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Correction of manufacturing deviations in waveguide filters and manifold multiplexers using metal insertions

Published online by Cambridge University Press:  28 May 2015

Santiago Cogollos*
Affiliation:
Instituto de Telecomunicaciones y Aplicaciones Multimedia, Universidad Politécnica de Valencia, Valencia, Spain. Phone: +34 963879197
Carlos Carceller
Affiliation:
Instituto de Telecomunicaciones y Aplicaciones Multimedia, Universidad Politécnica de Valencia, Valencia, Spain. Phone: +34 963879197
Mariam Taroncher
Affiliation:
Instituto de Telecomunicaciones y Aplicaciones Multimedia, Universidad Politécnica de Valencia, Valencia, Spain. Phone: +34 963879197
Vicente E. Boria
Affiliation:
Instituto de Telecomunicaciones y Aplicaciones Multimedia, Universidad Politécnica de Valencia, Valencia, Spain. Phone: +34 963879197
Marco Guglielmi
Affiliation:
European Space Research and Technology Centre, European Space Agency, Noordwijk, The Netherlands
Carlos Vicente
Affiliation:
Aurorasat Software and Testing, Valencia, Spain
María Brumos
Affiliation:
Instituto de Telecomunicaciones y Aplicaciones Multimedia, Universidad Politécnica de Valencia, Valencia, Spain. Phone: +34 963879197
*
Corresponding author: S. Cogollos Email: sancobo@dcom.upv.es
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Abstract

Microwave filters and multiplexers commonly employ tuning screws to compensate for small errors occurring during the fabrication process. Nevertheless, the use of tuning screws has some disadvantages, because the small gaps between the screws and the holes are prone to create unwanted effects when dealing with high-power signals, especially for space applications, and are also the source of potential radiation losses. In this paper, an alternative technique to correct manufacturing deviations is presented, in which tuning screws are replaced by fixed metal insertions. In this case, the correction is made by means of designing new insertion pieces that will be able to correct those small deviations. In order to find the dimensions of the new pieces, a space-mapping technique is applied. For verification purposes, the method has been applied over a circular-waveguide dual-mode filter and later over a manifold multiplexer containing the same type of filters. However, the technique can be directly extended to other types of waveguide filters and multiplexers where tuning screws are also employed.

Information

Type
Research Papers
Copyright
Copyright © Cambridge University Press and the European Microwave Association 2015 
Figure 0

Fig. 1. Proposed structure for a four-pole dual-mode filter in circular waveguide. The tuning and coupling screws have been replaced by fixed rectangular-shaped metal insertions.

Figure 1

Fig. 2. Side cut of the manufactured CWDM filter structure divided into five pieces.

Figure 2

Fig. 3. Manufactured CWDM filter with all its pieces assembled together.

Figure 3

Fig. 4. Detailed view of the pieces composing the CWDM filter as in Fig. 3.

Figure 4

Fig. 5. Ideal response obtained with a full-wave EM solver (FEST3D) compared with the measured response of the manufactured CWDM filter.

Figure 5

Fig. 6. Pieces with insertions allocated in the middle of each cavity in the CWDM filter.

Figure 6

Table 1. Penetration lengths obtained during the correction process of the CWDM filter.

Figure 7

Fig. 7. Measured responses after each iteration, compared with the simulated response, and the original fabrication of the CWDM filter.

Figure 8

Fig. 8. Comparison between the responses of the measured original prototype and the last SM iteration, together with the desired ideal response of the CWDM filter.

Figure 9

Fig. 9. Physical structure of the contiguous eight-channel multiplexer with herringbone configuration, and whose filters are four-pole CWDM filters.

Figure 10

Fig. 10. Ideal response for the CPRL of a contiguous eight-channel multiplexer obtained with a full-wave EM solver (FEST3D), compared with the response of the same multiplexer considering manufacturing deviations.

Figure 11

Fig. 11. Ideal transmission response for all channels of the ideal multiplexer simulated with two independent commercial EM solvers (FEST3D and MW Wizard).

Figure 12

Fig. 12. Response of the second channel filter with manufacturing deviations compared with the responses obtained with independent commercial software (HFSS and MW Wizard).

Figure 13

Fig. 13. Optimization of the EM model to match the module of the response of the second channel filter with manufacturing deviations.

Figure 14

Fig. 14. Optimization of the EM model to match the phase response of the second channel filter with manufacturing deviations.

Figure 15

Fig. 15. Evolution in the CPRL response of the corrected multiplexer (including manufacturing errors) for two iterations of the SM algorithm, compared with the simulated response of the original design, and the one of the multiplexer with the simulated errors.

Figure 16

Fig. 16. Evolution in the transmission response of the second channel of the corrected multiplexer (including manufacturing errors) for two iterations of the SM algorithm, compared with the simulated response of the original design, and the one of the multiplexer with the simulated errors.