CAD OF WAVEGUIDE COMPONENTS FOR ANTENNA FEED SYSTEMS:

STATE-OF-THE-ART
Invited paper
R. BEYER
Mician GbR
Bremen, Germany
E-mail: [email protected]
J. BORNEMANN
ECE Dept, University of Victoria
Victoria, B.C. Canada, V8W 3P6
E-mail: [email protected]
U. ROSENBERG
Marconi Communications GmbH
D-71520 Backnang, Germany
E-mail: [email protected]
J. UHER
EMS Technologies Canada
Ste-Anne-de-Bellevue, Que, Canada, H9X 3R2
E-mail: [email protected]

Abstract --- This papers summarizes the most recent research on CAD methods applied to waveguide components in
antenna feed systems. General design strategies utilizing full wave analysis modules are outlined. Progress in CPU -
efficient numerical codes and optimization methods is discussed. Advancement in full-wave design methods of
individual waveguide components is summarized. Examples of high performance complete feed systems are shown.

performance predictions even for narrow-band

1 INTRODUCTION components.
The use of low cost fabrication methods has been
Modern communication and radar antennas addressed through modelling of rounded corners
employ highly sophisticated feed systems. The resulting from a larger end-mill radius or the use
feed design quality continues to be critical to the of casting .
antenna overall performance. At higher microwave This focused research has resulted in dramatically
frequencies (say, at the C-band and up) waveguide reduced design time, improved RF performance,
is a common transmission medium, mainly due to excellent modelling accuracy, reduced fabrication
its low RF loss and high power handling time and cost.
capability. Over the recent decade a significant Within the limitation of allowable printing space
research effort was invested in advanced CAD this paper attempts to address the above mentioned
methods for waveguide components and entire research progress in the area of advanced CAD for
feed systems [1-3]. antenna feed systems utilizing waveguide
The research was focused on several design technology.
aspects. In the area of numerical modelling the The paper is organized in three sections. Section 2
emphasis was on improvement of full wave addresses general design strategies and guidelines.
analysis tools in terms of accuracy and efficiency Section 3 focuses on advancements in EM –
of handling complex electromagnetic problems. modelling methods and tools, whereas Section 4
Another very vibrant area of research was in summarizes state-of-the-art CAD of individual
advanced optimization methods. component in terms of design modelling efficiency
Novel design concepts leading to enhanced RF and achievable RF performance.
performance and/or simplified geometry have been
also reported.
Tuning screws have been gradually eliminated
from the feed components due to precision in

1
2 GENERAL DESIGN STRATEGIES AND vacuum. For space equipment, peak power
GUIDELINES requirements are verified by computing maximum
voltages across small gaps resulting from selected
An efficient design strategy is crucial to a design concept and comparing them against
successful design of any component or subsystem. experimentally determined threshold.
It is rather challenging to arrive at an universal Optimization. The preliminary design rarely leads
method for each single component but it is quite to the component’s RF performance meeting all
possible to specify a general design approach that design requirements. Therefore, an optimization
is then modified to suit specific design goals of process must be employed to arrive at the required
individual components. design goal. A number of advanced optimization
A typical design process of an antenna feed strategies have been recently developed. For many
component (or subsystem) can be broken down components an iterative full-wave analysis process
into the following steps: coupled to some gradient or non-gradient design
Specification of the design goal. which includes RF objective function verification / feedback algorithm
performance specifications with margins for can be used. For some more complex components or
manufacturing tolerances, thermal shift and systems with very large number of variables, other
performance degradation over system’s life ; methods such as space mapping might be more
Formulation of the design constraints; for suitable. Many of commercially available full wave
example, weight, volume, minimum size of a design software are equipped with optimization
geometrical detail or a geometrical parameter which tools.
often is related to the power handling capability, Dimensional Sensitivity Analysis - Once the
structural strength, manufacturabilty; this also nominal components dimensions have been
includes budget and schedule issues. established manufacturing tolerances should be
Trade-off Analysis which includes criteria considered to avoid excessive manufacturing cost
determined from the first two steps. This step leads without compromising the RF performance. This
to the baseline design selection; design step is especially critical for components
Preliminary design. If available, an existing data operating above the 20 GHz frequency range where
base can be used to determine initial electrical manufacturing tolerances are typically very tight.
dimensions of the component. Frequency scaling is Experimental Design Verification - The accuracy
a common practice, especially for wide-band of the above outlined CAD procedure should be
components. Many waveguide filter types can now verified by direct measurement. In recent design
be synthesized using full-wave characterization of practice, the stage involving manufacturing and
coupling sections. Transformers and directional testing breadboard models is often skipped.
couplers can be also synthesized using transmission However, such an approach is justified mainly for
line theory. hardware with design heritage. Novel components
Full wave analysis. A variety of powerful are typically developed involving breadboards. The
numerical methods utilizing full wave typical risk areas are in spurious modes spikes
characterization of arbitrarily shaped waveguide appearing in the frequency response, insufficient
discontinuities or entire components have been convergence used in the full-wave based design
recently developed. These methods allow the process, frequency shift due to the limited numerical
computation of the component’s S-parameters over accuracy of the software, imperfections in the
a predetermined frequency range in a very efficient geometry and others. Some “soft” tuning typically is
manner. a solution to potential discrepancies. If tuning is
Power handling capability verification. In antenna prohibited due to, say power handling issues,
feed systems average power handling requirements another design iteration is sometimes necessary.
are rarely a concern since the power dissipated in
low-RF-loss waveguides is typically very small. The
peak power requirements are related to either plasma
breakdown (corona) or electron breakdown in

2
3 CAD METHODS AND TOOLS variety of waveguide components. They also work
well in circular or elliptical waveguide structures,
Accurate performance predictions of state-of-the- although with reduced accuracy. Hence, they are
art waveguide equipment require modelling capable of providing excellent initial design
capabilities based on electromagnetic (EM) field dimensions to be fine-tuned by optimization
theory. A large variety of EM codes is routines. Recently, and especially for high-
commercially available, e.g. [4]. Without going performance filter structures, is was found that
into the individual details of such codes, the design optimizing the (equivalent-circuit) coupling matrix
engineer often finds two disadvantages associated of a filter structure has many advantages over
with them. First, relatively few are equipped with traditional designs by coupling-matrix rotations
optimization tools to design or numerically fine- [7].
tune a circuit or component. Secondly, many have Optimization: Linked to an accurate analysis tool,
field solver capabilities which are more desirable optimization varies a number of design dimensions
for general-purpose applications rather than to fit the performance specifications of the
waveguide structures. Although field solvers have component. Whereas much effort is still spent on
experienced a significant speed-up process over enhancing individual optimization strategies, it is
the last years, they are likely to be outperformed widely accepted that as long as the initial design
by modal field-matching approaches if the values are good and the cost function is well-
geometry fits the coordinates of the modal bases behaved, the majority of optimization codes will
used. Therefore, in CAD methods for waveguide arrive at a satisfactory solution to the design
technology, general field solvers are problem. Among the many different optimization
predominantly used to verify a design, not to approaches, e.g. [7], the MiniMax algorithm [9]
design a component. Essentially, the CAD consist has turned out to be a very reliable tool.
of three blocks: In the event that good initial values are not
Targeted Software: This is the center piece in available, optimization runs with fast and reliable
waveguide CAD tools. It consists of software targeted software packages will not necessarily
packages which are geared towards a specific converge within a reasonable design time frame.
component or class of components. Many routines This is mainly due to the significantly increased
are based on modal field-matching techniques and number of optimization steps. The only option is
cover a variety of rectangular and/or circular to reduce the time required for a single
waveguide components such as filters, optimization step by replacing the accurate
multiplexers, transformers and junctions, targeted software with an inaccurate, but
polarizers and orthomode transducers – to name significantly faster equivalent-circuit model.
only a few. They provide an accurate analysis Optimization is now carried out with the
within a reasonable CPU time and can easily be equivalent-circuit model, but the model itself is
linked to synthesis and optimization tools. frequently modified and updated by the accurate
Recently, companies such as MiCIAN combined a targeted software. This approach has recently been
variety of different waveguide structures and introduced as space mapping.
methods in commercially available CAD packages
[5]. 4 PERFORMANCE AND CAD STATUS
Initial Design: This is probably the most
important step in modern CAD. A large class of Waveguide runs To accommodate the variety of
mostly rectangular waveguide discontinuities and microwave system applications and their particular
components have been characterized in terms of antenna and feed system designs there are four
equivalent circuits, e.g. [6], which allow a common waveguide types, namely, the common
synthesis of required VSWR’s or coupling rectangular, circular, ridged, and elliptical
coefficients. Many of these design strategies have waveguides. Up to now, most standard CAD
meanwhile been coupled with targeted software methods (mode-matching, FEM) allow the
codes and hence allow a quasi-synthesis of a large computation of bends [5] and twists [10] in the

3
rectangular waveguide even with uncertainties as Diplexers. Diplexers in antenna feed systems
milling radii, to be considered in integrated typically require either narrowband (for single
structures. Ridged waveguides are used for channel separation) or broad-band operation (e.g.
extreme broad band applications, although their in multi-channel satellite antennas). Typical
handling is substantially more expensive compared requirements include low passband insertion loss
with rectangular types. FEM or FDTD based CAD high power handling capability, and high isolation
tools are available to solve low VSWR ridge between channels. These tight performance
waveguide routing issues. Elliptical waveguides specifications can be currently met with designs
(smooth wall and corrugated) were introduced for without any tuning elements over a wide
very long, low loss interconnections between frequency range including Ka-band (30/20 GHz).
transceiver and antenna. Their substantial The common filter types are: waveguide stubs,
advantage over other types is the realization of inductive irises, high-pass waveguide sections or
long, high performance, continuous waveguide corrugated low-pass filters. The filters are
runs. Recently an exact solution of the complex combined either by T-junctions or bifurcations
corrugated type has been obtained by a full wave [17]. Mode matching techniques are commonly
analysis [11]. These results have been used to used in full wave modelling. Initial design
establish overmoded operation for waveguide runs encompasses full-wave filter synthesis and
with further improved insertion loss properties at adjustment of the virtual short circuit plane
millimeter waveguide frequencies [12]. positions. MiniMax-type optimization routines are
very efficient optimization tools. Such fully
Filters. Owing to the substantial differences of the supported CAD design of these components is
crucial requirements (insertion loss, rejection, power generally necessary to accommodate extreme
handling, size, costs) for the variety of applications, requirements that are sometimes imposed on these
there is a broad spectrum of filter designs. Hence, components. For example, several Ku-band
there are numerous papers concerning CAD of diplexers have been designed for satellite antenna
filters and, thus, only few examples are presented systems (NAHUEL, SINOSAT, ASTRA2B)
due to the lack of space. Broad band filters such as satisfying low insertion loss (<0.15 dB), high
high pass filters using waveguide sections below return loss (>26dB) and band isolation (>50dB),
cut-off, corrugated and waffle-iron low pass filters high power handling capability (>500W CW,
can be designed accurately by CAD [5] with >12kW peak power handling, passive
commonly no need of any post tuning. Broad band intermodulation product control >200dBc) versus
cavity filters with cross couplings for the realization a space environmental temperature range of -100
of tailored filter responses may also be designed to +140 °C.
without the need of tuning in integrated waveguide
structures [13]. Multiplexers. The different multiplexing
Narrow band channel filters are basically realized principles are summarized in [18]. Owing to the
by overmoded rectangular cavity structures or use modularity of the circulator/filter chain and
circular dual-(multi-) mode cavities. Available directional filter approaches, the advances in CAD
CAD tools provide accurate prediction of response are dedicated to the required components (see
and geometry of complex cross coupled structures filter and coupler). Due to the large complexity of
[14] as well as of multimode cavity configurations multiple channel manifold multiplexers the
[15,16]. However, fine tuning is usually necessary principal design approach in [18] using full wave
since the tolerances of state-of-the-art modelling in the common manifold region and
manufacturing methods usually exceed the equivalent circuits for the narrow band filters is
allowable deviation of the dimensions. It should be still suitable. Recent advancements have been
noted that the application of CAD yields a provided in [19] for the determination of initial
tremendous reduction of experimental design manifold distances to improve the start conditions
expense. reducing the number of required optimization steps
and thus overall computation time. However, in a

4
final step the obtained equivalent circuits of the sections. Design of transitions in common Tx/Rx
filters are mapped to the geometrical dimensions antennas is typically more challenging, especially
[16] yielding a substantial reduction of if the Tx and Rx channels are widely separated in
experimental expense. frequency. The design of these transitions aims at
Orhomode Transducers A good survey of the high performance and large scale, low cost
different basic OMT – types is given in [18]. The production, since these transitions are often
proposed CAD possibilities have been extended required in relatively large quantities for single
due to the recent progress in analysis and polarized antenna feeds (rectangular-to-circular)
optimization [20] methods allowing also design and for the elliptical feeder waveguides. Thus, a
support of OMTs with a common circular novel BCMM CAD has been established for the
waveguide. The need of full wave designs has computation of arbitrarily curved cross sections of
been shown lately for mm-wave applications [21] transformer steps within a desired transition [12].
since experimental adjustment of such diminutive The proper consideration of milling radii at the
structures is nearly impossible. (However, it rectangular port within the CAD allows the
should be noted, that these designs comply with realization in one part by state-of-the-art CNC
essentially reduced performance demands.) Due to milling from the flange faces facilitating
complexity of high performance ( wideband) OMT manufacturing and costs.
the design of a compact device is still a Power combiners/dividers. The progress of full
challenging engineering task. For example, the wave CAD tools also extends and facilitates the
sophisticated compact design in [22] for large design of couplers / hybrids. In [26] a Riblet
scale low cost production can (up to now) hardly hybrid design variant is introduced that
be designed by available CAD tools. accommodates fully CAD and manufacturing
demands, however, with penalty of reduced
Polarizers. CAD tools have been developed over bandwidth. Recently, a new hybrid type has been
the past decade to design polarizer structures in a established that is based on a common overmoded
number of different waveguide technologies. waveguide supporting three propagating modes
Efficient modal field-matching software has long (TE10, TE11, and TM11)[27]. This design needs in
been available for rectangular corrugated particular full wave CAD support to accommodate
polarizers, e.g. [1]. More recent codes include with optimal performance demands. The inclusion
circular waveguide ridge and pin polarizers [23], of milling radii by advanced CAD tools [5] allows
and combinations of circular and rectangular to avoid experimental fine adjustment.
sections, e.g. [24], which are also suitable for dual- Entire feed systems In addition to the most
band applications. For critical cases, cost functions common single or dual polarized antenna
in the optimization process include specific angle operation, there are often extra tasks imposed on
specifications between the two linear components the feed system design. A brief outline of some
(usually ±90o) to counteract the influence of examples is given below.
connected circuitry. Applications with integrated transceiver/antenna
Septum polarizers assign two different linear solutions must provide receive/transmit signal
polarized ports to left-hand and right-hand circular diplexing, suppression of spurious signals like
polarized waves in the common port. CAD harmonics and broad band matching properties
advances have been reported on the variable while optimally fitting into a dedicated area in a
septum thickness [25] and the circular septum housing with direct interconnection of the antenna
polarizer [23] in which a bow-tie shaped septum port with the LNA and transmit amplifier port.
approximation is used for an efficient design Moreover, compatibility of electrical and
procedure. mechanical design has to be considered for
Transformers, Transitions. Transformers and applications utilizing different frequency bands.
transitions are very common in antenna feed An integrated feed system concept satisfying these
systems due to the need for combining demands consisting of dielectric back scatter feed,
components with RF ports of different cross- rectangular-to-circular waveguide transition,

5
 Integrated Antenna Coupling
Equipment
harmonic reject filter, diplexer Rx/Tx Diplexer
Rx
and isolators is shown in Fig 1.
Radio Equipment
The design challenge for feeds Housing Tx Harmonic
Isolators Reject Filter
employed in modern
communication satellite Circular Waveguide
to Back Scatter Feed
antennas is predominantly in
stringent requirements for low
RF loss, power handling,
polarization isolation and low
PIM level. Fig 2 shows a 30/20
GHz feed system used on the Feed Support
Waveguide Twist
Koreasat-3 Ka-band Gregorian for Horizontal or
antenna, [29] designed by EMS Vertical Polarized Service
Cut of
Technologies, Canada. This Antenna
high performance feed system Rectangular-to-Circular
LNA / Transmit
includes a corrugated horn, a Amplifier Module
Waveguide Transition
Integrated in Feed Support
dual band polarizer, a diplexer
and waveguide runs. Excellent Figure 1. Antenna feed system for a short haul radio featuring an
RF performance has been integrated antenna/transceiver solution (Marconi)
achieved without any tuning.

For high accuracy tracking (Monopulse) or for

increase of transmission reliability (angle
diversity) feed systems are used that provide
independent access to the signals of extra antenna
beams. In the Monopulse case only a narrow band
beacon signal has to be detected while for angle
diversity a complete frequency band must be
served [30]. Fig 3 shows the block diagram and
photograph of a 6 GHz angle diversity feed system
that is based on higher order mode excitations in
the feed. It consists of the feed horn, a multiple
mode transition, two OMTs and two Magic Tees,
each connected symmetrically to the vertical and
horizontal polarization port of the OMTs,
respectively. Thus, the interface ports at the Magic
Tee provide access to a main and a diversity
(‘Monopulse’) beam, respectively. In detail, a
signal at the sum port of the Magic Tee dedicated
to the vertical polarization excites the TE10 mode Figure 2. Koreasat-3 Ka-band antenna feed.
at the multiple mode transition that is associated
with the vertical polarized main beam. A signal at
TE02 dedicated to main and difference beam of the
the differential port excites the TE11/TM11 modes
antenna, respectively.
assigned to the horizontal difference beam. The
same holds for the Magic Tee serving the
horizontal polarization with the modes TE01 and

6
 Main - horizontal

Vertical Multiple Mode

Polarization Transition
Main

Magic Tees
Diversity

OMTs

Diversity - horizontal

Main
vertical
(Backside)

Diversity
vertical Diversity
Main horizontal
horizontal

Figure 3. 6GHz dual polarized integrated angle diversity feed system, based on multiple
mode excitation for the generation of independent horizontal and vertical main and
diversity beams (Marconi)

3. R. Beyer and F. Arndt, “ Efficient hybrid mode-

5 CONCLUSIONS matching finite-element method for the design of
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