Matched Horn Coupler Assembly for RF Rotary Joint
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Solution Overview
Problem
Existing RF rotational joints in antenna assemblies suffer from signal losses, electrical constraints like Passive Inter-Modulation (PIM) products, and mechanical limitations, especially when handling multiple axes of rotation and orthogonal polarizations for both transmit and receive signals.
Innovation Solution
A matched horn coupler assembly that replaces multiple rotating joints with a single unit, allowing wideband signals with low electrical losses and no PIM, enabling rotations about different axes without mechanical wear, and supporting multiple frequencies and polarizations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple rotating joints are used to handle multiple axes of rotation and orthogonal polarizations, then the antenna assembly can rotate about different axes, but the device complexity and mechanical wear increase
Solution Approach 1:
The patent combines multiple rotating joints into a single rotary joint that handles multiple axes of rotation and orthogonal polarizations simultaneously. The feed assembly integrates multiple feed horns and waveguide structures that can rotate together as one unit, eliminating the need for separate rotating joints for each axis and polarization channel.
Solution Approach 2:
The rotary joint is designed with universal functionality to handle multiple rotation axes, transmit and receive signals, and support orthogonal polarizations through a single structure. The feed assembly can accommodate various feed horn configurations and waveguide arrangements within one rotatable unit, making it applicable to multiple rotation scenarios.
2Ease of operation
If traditional rotating joints are used, then mechanical rotation is enabled, but RF signal losses and PIM products occur
Solution Approach 1:
The patent replaces traditional mechanical contact-based rotating joints with a design that uses waveguide structures and horn antennas. The RF signals travel through waveguides and are transmitted via electromagnetic fields between feed horns, eliminating mechanical sliding contacts that cause signal losses and Passive Inter-Modulation (PIM) products.
Solution Approach 2:
The feed horns and waveguides act as intermediaries that transmit RF signals without direct mechanical contact. The electromagnetic field serves as the mediator between the rotating and stationary portions of the antenna assembly, allowing signal transmission while avoiding the harmful effects of mechanical friction and contact wear.
3Adaptability or versatility
If rotating joints are used for wideband signals, then signal transmission is enabled, but electrical constraints like PIM products and frequency band limitations occur
Solution Approach 1:
The patent eliminates mechanical sliding contacts that generate PIM products by using waveguide and horn antenna structures for signal transmission. The RF signals are conveyed through electromagnetic fields in waveguides and between feed horns, which do not produce Passive Inter-Modulation products regardless of bandwidth or frequency.
Solution Approach 2:
The feed assembly is designed with parameters optimized for wideband operation, including horn antenna dimensions and waveguide geometries that maintain performance across broad frequency ranges. The structure supports multiple frequency bands and wideband signals without the electrical constraints that limit traditional rotating joints.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides low-loss, PIM-free signal transmission across various rotations and frequencies, scalable to millimeter-wave bands with constant performance and reduced mechanical complexity, suitable for spacecraft applications.
Implementation Method 1
RF rotational joint using a matched horn coupler assembly... capable of simultaneously convey Tx (Transmit) and Rx (Receive) RF signals
Implementation Method 2
two similar horn structures are juxtaposed and joined by a rotary bearing... wide ends of two similar horn structures
Data Source
AI summary
A matched horn coupler assembly is used in a RF rotational joint for conveying an electromagnetic signal. The coupler assembly includes first and second feed horns defining respective first and second horn longitudinal axes intersecting one another at an intersection point. The first and second feed horns connect to a mirror for conveying the signal there between with the intersection point lying on a reflecting surface of the mirror which defines a normal direction thereof at the intersection point. The normal direction is equally angularly spaced from both the first and second horn longitudinal axes. First and second lenses connect to the respective first and second feed horns and focus the signal there between and at the intersection point. At least one of the first and second feed horns is rotatably connected relative to the mirror about the respective horn longitudinal axis.