The right connection.
Passive Components for Space Applications
Bosch Telecom GmbH has an extensiveexperience in the field of passive componentsfor space applications. A multitude of filters,multiplexers and components from L- to Ka-bandand frequencies of up to 30 GHz have beendesigned, manufactured and qualified in variousprograms in the last 30 years.
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The Bosch CommunicationsBusiness Sector isstructured into the followingBusiness Units:
● Public Networks● Private Networks● Terminals● Security Systems● Space Communications● Broadband Networks
Bosch and the Worldof Telecommunications
Thermo vacuum chambers for testing space equipment
Robert Bosch GmbH is a world-wide company with a turnoverof almost DM 50.3 billion. Inthe Bosch CommunicationsBusiness Sector, about 19.000employees work in communi-cations technology. Its share oftotal Group turnover in 1998was 10 %, i. e. DM 5.0 billion.
In the Space Communicationssector, Bosch develops andmanufactures communicationequipment and systems for satel-lites and space vehicles. Bosch’smain space products are travel-ling wave tube amplifiers, multi-plexors and switches as well assolid-state equipment. More-over, Bosch is developing opticaltransmission systems whichoperate at very high bit rates totransmit information betweenmultimedia system satellites.
In the Public Networks sector,Bosch is active in the transmis-
sion, network access and switch-ing technology. The companydelivers fiber-optic and radio-based transmission systems com-plying with the SDH standard,ISDN network terminals, as wellas switching systems of theEWSD technology.
In the Private CommunicationsNetworks sector, Bosch deve-lops, manufactures, and marketsISDN communications systems.
In the Terminals sector, Boschhas mobile telephones in itsproduct line which comply withthe GSM and DECT standards.
In the Security Systems sector,Bosch offers fire-alarm andburglar-alarm systems.
The Broadband Networks sectoris one of the largest private net-work operators for the Germancable TV network.
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Transponder block diagram
Introduction
Passive component product scope
RCV
IFADIPL
IFADIPL
OMTCAMP
+TWTA
AntennaRX /TX
Bosch Telecom GmbH has anextensive experience in thefield of satellite filters. A multi-tude of filters and multiplexersfrom L- to Ka-band and fre-quencies of up to 30 GHz havebeen designed, manufacturedand qualified in various pro-grams in the last 30 years.
Bosch disposes of excellent in-house computer programs forthe design of all kinds of filterssuch as Tchebyscheff, ellipticfunction, pseudoelliptic func-tion, and linear phase (selfequalized) asymetrical charac-teristic, and for the effectivesimulation and optimization ofmultiplexers.
All necessary space qualifiedmanufacturing processes inclu-ding EDM (Electrical Dischar-ge Machining), silver platingand soldering facilities areavailable at Bosch Telecom forthe production of the flighthardware.
All tests are performed in thetest area fully equipped withthermal vacuum and vibrationtest facilities, high and lowpower computer-controlled testbenches.
IMUX
SWM
SWM
OMUX
RCV ReceiverSWM Switch MatrixTWTA Travelling Wave
Tube Amplifier
CAMP Channel AmplifierDIPL DiplexerIFA Input Filter
IMUX Input MultiplexerOMT Orthomode TransducerOMUX Output Multiplexer
Filter
Input FilterLow-pass FilterDiplexerInput MultiplexerOutput Multiplexer
Component
LoadCouplerCirculatorWaveguideTransitionsSwitch
Multiplexer Assembly
Input Multiplexers and Input Multiplexer Assemblies
Applications
● Communication satellite pay-loads
Main features
● Applications in L, S, C, X,Ku, Ka bands
● Large number of channelsper multiplexer
● Space-qualified and flightproven designs
● Superior performance ● Excellent temperature
stability● Quasi-elliptic filter functions
(8-4 + CD)
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● Selfequalized or externalequalization
● Very low losses due to highpractical Q factor of < 15000in Ku-band
● Large variety of usefulchannel bandwidth
● Prediction and controlling ofhigher modes
● Compact design
Koreasat 3Ka-bandinput multiplexer
Performance
● Compensated waveguidemanifold in aluminium,circulator coupling or hybridcoupling in waveguide orcoaxial technology
● Compensated filter cavitiesin thin wall INVAR silver-plated
● Achieved Ku-band IMUXtemperature drift of less than1.2 ppm/K
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RCV
IFADIPL
IFADIPL
OMTCAMP
+TWTA
AntennaRX /TX
IMUX
SWM
SWM
OMUX
● Complete in-house environ-mental test facility
● Powerful RF simulation andoptimization software allowsfinal design without bread-board step
● Typical delivery schedule:6 months
Echostar 101/102IMUX assembly
Heritage
Major programs: DFS Kopenikus,Echostar 101/102,Koreasat 3,Eurasiasat
Production
● IMUX assemblies(including switches, lowpassfilters, hybrids, circulators,isolators ... )
● Single channel filters ● Full RF, mechanical and
thermal custom design andlayout capability
EurasiasatX-band input multiplexer
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Output Multiplexers and Output Multiplexer Assemblies
Application
● Communication satellite pay-loads
● Combining of high powerchannels
Main Features
● Designs available for L, S, C,X, Ku, and Ka bands
● Variety of filter grade andfunctions available
● Contiguous, noncontiguous,and quasi-contiguous filtercharacteristics
● Inhouse developed RF simu-lation and optimisation soft-ware tools provide exactmodelling including influen-ce of tuning screws and accu-rate prediction of higherorder modes
● No breadboarding required● Simulation capability up to
32 channels
Performance
● Extremely low loss channelfilter design(Q > 12000 in C-Band andQ > 15000 in Ku-Band)
● Qualified high power / hightemperature design allowsband-edge operation of 65 Win C-Band and up to 240 Win Ku-Band
● Unsurpassed thermal stabilitydue to patented temperaturecompensated channel filtersand patented temperaturecompensated aluminiummanifold
● Measured ELFD < 0.4 ppm /K in Ku-band
● Exact fullwave simulation ofOMUX and auxiliary compo-nents provides extreme highpower handling capabilityand low PIM level designs
● Design verification by test upto 30 kW in Ku-band and24 kW in C-band
● Realisation of 14 channelmultiplexers in C-Band and15 channels in Ku-Band
● Full band multiplexing: 2GHz in Ku-Band and 800MHz in C-Band
● Multiplexing with non-mono-tonic channel sequence tosimplify waveguide routing
● Thinwall INVAR waveguidefilter technology
● Fully integrated subsystemsavailable (incl. isolators andswitches) for optimum RFperformance
● Full RF, mechanical, andthermal custom design andlayout capability
Sesat and Intelsat output multiplexer assembly
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Heritage
Major programs:Inmarsat 3, Hotbird 2/4/5,Intelsat 805/806,Koreasat 1/2/3,Echostar 101-104, Telesat,Sesat, Astra 2B, GE 1A/2A
Astra 2/3 output multiplexer
RCV
IFADIPL
IFADIPL
OMTCAMP
+TWTA
AntennaRX /TX
IMUX
SWM
SWM
OMUX
Production
● Complete in-house environ-mental test facility
● Fully automatic TV Tests
● Extensive in-house highpower test facilities incl. ring-resonators up to Ka-band formultipaction, corona, andPIM measurements
● Typical cycle time:< 6 months for assembliesand < 5 months for multi-plexer
Koreasat 3Ka-band output multiplexerassembly
Receive/transmit banddiplexers
Satellite antenna feed systemsare generally exposed to extre-me environmental conditions asfor example temperatures rang-ing from –120 to +140 degree C.Especially for such applications,Bosch has established a uniquehigh performance diplexerapproach for separation of thereceive and transmit bands serv-ed by one polarisation of a dedi-cated antenna. The design isbased on a completely integrat-ed unit, comprising a high passand a corrugated low pass filter
that are directly interconnectedwith a sophisticated broadbandwaveguide branching. This inte-grated approach allows the reali-sation of the diplexer by state-of-the-art CNC milling techniquesfrom aluminium silverplatedwithout the need on any tuningto cope with the inherentdemands for feed system appli-cations, namely● low insertion loss (<0.15 dB)● good matching properties
(>26 dB)● high receive/transmit band
isolation● flat amplitude and group delay
response
● high power handling capability– low dissipated power
(to facilitate the overallthermal design)
– high peak power handling(tested up to 12 kW withoutmultipacting)
– no generation of passiveintermodulation products(tested up to –155 dBm)
These outstanding propertieshave been proved by severaldiplexers for different programs,as Nahuel, GE 5, Sinosat,Astra 2B, Intelsat KTV
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Diplexers
Ka-band diplexer
RCV
IFADIPL
IFADIPL
OMTCAMP
+TWTA
AntennaRX /TX
IMUX
SWM
SWM
OMUX
Diplexer for Nahuelsatellite programme
Passive components for space applications
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Application
● Communication satellite pay-loads
● Part of higher level integra-ted subassemblies or stand-alone units
Main Features
● Products include ferrite devi-ces, couplers, power combi-ners and splitters, transitionsand low / high power termi-nations
● Designs available for L, S, C,X, Ku, and Ka bands
● Inhouse developed RF simu-lation and optimisation soft-ware tools provide exactmodelling of ferrites, absor-bing materials and ceramics
● No breadboarding required● Low loss and lightweight
designs● High power handling capabi-
lity at extreme temperatures,multipacting and PIMP-free
● Thinwall aluminium techno-logy incl. EDM and dip-bra-zing
● Full RF, mechanical, andthermal design and layoutcapability
Production
● Complete in-house environ-mental test facility
● Fully automatic TV Tests ● Extensive in-house high
power test facilities incl. ring-resonators up to Ka-band formultipaction, corona, andPIM measurements
● Cycle time < 5 months
Heritage
Major programs:Intelsat 805/806,Echostar 101-104, Eurasiasat,Astra 2B, GE 1A/2A
Filters and Components
AstraOutput Filter assembly
EurasiasatInput Filter
AstraCoupler
RCV
IFADIPL
IFADIPL
OMTCAMP
+TWTA
AntennaRX /TX
IMUX
SWM
SWM
OMUX
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Applications:● Redundancy switch matrices
for satellite payloads
Main features:● Optimum RF performance● Covering C, X, Ku, Ka band● C-type and R-type switches● Single switches, switch blocks
and switch matrices● Random and sequential access
actuators with high torquemargin
● Magnetically latching in everyposition
● Mechanically simple designwith minimum number ofpiece parts
● Highest switching reliabilty● RF power handling capability
up to 1400 W (in Ku band)● Multipactor and PIMP free● High level vibration and shock
load capability (up to 70 grms)● Reed switch telemetry
Production:● Typical delivery schedule: 3 ... 6
months depending on switch type
Technical description:● Modular design● Central preloaded ball bearing
with dry lubricant● RF housing and RF rotor
machined in one part● Large gap between rotor and
housing for high RF powerhandling
● Integrated protecting RF windows
● Simple actuator principles
Heritage:● Fully qualified and delivered for
the following major programs:Sesat, Telesat, Echostar 4,Koreasat 3, Intelsat 9, Eurasiasat,Poseidon, Helios 2, Metop,Insat 3, Spot, GE1A/2A,N-Sat
Microwave Switches for Space Applications
Microwave switch
Bosch switch family
RCV
IFADIPL
IFADIPL
OMTCAMP
+TWTA
AntennaRX /TX
IMUX
SWM
SWM
OMUX
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Future Developments
C-band front end withplanar HTSC filters
Dielectric Filters
Electroformed filters
High temperature super-conducting and cryogenicsubsystems
● Receiver Units, Input Multi-plexers and filter assemblieswith extremely low mass,volume and noise figures
● Output Multiplexers and filterassemblies with extremely lowinsertion losses, small weightand volume
● Low Phase Noise Oscillators● Cryogenic Systems
Electroformed filters andfilter arrays
● Good achievement of predict-ed RF performance due toextreme accurate design soft-ware and better than 5 µmtolerances
● Special dielectric insert designfor high practical Q values upto 24000 at Ku-band
● Temperature compensateddesign
● Tuning free production● Low cost manufacturing of the
negative form● Extremely lightweight● Good reproducibility at large
quantity● Mechanical solutions of filter
array assemblies
Dielectric filters● Significant reducing
of volume
CryogenicC-band OMUX withdielectric filters
Bosch Telecom GmbHSpace Communications SystemsGerberstrasse 33D-71522 Backnang
Telephone +49 71 9113-38 45Telefax +49 71 9113-34 22
http://www.bosch-telecom.com © B
osch
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Our Representative in the USAand Canada:
Peter LüstElectronic Note Space Systems300 Esplanade Drive,9th floor, Suite 900,Oxnard, California 93030,USA
Telephone 805-981-9178Telefax 805-981-9147