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