begining of 2005 MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 27
C band DR OMUX (Delivered or under development ) 13 channel DR C Band Omux 64 W 10 channel DR C Band Omux 55 to 85W 10 channel DR C Band Omux 80W 13 channel DR C Band Omux 40 to 80W 14 & 15 channel DR C Band Omux 55W 49 Omux and more than 400 channels are already produced. MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 28
13 Channel C Band DR OMUX MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 29
C Band DR OMUX Assembly Wide Band 9 channels Assy with LPF and TC on a mezzanine. 72 MHz useful channel bandwidth Frequency band : 3.4 to 4.2 GHz MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 30
15 channel C Band DR OMUX MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 31
Ku & Ka band OMUX 20 channels Ku band Omux with 110W/Ch at 60 C 5 channels Ka band Omux with 130W/Ch at 70 C MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 32
3 High Power Aspects PIM Test MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 33
C band DR OMUX (In Flight PIM heritage) Pim already tested on program : 7 channel : 4 th order / Measured at -180 dbc 9 channel : 4 th order / Measured at -185 dbc 12 channel : 8 th order / Measured at -182 dbc MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 34
3 High Power Aspects MULTIPACTOR MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 35
European Space Agency (ESA) support theoretical and practical development Improve multipactor phenomenon understanding Recommendation in a guideline : Space engineering multipaction design and test ALCATEL SPACE collaboration on several study program with ESA and CNES (French Spatial Agency) Definition of an internal multipactor industrial rules MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 36
ALCATEL verification routes for SINGLE CARRIER RF signal THEN TEST IS REQUIRED. with P spec +6 db on a Qualification Model Or with P spec +3 db on all deliverable units End No No Start IF TEST HERITAGE with 6 db margin No demonstrated on a Yes Qualified equipment IF P T-IN > P spec + 8 db by ANALYSIS Yes Yes THEN ACCEPTED without test End MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 37
ALCATEL SPACE verification routes for MULTICARRIER RF signal THEN TEST IS REQUIRED. with P spec +6 db on a Qualification Model Or with P spec +3 db on all deliverable units End No No Yes Start IF TEST HERITAGE with P mean +6 db margin demonstrated on a Qualified equipment IF P T-IN > P peak + 6 db by ANALYSIS IF reliable ANALYSIS with P 20,n methodology IF IF No No Yes P T-IN > P 20,n + 9 db by ANALYSIS No P T-IN > P 20,n + 6 db by ANALYSIS Yes Yes No Yes THEN ACCEPTED without test End THEN REJECTED End MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 38
Multipactor Tests Means ALCATEL SPACE facilities in C, X, Ku and Ka band According to ESA guideline : 3 detection methods Microwave nulling 3rd harmonic noise Close to carrier noise MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 39
Multipactor C band OMUX Analysis and Test Single carrier section (TNC connector, DR, Channel filter) : Analysis is possible but complex and questionable. In parallel : validation test at 3 db on EQM. Multi-carrier section (Manifold, Output Irises) : Classical multi-carrier analysis + validation test at 3 db on EQM MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 40
Multipactor C band Heritage (1/2) OMUX Qualification Model (5 channels) 1 st test 3 TNC access powered simultaneously with 160W OMUX Qualification Model (5 channels) 2 nd test 1 TNC access powered with 170W and 1 waveguide access powered with 220W Test successfull MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 41
Multipactor C band Heritage (2/2) DIPLEXER (double post waveguide) 1 st test 12 carriers of 68W + 6 carriers of 68W (T env = 85 C) DIPLEXER (double post waveguide) 2 nd test 12 carriers of 108W + 6 carriers of 108W (T env = 25 C) Test successfull MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 42
MP Ku band Heritage OMUX 20 channels 19 carriers of 140W (Pmean = 2660W) Test successful MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 43
Multipactor Ku Band Low Pass Filter (ESA support) Tested with 17 carriers of 177W (Pmean = 3000W) Test successful MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 44
CONCLUSION C band DR filter since 1995 High Power capabilities Dimensions and mass saving State of the Art 49 Omux and more than 400 channels produced as 80W at 85 on a 13 channels (in flight) or 55W at 75 on a 15 channels (under development) MB: FILTER II: PRACTICAL ASPECTS OF MICROWAVE FILTER DESIGN AND REALIZATION (13/06/05) 45