FINMECCANICA - Klystron (ASI WS sessione 3)

Transcription

Klystron e TWT dalla banda L alla banda W
per payload spaziali - E‐‐gun e Catodi per
electric propulsion
R. Martorana, A. Spatola, P. Arpesi
19 Gennaio 2016 – ASI, Roma.
Primo Workshop Nazionale su “La Componentistica Nazionale per
lo Spazio: Stato dell’arte, Sviluppi e Prospettive"
Table of Contents
Palermo Plant – TWT & Microelectronics
• History
• Technology
• Highlights
• Heritage and Trend
• Product and Technology Roadmap
Space Activities
• Feasibility study on pulsed Klystron for Ka-band SAR instruments
• C-band Klystron Breadboard for MetOp SG SCA
• Cathodes for Neutralizers
Palermo Plant – TWT & Microelectronics
•
•
•
•
•
History
Technology
Highlights
Heritage and Trend
Product and Technology Roadmap
© 2014 Finmeccanica S.p.A. All rights reserved
History
• 1956 The Palermo Plant was established by ELSI.
• 1960 Raytheon-ELSI was founded as ELSI merged with Raytheon for the production of
vacuum electronic devices and microwave tubes (magnetrons and klystrons).
• 1975 the core business of the Palermo Plant became the design and manufacturing of
high power microwave tubes such as High Power Coupled Cavity TWT’s for Tornado,
etc….
• 1992 ALELCO S.p.A. was formed from the merging of the Microwave Tube Divisions of
Elettronica S.p.A. (Helix TWT’s) and Alenia S.p.A. (Coupled Cavity TWT’s).
Microelectronic business is introduced.
• 2003 the assets of ALELCO have been assigned to the new company Galileo Avionica
S.p.A
• 2009 Galileo Avionica and Selex Sensors & Airborne Systems merged into the
transnational company Selex Galileo.
• 2010 the Palermo site has been organized as a Centre of Excellence for satisfying our
Customer and being their partner for Microwave Power and Integrated Receiver and
Exciter Solutions for Radar, Security, EW&ESM Systems.
• 2013. Palermo site maintain his structure with the new Selex ES company.
• 2016. Finmeccanica “One Company”.
4
TWT Technologies and Capabilities
Key high power vacuum device technology includes: vacuum
expertise including brazing, RF induced and resistance welding;
etching and plating; manual and automated microwave high power
CW and pulsed testing; facilities for inspection, including CNC
contactless equipment and SEM electronic microscope.
5
Palermo Plant - Highlights
Total land:
16,000 sq meters
Production area:
5,000 sq meters
Class 10.000 clean rooms:
TWT clean rooms
400 sq meters
Microelectronics
600 sq meters
6
Heritage
Combat radar for Tornado
-1800 TWTs produced since the 80s
Captor for EF Typhoon
-500 TWTs produced since the ‘94
ET980 – CC TWT
ET963 – CC TWT
Tx in the Aster missile seeker
-1000 TWTs produced since the 2003
ET5515 – mini TWT
1000 TWT produced since the ‘95
ET6404 – Helix TWT
Helix TWT & Microelectronics for
SCP01 Radar
Helix TWT & Microelectronics for
Grifo Radar
7
New Products
Wide band
Front End
Solid State
Power
Amplifiers
RF and uW Hybrids
Mini TWT and MPM for
EW, UAV, Comms,
Radar
Space Tubes and
Hybrids
8
Vacuum Devices - Products and Technology Roadmap
TRL 1-2
TRL 3-4
Decreasing TRL – Increasing research effort
TRL 5-6
Millimeter SWS
Anodeless elctron guns
Space qual cathodes
High efficiency SWS
9-10 GHz
12kW 10%
C band
60kW 5%
PPM
C band
25kW CW
Klystron
Large CC Tubes
Ka Band Klystron
feasbility study
Space Tubes
TRL 7-8-9
6-18 GHz
150W
6-18 GHz
150W
150W
4,5-18GHz
18GHz
125W
125W
4,5-18GHz
18GHz
125W
125W
Fully qualified
production line
C band EBB
Klystron
9-10 GHz
1.5kW
1.5kW
MPM
X band and Ku band
for SAR / EOS
2626-40GHz
100W
32 - 38
GHz 100W
- 38
Mini TWTs 32
GHz 100W
9-10 GHz
1.5kW
2626-40GHz
40GHz
100W
00W
1818-40GHz
40GHz
100W
00W
1818-40GHz
40GHz
100W
00W
TWT
2013
2014
2015
2016
2017
2018
9
Space Activities
• Feasibility study on pulsed Klystron for Ka-band SAR
instruments
10
Activities for Space
Finmeccanica TWT capabilities can be successfully exploited for the
Space business. For this reason in the last four years several
ventures have been undertaken also with the support of the ESA
and Airbus.
• Feasibility study on pulsed Klystron for Ka-band SAR Instruments
11
Feasibility Study on pulsed Klystron for
Ka-band SAR Instruments
Supported by ESA
12
Ka-band Klystron – the Feasibility Study
An ESA internal study on the feasibility of a Ka-band SAR instrument and interferometer
has pointed to the need of a Ka-band High Power Amplifier (HPA) with capabilities
beyond what is currently available on the market.
ESA is currently investigating with Industry the feasibility of Ka-band SAR missions for
which a pulsed Ka-band High Power Amplifier is required.
Within this framework and contracted by ESA, Finmeccanica TWT team has successfully
completed a feasibility study for a High power HPA inclusive of the vacuum tube with the
characteristics summarized in the following table.
Parameter
Operating Frequency Range
Unit
GHz
Range/Limit
35.75
Operating Bandwidth
Transmitted Peak Power
MHz
W
≥350
3500
%
13
Duty Cycle
In Orbit lifetime
≥ 5 years
© 2014 Finmeccanica Ltd – All rights reserved
13
Ka-band Klystron – Conclusions
The Feasibility Study has shown that the vacuum tube technology can achieve the
required performance in terms of peak power and bandwidth but, currently, no existing
space qualified EIK is available, achieving the challenging Ka-band SAR requirements
no technological showstopper prevent the development of a new
Ka band pulsed vacuum tube.
the development of a new vacuum tube is needed in order to develop
a space high power amplifier for this application.
Moreover, since no European product is available for the purpose, either space or
avionic/ground, export restrictions may be an issue,
the opportunity to develop a fully European device for such
application has been looked at, as a further objective.
14
C-band Klystron Breadboard for MetOp SG SCA and
Cathode life test
Supported by ESA / Airbus
15
C-band Klystron – Introduction
•
Radar based instruments are essential for Earth Observation purposes.
•
The key issue relevant to the EO Radars is the availability of vacuum tube amplifiers
delivering several kW output power.
•
A pre-development of a C-band klystron is presently running at Finmeccanica in
Palermo, Italy, focused on the MetOp Second Generation Scatterometer, under ESA
contract, aiming to an all-European device.
•
Main characteristics and design requirements:
1. Carrier frequency
5.3 GHz
2. Peak Power
2 kW ÷ 3 kW
3. Duty cycle
1% ÷ 7%
•
The development plan includes a cathode life test for the verification of the extended
lifetime requirements.
16
C-band Klystron – Design and Development (1/2)
•
The running development is grounded on the Finmeccanica space projects heritage and
production tubes line established in 1950 with technologies well proven in the military
environment.
•
Objective = TRL 5
•
Klystron Breadboard (BB) has been completed to demonstrate the RF peak performances
verification at low duty cycle, an EBB (Elegant BB) will follow (Q1-2016) for electrical
performances verification at full duty cycle and over qualification temperature range.
•
The BB constructional features are representative of the flight model for the: Electron gun,
the RF structure and the Magnetic focusing structure.
17
C-band Klystron – Design and Development (2/2)
•
The vacuum tube has been manufactured, assembled and tested and the results have
confirmed that the Finmeccanica technology meets the RF performance at low duty
cycle. A multipactor analysis has been carried out resulting in more than 8 dB margin.
SYMB.
F
PARAMETER
Operating Frequency
LIMIT-VALUES
MIN
MAX
UNITS
MEASURES
MHz
5355
5354
5356
DC
Duty Cycle
1%
1%
Po
Peak Output Power
2.2
2.8
kW
3.334
ΔPo
Output Power Variation over
---
0.2
dB
0.2
Harmonics (up to 5th)
---
-20
dBc
-20
Spurious
---
-50
dBc
-50
0.575
1%
frequency range
HOR
S
PW
Pulse Length
1.15
1.15
msec
PRF
Pulse Repetition Frequency
8.7
8.7
Hz
8.7
RF input power
28
34
dBm
29.3
Pin
VSWR Source and Load VSWR
•
---
1.25:1
1.25:1
ηe
Electronic efficiency
30%
---
32.6%
ηtot
Tube efficiency
40%
---
41%
An EBB (Elegant BB) Model designed for electrical performances verification at full duty
cycle and over qualification temperature range shall be finalized by the first quarter 2016.
18
C-band Klystron – The Way forward to Space
•
•
In February 2016 the EBB shall be finalized. Should the METOP SG SCA be continued
based on the Finmeccanica Klystron solution a set of EMs shall be implemented
Purpose of the EMs will be to demonstrate the required RF and electrical performances in
the space environment, see the table. The EMs (3 off) will be representative in Form, Fit,
and Functions of the flight klystron and made with commercial parts
TEST
Dimensional
Electrical
Vibration
Mechanical Shock
Hot/Cold temperature
Thermal Vacuum
Temperature mapping (operating)
Temperature mapping (overduty)
External discharges (corona)
Life Test
EM1
X
X
X
X
EM2
X
X
EM3
X
X
X
X
X
X
X
X
X
•
The EQM, PFM and Flight Models of the program shall follow as summarized in the table
herein after.
•
A cathode life test is being implemented in
order to demonstrate that proprietary
Finmeccanica cathode technology is suitable
for Space operational requirement.
Deliverable
EM *
EQM
PFM/FM1
FM2
FM3
FM4
FM5
FM6
FM spare
METOP SCA
Phase
B2
C
D
D
D
D
D
D
D
Master Plan
03/02/2017
16/11/2017
26/07/2018
10/01/2019
27/06/2019
12/12/2019
28/05/2020
12/11/2020
29/04/2021
19
Cathode Life Test and the C-band Klystron
•
•
•
•
The Cathode life test is a program running at Finmeccanica Palermo premises under
Airbus/ESA contract, with the purpose to demonstrate the accelerated life test and that
Finmeccanica cathode technology is suitable for the space application and to verify the life
of the cathode that will be assembled on the klystron for the application in the MetOp
instrument.
The activities comprise the manufacturing 7 diodes, named Life Test Vehicles (LTV)
employing the expected cathode geometry designed for the Klystron and operated at the
required current density.
The LTV’s performance will be assessed for different cathode temperatures that will be set
at the beginning of life:
3 LTV’s will be tested at nominal cathode temperature
2 LTV’s at 40°C more than the nominal temperature
2 LTV’s at 80°C more than the nominal temperature
•
All the LTV’s will be ran with “heater on” only.
•
On monthly basis their performance will be recorded.
•
•
20
Cathode Life Test Status
•
•
•
•
LTVs began the test in October.
By April 2016 the first results will demonstrate the expected life (as a first evaluation)
Every six months further improved predictions will be available.
The test will be completed by July 2017 and will demonstrate the accelerated life of 7.5
years mission requirement for the MetOp SG
21
C-band Klystron – Conclusions
•
Radar based instruments are essential for Earth Observation purposes, availability of
vacuum tube amplifiers delivering kW output power is a key issue relevant to the Radar.
•
A C-band klystron for the Windscatterometer Instrument for MetOp Second Generation is
under development at Finmeccanica, under ESA contract.
•
A representative Breadboard (BB) has been completed and the electrical test results
have shown excellent results, demonstrating that the design and technology selected
and available in Finmeccanica can meet the required performances.
Way forward…
•
The development plan includes a cathode life test, currently running, for the verification
of the extended lifetime requirements.
•
The present development will be shortly completed with an EBB, fully representative of
the flight model. This will allow to achieve a TRL 5.
•
Should the METOP SG SCA be continued based on the Finmeccanica Klystron solution
a set of EMs shall be implemented to be available in 1 year. Purpose of the EMs will be
to demonstrate the required RF and electrical performances in the space environment.
•
The EQM shall be available by the Q4’17 and the PFM by the Q3’18 in accordance to
the METOP program master plan currently available.
22
Cathodes for Neutralizers
Self funded
23
CATHODES Technologies
•
•
•
•
The cathode technology available at Finmeccanica and presently being qualified for
Space operation has been implemented for application as E-gun in the Electron tubes
but this asset can be also exploited for providing Electric Propulsion (EP) systems with
Cathode / Neutralizer.
The EP is becoming a key solution for the management of the orbit for LEO/GEO
payloads especially if mini and micro satellite are considered and with respect to
conventional propulsion systems.
The Cathode/Neutralizer is a “key” component of an Electric Propulsion (EP) System,
and can significantly affect the performances and reliability of the whole EP system.
Finmeccanica, Florence team, has accumulated a remarkable heritage on the Ion
Thruster installed on ARTEMIS satellite using cathode procured from the US, the future
developments in the field are based on the proprietary cathode developed in the Palermo
plant.
24
Conclusions
Finmeccanica Vacuum Tubes capabilities are being successfully exploited in
the Space field and several new developments are foreseen.
•
•
•
The C-band Klystron for MetOp SG SCA phase B and C development
and supply of the items for the flight units.
• The Cathode life test is running in order to demonstrate 7.5 years
operating life for satisfying the MetOp SG requirements.
Development of pulsed Klystron for Ka-band SAR instruments that the
ESA is going to implement in the near term.
Cathodes for Neutralizers for the ESA programs and other foreign
entities.
Other opportunities might include the “space upgrading” of existing Helix
TWTs for:
- L / C / X band SAR Earth Observation systems for LEO satellites;
- Ku / Ka / W band for communication satellites;
To be intended for different applications by several Countries.
25
THANK YOU FOR YOUR ATTENTION
Pier Giorgio Arpesi
Time & Frequency - Space Platforms & Robotics - Airborne and Space Systems Division
[email protected]
Antonio Spatola
Sales – TWT & Microwave – Airborne and Space Systems Division
[email protected]
(mob.) +39 3357147793 (tel.) +39 0916482949
Via Villagrazia 79, – Palermo – 90125 – Italy

FINMECCANICA - Klystron (ASI WS sessione 3)

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