The Cassini Mission Ka-Band TWT
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Accurate Time-Dependent Traveling-Wave Tube Model Developed for Computational Bit-Error-Rate Testing
The phenomenal growth of the satellite communications industry has created a large demand for traveling-wave tubes (TWT's) operating with unprecedented specifications requiring the design and production of many novel devices in record time. To achieve this, the TWT industry heavily relies on computational modeling. However, the TWT industry's computational modeling capabilities need to be improved because there are often discrepancies between measured TWT data and that predicted by conventional two-dimensional helical TWT interaction codes. This limits the analysis and design of novel devices or TWT's with parameters differing from what is conventionally manufactured. In addition, the inaccuracy of current computational tools limits achievable TWT performance because optimized designs require highly accurate models. To address these concerns, a fully three-dimensional, time-dependent, helical TWT interaction model was developed using the electromagnetic particle-in-cell code MAFIA (Solution of MAxwell's equations by the Finite-Integration-Algorithm). The model includes a short section of helical slow-wave circuit with excitation fed by radiofrequency input/output couplers, and an electron beam contained by periodic permanent magnet focusing. A cutaway view of several turns of the three-dimensional helical slow-wave circuit with input/output couplers is shown. This has been shown to be more accurate than conventionally used two-dimensional models. The growth of the communications industry has also imposed a demand for increased data rates for the transmission of large volumes of data. To achieve increased data rates, complex modulation and multiple access techniques are employed requiring minimum distortion of the signal as it is passed through the TWT. Thus, intersymbol interference (ISI) becomes a major consideration, as well as suspected causes such as reflections within the TWT. To experimentally investigate effects of the physical TWT on ISI would be prohibitively expensive, as it would require manufacturing numerous amplifiers, in addition to acquiring the required digital hardware. As an alternative, the time-domain TWT interaction model developed here provides the capability to establish a computational test bench where ISI or bit error rate can be simulated as a function of TWT operating parameters and component geometries. Intermodulation products, harmonic generation, and backward waves can also be monitored with the model for similar correlations. The advancements in computational capabilities and corresponding potential improvements in TWT performance may prove to be the enabling technologies for realizing unprecedented data rates for near real time transmission of the increasingly larger volumes of data demanded by planned commercial and Government satellite communications applications. This work is in support of the Cross Enterprise Technology Development Program in Headquarters' Advanced Technology & Mission Studies Division and the Air Force Office of Scientific Research Small Business Technology Transfer programs.
Kory, Carol L.↗
Efficiency enhancement of dual-mode traveling wave tubes at saturation and in the linear range by use of spent-beam refocusing and multistage depressed collectors
An axisymmetric, multistage depressed collector of fixed geometric design was evaluated in conjunction with an octave-bandwidth, dual-mode TWT. The TWT was operated over a wide range of conditions to simulate different applications. The collector was operated in three-, four-, and five-stage configurations, and its performance was optimized (within the constraint of fixed geometric design) over the range of TWT operating conditions covered. For operation of the dual-mode TWT at and near saturation, the collectors increased the TWT overall efficiency by a factor of 2 1/2 to 3 1/2. Collector performance was relatively constant for both the high and low TWT modes and for operation of the TWT across an octave bandwidth. For operation of the TWT in the linear, low-distortion range, collector efficiencies of 90 percent and greater were obtained, leading to a five- to twelvefold increase in the TWT overall efficiency for the range of operating conditions covered and reasonably high (greater than 25 percent) overall efficiencies well below saturation.
Ramins, P.↗
Multistage depressed collector with efficiency of 90 to 94 percent for operation of a dual-mode traveling wave tube in the linear region
An axisymmetric, multistage, depressed collector of fixed geometric design was evaluated in conjunction with an octave bandwidth, dual mode traveling wave tube (TWT). The TWT was operated over a wide range of conditions to simulate different applications. The collector performance was optimized (within the constraint of fixed geometric design) over the range of TWT operating conditions covered. For operation of the TWT in the linear, low distortion range, 90 percent and greater collector efficiencies were obtained leading to TWT overall efficiencies of 20 to 35 percent, as compared with 2 to 5 percent with an undepressed collector. With collectors of this efficiency and minimized beam interception losses, it becomes practical to design dual mode TWT's such that the low mode can represent operation well below saturation. Consequently, the required pulse up in beam current can be reduced or eliminated, and this mitigates beam control and dual mode TWT circuit design problems. For operation of the dual mode TWT at saturation, average collector efficiencies in excess of 85 percent were obtained for both the low and high modes across an octave bandwidth, leading to a three to fourfold increase in the TWT overall efficiency.
Ramins, P.↗
Performance of computer-designed small-sized four-stage depressed collector for operation of dual-mode traveling wave tube
A computer-designed axisymmetric 2.4-cm-diameter four-stage depressed collectors was evaluated in conjunction with an octave bandwidth, dual-mode traveling wave tube (TWT). The TWT was operated over a wide range of conditions to simulate different applications. The collector performance was optimized (within the constraint of fixed collector geometry which was designed for operation of the TWT at saturation) over the range of TWT operating conditons covered. For operation of the dual-mode TWT at saturation, average collector efficiencies of 81 1/2 and 82 percent for the high and low modes, respectively, were obtained across an octave bandwidth, leading to a three-fold increase in the TWT overall efficiency. For operation of the TWT in the linear, low distortion range, collector efficiencies of 87 to 92 percent were obtained, leading to TWT overall efficiencies as high as 35 percent. For operation of the dual-mode TWT over a 10 to 1 range in output power, overall efficiencies of 14 to 41 percent were obtained.
Ramins, P.↗
A three-dimensional finite-element thermal/mechanical analytical technique for high-performance traveling wave tubes
Current research in high-efficiency, high-performance traveling wave tubes (TWT's) has led to the development of novel thermal/ mechanical computer models for use with helical slow-wave structures. A three-dimensional, finite element computer model and analytical technique used to study the structural integrity and thermal operation of a high-efficiency, diamond-rod, K-band TWT designed for use in advanced space communications systems. This analysis focused on the slow-wave circuit in the radiofrequency section of the TWT, where an inherent localized heating problem existed and where failures were observed during earlier cold compression, or 'coining' fabrication technique that shows great potential for future TWT development efforts. For this analysis, a three-dimensional, finite element model was used along with MARC, a commercially available finite element code, to simulate the fabrication of a diamond-rod TWT. This analysis was conducted by using component and material specifications consistent with actual TWT fabrication and was verified against empirical data. The analysis is nonlinear owing to material plasticity introduced by the forming process and also to geometric nonlinearities presented by the component assembly configuration. The computer model was developed by using the high efficiency, K-band TWT design but is general enough to permit similar analyses to be performed on a wide variety of TWT designs and styles. The results of the TWT operating condition and structural failure mode analysis, as well as a comparison of analytical results to test data are presented.
Bartos, Karen F.↗
A three-dimensional finite-element thermal/mechanical analytical technique for high-performance traveling wave tubes
Current research in high-efficiency, high-performance traveling wave tubes (TWT's) has led to the development of novel thermal/mechanical computer models for use with helical slow-wave structures. A three-dimensional, finite element computer model and analytical technique used to study the structural integrity and thermal operation of a high-efficiency, diamond-rod, K-band TWT designed for use in advanced space communications systems. This analysis focused on the slow-wave circuit in the radiofrequency section of the TWT, where an inherent localized heating problem existed and where failures were observed during earlier cold compression, or 'coining' fabrication technique that shows great potential for future TWT development efforts. For this analysis, a three-dimensional, finite element model was used along with MARC, a commercially available finite element code, to simulate the fabrication of a diamond-rod TWT. This analysis was conducted by using component and material specifications consistent with actual TWT fabrication and was verified against empirical data. The analysis is nonlinear owing to material plasticity introduced by the forming process and also to geometric nonlinearities presented by the component assembly configuration. The computer model was developed by using the high efficiency, K-band TWT design but is general enough to permit similar analyses to be performed on a wide variety of TWT designs and styles. The results of the TWT operating condition and structural failure mode analysis, as well as a comparison of analytical results to test data are presented.
Shalkhauser, Kurt A.↗
Technique Developed for Optimizing Traveling-Wave Tubes
A traveling-wave tube (TWT) is an electron beam device that is used to amplify electromagnetic communication waves at radio and microwave frequencies. TWT s are critical components in deep-space probes, geosynchronous communication satellites, and high-power radar systems. Power efficiency is of paramount importance for TWT s employed in deep-space probes and communications satellites. Consequently, increasing the power efficiency of TWT s has been the primary goal of the TWT group at the NASA Lewis Research Center over the last 25 years. An in-house effort produced a technique (ref. 1) to design TWT's for optimized power efficiency. This technique is based on simulated annealing, which has an advantage over conventional optimization techniques in that it enables the best possible solution to be obtained (ref. 2). A simulated annealing algorithm was created and integrated into the NASA TWT computer model (ref. 3). The new technique almost doubled the computed conversion power efficiency of a TWT from 7.1 to 13.5 percent (ref. 1).
Wilson, Jeffrey D.↗
Modular Low-Heater-Power Cathode/Electron Gun Assembly for Microwave and Millimeter Wave Traveling Wave Tubes
A low-cost, low-mass, electrically efficient, modular cathode/electron gun assembly has been developed by FDE Inc. of Beaverton, Oregon, under a Small Business Innovation Research (SBIR) contract with the NASA Glenn Research Center at Lewis Field. This new assembly offers significant improvements in the design and manufacture of microwave and millimeter wave traveling-wave tubes (TWT's) used for radar and communications. It incorporates a novel, low-heater-power, reduced size and mass, high-performance barium dispenser type thermionic cathode and provides for easy integration of the cathode into a large variety of conventional TWT circuits. Among the applications are TWT's for Earth-orbiting communication satellites and for deep space communications, where future missions will require smaller spacecraft, higher data transfer rates (higher frequencies and radiofrequency output power), and greater electrical efficiency. A particularly important TWT application is in the microwave power module (a hybrid microwave/millimeter wave amplifier consisting of a low-noise solid-state driver, a small TWT, and an electronic power conditioner integrated into a single compact package), where electrical efficiency and thermal loading are critical factors and lower cost is needed for successful commercialization. The design and fabrication are based on practices used in producing cathode ray tubes (CRT's), which is one of the most competitive and efficient manufacturing operations in the world today. The approach used in the design and manufacture of thermionic cathodes and electron guns for CRT's has been optimized for fully automated production, standardization of parts, and minimization of costs. It is applicable to the production of similar components for microwave tubes, with the additional benefits of low mass and significantly lower cathode heater power (less than half that of dispenser cathodes presently used in TWT s). Modular cathode/electron gun assembly. The modular cathode/electron gun assembly consists of four subassemblies the cathode, the focus electrode, the header (including the electrical feedthroughs), and the gun envelope (including the anode) a diagram of which is shown. The modular construction offers a number of significant advantages, including flexibility of design, interchangeability of parts, and a drop-in final assembly procedure for quick and accurate alignment. The gun can accommodate cathodes ranging in size from 0.050 to 0.250-in. in diameter and is applicable to TWT's over a broad range of sizes and operating parameters, requiring the substitution of only a few parts: that is, the cathode, focus electrode, and anode. The die-pressed cathode pellets can be made with either flat or concave (Pierce gun design) emitting surfaces. The gun can be either gridded (pulse operation) or ungridded (continuous operation). Important factors contributing to low cost are the greater use of CRT materials and parts, the standardization of processes (welding and mechanical capture), and tooling amenable to automated production. Examples are the use of simple shapes, drawn or stamped metal parts, and parts joined by welding or mechanical capture. Feasibility was successfully demonstrated in the retrofit and testing of a commercial Kaband (22-GHz) TWT. The modular cathode/electron gun assembly was computer modeled to replicate the performance of the original electron gun and fabricated largely from existing CRT parts. Significant test results included demonstration of low heater power (1.5-W, 1010 C brightness temperature for a 0.085-in.-diameter cathode), mechanical ruggedness (100g shock and vibration tests in accordance with military specifications (MIL specs)), and a very fast warmup. The results of these tests indicate that the low-cost CRT manufacturing approach can be used without sacrificing performance and reliability.
Wintucky, Edwin G.↗
Analytical prediction with multidimensional computer programs and experimental verification of the performance, at a variety of operating conditions, of two traveling wave tubes with depressed collectors
Experimental and analytical results are compared for two high performance, octave bandwidth TWT's that use depressed collectors (MDC's) to improve the efficiency. The computations were carried out with advanced, multidimensional computer programs that are described here in detail. These programs model the electron beam as a series of either disks or rings of charge and follow their multidimensional trajectories from the RF input of the ideal TWT, through the slow wave structure, through the magnetic refocusing system, to their points of impact in the depressed collector. Traveling wave tube performance, collector efficiency, and collector current distribution were computed and the results compared with measurements for a number of TWT-MDC systems. Power conservation and correct accounting of TWT and collector losses were observed. For the TWT's operating at saturation, very good agreement was obtained between the computed and measured collector efficiencies. For a TWT operating 3 and 6 dB below saturation, excellent agreement between computed and measured collector efficiencies was obtained in some cases but only fair agreement in others. However, deviations can largely be explained by small differences in the computed and actual spent beam energy distributions. The analytical tools used here appear to be sufficiently refined to design efficient collectors for this class of TWT. However, for maximum efficiency, some experimental optimization (e.g., collector voltages and aperture sizes) will most likely be required.
Dayton, J. A., Jr.↗
Secondary-electron-emission losses in multistage depressed collectors and traveling-wave-tube efficiency improvements with carbon collector electrode surfaces
Secondary-electron-emission losses in multistage depressed collectors (MDC's) and their effects on overall traveling-wave-tube (TWT) efficiency were investigated. Two representative TWT's and several computer-modeled MDC's were used. The experimental techniques provide the measurement of both the TWT overall and the collector efficiencies. The TWT-MDC performance was optimized and measured over a wide range of operating conditions, with geometrically identical collectors, which utilized different electrode surface materials. Comparisons of the performance of copper electrodes to that of various forms of carbon, including pyrolytic and iisotropic graphites, were stressed. The results indicate that: (1) a significant improvement in the TWT overall efficiency was obtained in all cases by the use of carbon, rather than copper electrodes, and (2) that the extent of this efficiency enhancement depended on the characteristics of the TWT, the TWT operating point, the MDC design, and collector voltages. Ion textured graphite was found to be particularly effective in minimizing the secondary-electron-emission losses. Experimental and analytical results, however, indicate that it is at least as important to provide a maximum amount of electrostatic suppression of secondary electrons by proper MDC design. Such suppression, which is obtained by ensuring that a substantial suppressing electric field exists over the regions of the electrodes where most of the current is incident, was found to be very effective. Experimental results indicate that, with proper MDC design and the use of electrode surfaces with low secondary-electron yield, degradation of the collector efficiency can be limited to a few percent.
Ramins, P.↗
Overall Traveling-Wave-Tube Efficiency Improved By Optimized Multistage Depressed Collector Design
Depressed Collector Design The microwave traveling wave tube (TWT) is used widely for space communications and high-power airborne transmitting sources. One of the most important features in designing a TWT is overall efficiency. Yet, overall TWT efficiency is strongly dependent on the efficiency of the electron beam collector, particularly for high values of collector efficiency. For these reasons, the NASA Glenn Research Center developed an optimization algorithm based on simulated annealing to quickly design highly efficient multistage depressed collectors (MDC's). Simulated annealing is a strategy for solving highly nonlinear combinatorial optimization problems. Its major advantage over other methods is its ability to avoid becoming trapped in local minima. Simulated annealing is based on an analogy to statistical thermodynamics, specifically the physical process of annealing: heating a material to a temperature that permits many atomic rearrangements and then cooling it carefully and slowly, until it freezes into a strong, minimum-energy crystalline structure. This minimum energy crystal corresponds to the optimal solution of a mathematical optimization problem. The TWT used as a baseline for optimization was the 32-GHz, 10-W, helical TWT developed for the Cassini mission to Saturn. The method of collector analysis and design used was a 2-1/2-dimensional computational procedure that employs two types of codes, a large signal analysis code and an electron trajectory code. The large signal analysis code produces the spatial, energetic, and temporal distributions of the spent beam entering the MDC. An electron trajectory code uses the resultant data to perform the actual collector analysis. The MDC was optimized for maximum MDC efficiency and minimum final kinetic energy of all collected electrons (to reduce heat transfer). The preceding figure shows the geometric and electrical configuration of an optimized collector with an efficiency of 93.8 percent. The results show the improvement in collector efficiency from 89.7 to 93.8 percent, resulting in an increase of three overall efficiency points. In addition, the time to design a highly efficient MDC was reduced from a month to a few days. All work was done in-house at Glenn for the High Rate Data Delivery Program. Future plans include optimizing the MDC and TWT interaction circuit in tandem to further improve overall TWT efficiency.
Vaden, Karl R.↗
Experimental verification of the multistage depressed collector design procedure for a high-perveance, helix-type, traveling-wave tube
The validity of a computational procedure for the design of multistage depressed collectors (MDC's) is demonstrated for a traveling wave tube (TWT) with a perveance of .00000123. The MDC is used with spent-beam refocusing to improve substantially the efficiency of the TWT. Reports on this subject have verified, under a variety of operating conditions, the MDC design procedure for TWT's with lower perveance. The design procedure is based on two computer programs that create a mathematical model of the electric and magnetic fields of the TWT refocuser MDC system and its electron beam. The two principal outputs of the analysis are a description of the radiofrequency (RF) performance of the TWT and the trajectories of representatives groups of charges from the input of the TWT to their points of interception on the MDC electrodes.
Dayton, J. A., Jr.↗
Performance of textured carbon on copper electrode multistage depressed collectors with medium-power traveling wave tubes
Performance of multistage depressed collectors (MDCs) using textured carbon on copper substrate electrode surfaces was evaluated in conjunction with medium-power traveling wave tubes (TWTs). The MDC and TWT overall efficiencies for these electrodes were measured and compared with those obtained with the same TWT and a copper electrode MDC of identical design. Long-term stability of the carbon-coated copper electrode surfaces was investigated by periodic evaluation of TWT-MDC performance over an extended period of continuous wave (CW) operation. Application of textured carbon coating on copper MDC electrode surfaces produced a 13% improvement in both MDC and TWT overall efficiencies for the TWT-MDC tests. During 1600 hr of CW operation with a medium power TWT, no significant changes in MDC performance were noted. This indicated good stability of the textured carbon electrode surfaces. This stability was confirmed by scanning electron microscope examinations of the electrode surfaces before assembly of the MDC and after completion of the test program.
Ramins, Peter↗
Traveling-wave-tube efficiency improvement by a low-cost technique for deposition of carbon on multistage depressed collector
A simple method of improving the traveling-wave-tube (TWT) and multistage depressed collector (MDC) efficiency has been demonstrated. The efficiency improvement was produced by the application of a thin layer of carbon to the copper electrodes of the MDC by means of a rapid, low-cost technique involving the pyrolysis of hydrocarbon oil in electric arc discharges. Experimental results with a representative TWT and MDC showed an 11 percent improvement in both the TWT and MDC efficiencies as compared to those of the same TWT and MDC efficiencies with bare copper electrode surfaces. An extended test with a 500-W, continuous wave (CW) TWT and small-sized MDC indicated good stability of the carbon coated electrode surfaces after a relatively small initial degradation in TWT overall and apparent MDC efficiencies.
Ebihara, Ben T.↗
Pulsed response of a traveling-wave tube
The consequence of frequency-domain multiple access (FDMA) channelization in a satellite communications system is that the ground- and space-based components are often required to operate at reduced output power to prevent the generation of distortions. However, the components of a time-division multiple access (TDMA) satellite system, such as a traveling-wave tube (TWT), can operate at the highest output power because the channelization technique is relatively insensitive to the distortions resulting from saturated operation. A Hughes 30-GHz TWT was tested to determine the suitability of such a device in a TDMA system. Testing was focused on the ability of the TWT to rise up to full power at the leading edge of TDMA bursts, which were simulated by a pulse train. A Wavetek model 8502A peak power meter was used to display and measure the pulsed signal waveform. Measurements of the TWT output signal rise time indicate that the TWT lengthened the rise time by 10 to 20 nsec. Imposing a modulator turn-on time that precedes the data burst by the TWT rise time is a logical approach to coordinating the traveling-wave tube amplifier and modulator specifications.
May, Brian D.↗
A More Accurate and Efficient Technique Developed for Using Computational Methods to Obtain Helical Traveling-Wave Tube Interaction Impedance
The phenomenal growth of commercial communications has created a great demand for traveling-wave tube (TWT) amplifiers. Although the helix slow-wave circuit remains the mainstay of the TWT industry because of its exceptionally wide bandwidth, until recently it has been impossible to accurately analyze a helical TWT using its exact dimensions because of the complexity of its geometrical structure. For the first time, an accurate three-dimensional helical model was developed that allows accurate prediction of TWT cold-test characteristics including operating frequency, interaction impedance, and attenuation. This computational model, which was developed at the NASA Lewis Research Center, allows TWT designers to obtain a more accurate value of interaction impedance than is possible using experimental methods. Obtaining helical slow-wave circuit interaction impedance is an important part of the design process for a TWT because it is related to the gain and efficiency of the tube. This impedance cannot be measured directly; thus, conventional methods involve perturbing a helical circuit with a cylindrical dielectric rod placed on the central axis of the circuit and obtaining the difference in resonant frequency between the perturbed and unperturbed circuits. A mathematical relationship has been derived between this frequency difference and the interaction impedance (ref. 1). However, because of the complex configuration of the helical circuit, deriving this relationship involves several approximations. In addition, this experimental procedure is time-consuming and expensive, but until recently it was widely accepted as the most accurate means of determining interaction impedance. The advent of an accurate three-dimensional helical circuit model (ref. 2) made it possible for Lewis researchers to fully investigate standard approximations made in deriving the relationship between measured perturbation data and interaction impedance. The most prominent approximations made in the analysis were addressed and fully investigated for their accuracy by using the three-dimensional electromagnetic simulation code MAFIA (Solution of Maxwell's Equations by the Finite Integration Algorithm) (refs. 3 and 4). We found that several approximations introduced significant error (ref. 5).
Kory, Carol L.↗
Power and Efficiency Optimized in Traveling-Wave Tubes Over a Broad Frequency Bandwidth
A traveling-wave tube (TWT) is an electron beam device that is used to amplify electromagnetic communication waves at radio and microwave frequencies. TWT's are critical components in deep space probes, communication satellites, and high-power radar systems. Power conversion efficiency is of paramount importance for TWT's employed in deep space probes and communication satellites. A previous effort was very successful in increasing efficiency and power at a single frequency (ref. 1). Such an algorithm is sufficient for narrow bandwidth designs, but for optimal designs in applications that require high radiofrequency power over a wide bandwidth, such as high-density communications or high-resolution radar, the variation of the circuit response with respect to frequency must be considered. This work at the NASA Glenn Research Center is the first to develop techniques for optimizing TWT efficiency and output power over a broad frequency bandwidth (ref. 2). The techniques are based on simulated annealing, which has the advantage over conventional optimization techniques in that it enables the best possible solution to be obtained (ref. 3). Two new broadband simulated annealing algorithms were developed that optimize (1) minimum saturated power efficiency over a frequency bandwidth and (2) simultaneous bandwidth and minimum power efficiency over the frequency band with constant input power. The algorithms were incorporated into the NASA coupled-cavity TWT computer model (ref. 4) and used to design optimal phase velocity tapers using the 59- to 64-GHz Hughes 961HA coupled-cavity TWT as a baseline model. In comparison to the baseline design, the computational results of the first broad-band design algorithm show an improvement of 73.9 percent in minimum saturated efficiency (see the top graph). The second broadband design algorithm (see the bottom graph) improves minimum radiofrequency efficiency with constant input power drive by a factor of 2.7 at the high band edge (64 GHz) and increases simultaneous bandwidth by 500 MHz.
Wilson, Jeffrey D.↗