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DOE OSTI2023

Design, Manufacturing, Assembly, and Lessons Learned of the Pre-production 325 MHz Couplers for the PIP-II Project at Fermilab

Five 325 MHz high-power couplers will be integrated into the pre-production Single Spoke Resonator Type-II (ppSSR2) cryomodule for the PIP-II project at Fermilab. Couplers were procured by both Fermilab and IJCLAB for this effort. The design of the coupler is described, including design optimizations from the previous generation. This paper then describes the coupler life cycle, including design, manufacturing, and assembly, along with the lessons learned at each stage.

43 PARTICLE ACCELERATORS↗

DOE OSTI2026

Autonomous Coupler Alignment Using Position-Based Visual Servoing in a ROS 2 Framework

As robotic arms are becoming increasingly common alongside humans as collaborative robots, their high precision in motion enables tasks to be performed at significantly higher speeds with reduced disruption in the environment. The Fermi National Accelerator Laboratory is exploring this application by incorporating a UR16e from Universal Robots in a cleanroom setting during assembly of couplers to superconducting radio frequency cavities as part of the PIP-II project. The goal of the robotic assembly process is to precisely position the UR16e robot so that the coupler flange, mounted on the robot’s end-effector, is accurately aligned with and pressed against the cavity flange, requiring only final fastening by a lab technician. This thesis builds upon an initial system in which the robotic process was limited to the alignment phase using position-based visual servoing with an eye-in-hand camera to only align the coupler to the cavity with an offset distance. The objective of this thesis is to further advance autonomous robotic assembly by extending the process. To this end, the entire software framework was reconstructed, as the previous development environment posed significant challenges in modifying the software and adapting to hardware changes. The main contributions of this thesis are as follows: (i) a modular and scalable software framework based on ROS~2 was developed to facilitate performance expansion and interchangeability of software and hardware components; (ii) the desired alignment position for position-based visual servoing was parameterized to enable flexible configuration; and (iii) a methodology was developed to close the offset distance between the coupler and cavity utilizing the internal force-torque sensing capability of the UR16e, as visual feedback is not available during the offset-closing phase. The proposed autonomous robotic assembly reduces assembly time and technician involvement, thereby minimizing the risk of airborne particulate contamination, which is essential in the cleanroom setting. Moreover, the ROS~2-based framework provides a foundation for further expansion and continued advancement of robotic automation in Fermilab.

Giffen, Nickolas [Northern Illinois U.]↗

DOE OSTI2026

Test cavity and Iris-to-Coax transition for tuning and high-power verification of SNS DTL iris couplers

The Spallation Neutron Source (SNS) Drift Tube Linac (DTL) employs iris couplers to efficiently deliver RF power into the accelerating structure. To support the development, tuning, and high‑power conditioning of these couplers prior to installation in the actual DTLs, a dedicated test cavity and an iris‑to‑coaxial transition structure have been designed. This work presents the electromagnetic design, simulation, and optimization of the test setup, enabling precise characterization of the iris coupler’s performance. The transition structure allows for tuning of the iris opening dimensions without requiring a waveguide taper or full‑size waveguide transitions, while maintaining impedance matching between the coaxial feed and the iris geometry to minimize reflection and power loss. During low‑power tests, the iris opening di-mensions can be evaluated using the iris‑to‑coax transi-tion attached to the test cavity. For high‑power condi-tioning, full‑size waveguides with ceramic vacuum win-dows are connected to the test cavity to replicate opera-tional conditions. Key design parameters were optimized using computer-aided simulation, and sensitivity studies were conducted to assess the impact of mechanical toler-ances on RF performance. The resulting test platform provides a reliable and efficient means for tuning and validating iris couplers, contributing to improved opera-tional stability in the SNS DTL.

Lee, Sung-Woo [ORNL] (ORCID:000000030915835X)↗

DOE OSTI2025

A Misalignment Tolerant Magnetic Coupler Design and Implementation for Wireless Charging of Unmanned Aerial Vehicles (UAVs)

Wireless power transfer technology is getting more attention these days as a part of expanded battery charging infrastructure and network at a wide range of power levels. Charging Unmanned aerial vehicles (UAVs) is one wireless charging application, and charging their batteries can be challenging because they have short flight times and are frequently charged. For wireless charging of UAVs, the misalignment performance of the magnetic coupler pads is critical because landing on a charging pad at a perfectly aligned position is difficult and can be time-consuming. Different coil shapes and system structures have been proposed in the literature to overcome this challenge. A new design with a high misalignment tolerance is needed; therefore, to fill this gap, a wireless power transfer system has been designed for a 250 W UAV battery charging system with a new magnetic coupler design. A 3D model of the proposed design was created, and finite element simulations were performed. To prove the proposed design, the magnetic coupler prototypes were developed, and experimental results are presented herein. The misalignment tolerance of the proposed system was observed for various rotational positions of the secondary coil, from 0° to 360°. The results demonstrate that DC–DC efficiency varies between 80% and 85% within full 360° rotation of the receiver coil. This result enables the proposed system to address the misalignment problem for wireless charging of UAVs.

UAVs↗

DOE OSTI2019

Modulational instability in oppositely doubled-doped directed couplers with a non-kerr-like nonlinear refractive-index change

We theoretically investigate modulation instability (MI) in a two-core nonlinear oppositely directed coupler with a negative-index material channel in the presence of a non-kerr-like nonlinear refractive-index change. Using linear stability analysis, we obtain an expression for the instability gain. It is found that the MI in the nonlinear two-core oppositely directed coupler is significantly influenced by the ratio of the forward- to backward-propagating wave power, nonlinearity, power and saturation. In the normal dispersion regime, the septic nonlinearity is found to suppress the MI by reducing both the gain and width of the instability nonlinearity. But in anomalous dispersion regime, the situation is different because septic nonlinearity enhances the MI by increasing both the gain and width of MI. The increase of septic nonlinearity both in normal and anomalous dispersion regimes increases the gain of the instability nonlinearity. Thus, we report new ways to generate and manipulate the MI and solitons in two-core oppositely directed couplers with a particular emphasis on a negative-index material (NIM) channel in presence of septic nonlinearity.

36 MATERIALS SCIENCE↗

DOE OSTI2021

A hybrid coupler for directing quantum light emission with high radiative Purcell enhancement to a dielectric metasurface lens

Quantum photonic technologies such as quantum sensing, metrology, and simulation could be transformatively enabled by the availability of integrated single photon sources with high radiative rates and photon collection efficiencies. We address these challenges for quantum emitters formed from color center defect sites such as those in hexagonal boron nitride, which are promising candidates as single photon sources due to their bright, stable, polarized, and room temperature emission. We report design of a nanophotonic coupler from color center quantum emitters to a dielectric metasurface lens. The coupler is comprised of a hybrid plasmonic–dielectric resonator that achieves a large radiative Purcell enhancement and partial control of far-field radiation. We report radiative Purcell factors up to 285 and photon collection efficiencies up to 89% for a lossless metasurface, applying a continuous hyperboloidal phase-front. Our hybrid plasmonic–dielectric coupler interfacing two nanophotonic elements is a compound optical element, analogous to those found in microscope objective lenses, which combine multiple optical functions into a single component for improved performance.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2025

Triangular cross-section grating couplers for integrated quantum nanophotonic hardware in silicon carbide

We design, fabricate, and characterize fishbone grating couplers for triangular cross-section photonics in silicon carbide compatible with color center integration. The periodic and aperiodic grating coupler designs are optimized to outcouple up to 31% of light in the fundamental TE mode of a triangular waveguide. The devices are fabricated using an ion beam etching process in a 4H–SiC sample implanted with NV center ensembles. The room-temperature transmission and the cryogenic NV center photoluminescence collection measurements indicate experimental grating coupler efficiency of up to 24%. This result provides a scalable method to efficiently extract color center light from SiC quantum nanophotonic devices to free-space optics.

Saha, Pranta↗

DOE OSTI2022

Design, Manufacturing, Assembly, Testing, and Lessons Learned of the Prototype 650 MHz Couplers

Six 650 MHz high-power couplers will be integrated into the prototype High Beta 650 MHz (HB650) cryomodule for the PIP-II project at Fermilab. The design of the coupler is described, including design optimizations from the previous generation. This paper then describes the coupler life-cycle, including manufacturing, assembly, testing, conditioning and the lessons learned at each stage.

43 PARTICLE ACCELERATORS↗

NASA NTRS1984

Fiber optic data bus using Frequency Division Multiplexing (FDM) and an asymmetric coupler

A fiber optic data bus, using frequency division multiplexing (FDM) is discussed. The use of FDM is motivated by the need to avoid central control of the bus operation. A major difficulty of such a data bus is introduced by the couplers. An efficient low loss access coupler with an asymmetric structure is presented, and manufacturing processes for the coupler are proposed.

Zanger, M.↗

NASA NTRS1987

Directional couplers for detecting the TE sub 11 and TE sub 12 circular waveguide modes

The theoretical and experimental results for a pair of mode-selective directional couplers designed to detect the TE sub 11 and TE sub 12 modes in a multimode circular wavelength are described. A brief description of the design of the couplers is presented, followed by a comparison of their measured and calculated parameters. The couplers were used to measure the characteristics of a circular waveguide mode converter. The results of these measurements are described.

Hoppe, D.↗

NASA NTRS1987

X-band phase calibration generator coupler

A new type of phase calibration generator (PCG) coupler was developed for the Deep Space Network (DSN) X-band antennas that can be located directly behind the feedhorn. The advantage of this is that the calibration includes more of the system. The disadvantage is that the overmoded waveguide at this location must be coupled in a mode-selective manner. Low-power and high-power PCG couplers have been successfully produced, and the RF test results from a PCG coupler are given.

Stanton, P. H.↗

NASA NTRS1989

Fabrication Of Fiber-Optic Waveguide Coupler

Technique for making four-port, single-mode fiber-optic waveguide couplers requires no critically-precise fabrication operations or open-loop processes. Waveguide couplers analogous to beam-splitter prisms. Essential in many applications that require coherent separation or combination of two waves; for example, for interferometric purposes. Components of optical waveguide coupler held by paraffin on microscope slide while remaining cladding of two optical fibers fused together by arc welding.

Goss, Willis↗

NASA NTRS1988

Cross-guide coupler modeling and design

Modeling of cross-guide couplers based on the theory of equivalent electric and magnetic dipoles of an aperture is described. Additional correction factors due to nonzero wall thickness and large aperture are also included in this analysis. Comparisons of the measured and calculated results are presented for cross-guide couplers with circular or cross-shaped coupling apertures. A cross-guide coupler was designed as a component of the C-band feed to support the Phobos mission.

Chen, J.↗

NASA NTRS1991

New channelised coplanar waveguide to rectangular waveguide post and slot couplers

Two new coplanar waveguide to rectangular waveguide couplers with coupling through a post and a slot are experimentally demonstrated. The couplers operate over the Ku-band transmission and X-band reception frequencies that are designated for satellite communications. The measured insertion loss and return loss are about 1 dB, respectively, for both couplers.

Simons, R. N.↗

NASA NTRS1993

Method for non-destructive estimation of waveguide directional coupler dimensions

A method for estimating the size and location of couplings within a waveguide directional coupler is provided. The method is applied to a waveguide directional coupler having a main transmission waveguide connected to an auxiliary transmission waveguide by a number of bore hold couplings. The bore hold couplings are in the interior of the waveguide directional coupler and, therefore, are not easily measurable. The method generally includes the steps of applying a two-sided tape to a member, inserting and securing the member within the main transmission waveguide, pouring a fine particulate substance such as talc into the auxiliary transmission waveguide such that a portion of the talc enters the bore hole couplings and adheres to the two-sided tape, and withdrawing the member such that the size and location of the bore hole couplings can be determined by measuring the size and location of marks on the two-sided tape caused by the fine particular substance adhering to the two-sided tape.

Perez, Raul M.↗

NASA NTRS1994

Thin-ribbon tapered coupler for dielectric waveguides

A recent discovery shows that a high-dielectric constant, low-loss, solid material can be made into a ribbon-like waveguide structure to yield an attenuation constant of less than 0.02 dB/m for single-mode guidance of millimeter/submillimeter waves. One of the crucial components that must be invented in order to guarantee the low-loss utilization of this dielectric-waveguide guiding system is the excitation coupler. The traditional tapered-to-a-point coupler for a dielectric rod waveguide fails when the dielectric constant of the dielectric waveguide is large. This article presents a new way to design a low-loss coupler for a high- or low-dielectric constant dielectric waveguide for millimeter or submillimeter waves.

Yeh, C.↗

NASA NTRS1996

Simulation of TunneLadder Traveling-Wave Tube Input/Output Coupler Characteristics Using MAFIA

RF input/output coupler characteristics for the TunneLadder traveling-wave tube have been calculated using the three-dimensional computer code, MAFIA and compared to experimental data with good agreement. Theory behind coupling of the TunneLadder interaction circuit to input and output waveguides is presented and VSWR data is calculated for variations on principal coupler dimensions to provide insight into manufacturing tolerances necessary for acceptable performance. Accuracy of results using MAFIA demonstrates how experimental hardware testing of three-dimensional coupler designs can be reduced.

Kory, Carol L.↗

NASA NTRS2008

Efficient Coupler for a Bessel Beam Dispersive Element

A document discusses overcoming efficient optical coupling to high orbital momentum modes by slightly bending the taper dispersive element. This little shape distortion is not enough to scramble the modes, but it allows the use of regular, free-beam prism coupling, fiber coupling, or planar fiber on-chip coupling with, ultimately, 100 percent efficiency. The Bessel-beam waveguide is bent near the contact with the coupler, or a curved coupler is used. In this case, every Bessel-beam mode can be successfully coupled to a collimated Gaussian beam. Recently developed Bessel-beam waveguides allow long optical delay and very high dispersion. Delay values may vary from nanoseconds to microseconds, and dispersion promises to be at 100 s/nm. Optical setup consisted of a red laser, an anamorphic prism pair, two prism couplers, and a bent, single-mode fiber attached to prisms. The coupling rate increased substantially and corresponded to the value determined by the anamorphic prism pair.

Savchenkov, Anatoliy↗