In this program, all components and assemblies have been successfully developed, designed and qualified that make Tesat a one-stop shop for all passive C-band hardware. The range of devices developed and qualified comprises low and high power applications, and extends from relatively simple components such as test couplers to highly integrated assemblies such as Input and Output networks.
Therefore as a result of this program in total more than different 20 equipments for C-Band downlink (3.4 GHz to 4.2 GHz) and C-Band uplink (5.85 GHz to 6.65 GHz) are now available.
Coaxial switches are bought-in products from a European source and are readily integrated into and tested as part of Tesat assemblies.
All devices have been designed in state-of-the- art technologies. They provide the required RF functionality (including power handling where applicable) with a minimum of mass and volume.
Qualification environmental levels (thermal and mechanical) envelop all known costumer specifications for geostationary orbit applications. Also, all newly needed materials and processes have been qualified.
Manufacturing aspects have been taken into account from the beginning of the design activities. This has resulted in a very good producibility of all devices, delivering predictable and reliable performance with a high yield
Main challenge in the project was the sheer number of devices to be developed, manufactured and tested.
The amount of different design approaches for low and high power applications was challenging. For manufacturing also some new processes have to be defined, implemented and qualified. The scope of the tests was quite extensive for all components. Especially the high power and vibration tests exhausted the limits of the test equipment.
More than different 20 equipments for C-Band downlink (3.4 GHz to 4.2 GHz) and C-Band uplink (5.85 GHz to 6.65 GHz) are now available.
The range of devices developed and qualified comprises low and high power applications, and extends from relatively simple components such as test couplers to highly integrated assemblies such as Input and Output networks.
The approach in this project was to develop and qualify each component as standalone equipment. Nevertheless an INET and an ONET have been build up, containing of a switch matrix and related filters, circulators and loads.
Development of electric design by analysis and by breadboarding.
Development and qualification of materials and processes.
Qualification of fully assembled equipments (EQM level).
The close out of the project was in 2017.
The project has been completed. In total over 20 equipments (components, switches, IMUX, OMUX and also INET and ONET) have been developed and tested, most of them from feasibility study to operational.
Some of the equipments qualified in this project, such as switches, Imux and Onet, have been sold already for flight.
ESA’s support was vital for achieving robust designs for our C-Band equipment. Thanks to help of ESA’s experts, we were able to address also fabrication issues early on, allowing us to ramp up our in-house production more rapidly.