Single E-probe Waveguide Coupler for High-Power RF Testing

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Solution Overview

Problem

High powered horn antennas in satellite communications pose challenges for testing electronics due to high flux density, requiring large and expensive test configurations, and existing solutions like air links and directional couplers face limitations in power handling and cost.

Innovation Solution

A system using a surrogate waveguide with a single electric field probe and a power attenuation device, eliminating the need for directional couplers, allows for reduced radiating aperture testing in a less reflective environment, increasing power handling and reducing costs by 3 to 10 times.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a Field Aperture Load configuration with actively cooled aluminum plate is used to test horn antenna electronics, then the testing capability is provided, but the test configuration size increases and costs increase due to limited absorption and cooling rate

Engineering Contradiction:

Improvetesting capabilityVSAvoidtest configuration size

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

An intermediary cooling system is introduced between the absorber and the environment, using a heat pipe or thermoelectric cooler to actively remove heat from the absorber. This allows the absorber to maintain lower temperature and handle higher power densities without requiring a larger overall test configuration, thus resolving the contradiction between testing capability and configuration size.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If the absorber pad is moved farther from the horn antenna to reduce flux density, then the maximum allowable flux density is reduced, but the entire FAL configuration must grow larger

Engineering Contradiction:

Improveflux densityVSAvoidFAL configuration size

Core Design Contradiction:

Object-affected harmful factorsVSVolume of stationary object

Solution Approach 1:

The physical state of the absorber is changed from passive to active cooling mode, fundamentally altering its thermal parameters. This allows the absorber to withstand higher flux densities at closer distances, enabling flux density control without increasing the overall FAL configuration size.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If air links with probe antennas are used to couple RF to the satellite, then RF coupling is achieved, but large vacuum chambers with limited availability and expensive supporting structure are required

Engineering Contradiction:

ImproveRF couplingVSAvoidvacuum chamber size

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The air link coupling mechanism is extracted and replaced with direct waveguide-to-waveguide coupling through the surrogate waveguide. This eliminates the need for large vacuum chambers and complex air link infrastructure, achieving RF coupling through a compact, integrated structure.

Inventive Principle:

Principle #2Taking out (Extraction)

4Adaptability or versatility

If a directional E-probe coupler is used for testing spacecraft payload designs, then testing of spot beams is enabled, but power handling is limited due to thermal constraints

Engineering Contradiction:

Improvespot beam testing capabilityVSAvoidpower handling

Core Design Contradiction:

Adaptability or versatilityVSPower

Solution Approach 1:

An intermediary active cooling system is introduced to the E-probe coupler, using heat pipes or thermoelectric coolers to actively remove heat from the probe and surrounding components. This allows the coupler to maintain operational temperatures while handling significantly higher power levels, resolving the contradiction between spot beam testing capability and power handling.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enables efficient testing of high power payloads in smaller vacuum chambers with reduced flux density and increased power handling, accommodating newer spacecraft designs without internal test couplers, while minimizing reflections and costs.

Implementation Method 1

a radiation absorbing surface is positioned facing a primary direction of energy propagation from the flared end of the aperture portion of the surrogate waveguide

Methodology Applied

Scientific EffectElectromagnetic radiation: Electromagnetic Induction

Implementation Method 2

a radiation absorbing surface is positioned facing a primary direction of energy propagation from the flared end of the aperture portion of the surrogate waveguide

Methodology Applied

Scientific EffectElectromagnetic absorption: Absorption (EM radiation)

Data Source

PatentUS10097285B2Single E-probe reduced aperture waveguide coupler

Publication Date: 2018.10.09 THE BOEING CO

AI summary

A temporary microwave horn antenna coupling device is configured for collecting or injecting quantifiable samples of RF energy. The device comprises a reduced and highly matched radiating aperture, and a waveguide mounted single electric field probe. The electric field probe can be oriented at 45 degrees to the horizontal and vertical electric fields of a linearly polarized antenna, or oriented for a single linear polarization to the electric field in a circular polarized antenna. The electric field probe is connected to an attenuator and/or lossy cable for reduced reflections and gradient thermal dissipation.