Signal translation and amplification system

Abstract: A satellite is formed with a signal translation and amplification system which includes at least one communication path. Each communication path includes a plurality of radiation-cooled TWTs (50a,50b) powered by a single EPC (52). Also included in the communication path is a high efficiency radiation panel (54) capable of transmitting heat generated by the TWTs and EPC into space and a radiating collector (70) which is directly applied to each TWT, and is capable of transmitting heat generated by the TWT into space.

Description: This invention relates generally to high power satellites, and in particular, to a unique combination of high power amplifiers and heat dissipation techniques that can be utilized by an earth satellite. This permits a significant increase in output power for a given satellite size thus reducing satellite launch mass and, therefore, cost. A major benefit which results from providing stronger signals from satellite transmissions to earth based receivers is that smaller, less expensive, and simpler earth based satellite receive antennas ("dishes") can be employed. The use of smaller satellite dishes makes the use of satellite transmission more competitive with terrestrial transmission modes such as fiber, cable, etc., which will likely result in greater acceptance of satellite communications in general. One technique for providing stronger satellite signals involves increasing the signal strength of the travelling wave tube (hereinafter referred to as "TWT") applied to each channel, or an increase in the number of TWTs of similar strength being applied to each channel, in an effort to produce a stronger signal being transmitted over each channel by the satellite. An increase in the signal strength being produced by each TWT typically requires a careful consideration of the cooling configuration, since a substantial portion of the energy associated with the production of the signal within each TWT is converted into heat energy which must be removed. In recent decades, design considerations for satellites, and more particularly communication satellites, have included providing satellites with more power for each channel, and more channel transmission capabilities for each satellite. These considerations have frequently been balanced against other considerations which include the weight of the satellite. The greater the weight of the satellite (greater satellite operational lifetimes typically require satellites with a greater mass) generally the greater is the cost of the launch vehicle required for the satellite. One component which is frequently used in communication satellites is the TWT which functions as the power amplifier. A travelling wave tube amplifier (hereinafter referred to as "TWTA") generally consists of a TWT plus its high voltage power supply (or electronic power conditioner, "EPC"). One design limitation of the TWT is that it generates a considerable amount of heat. Most high power communication satellites presently use conduction-cooled TWTs. The use of conduction cooled TWTs necessitates the use of heat spreaders and heat pipes to distribute the heat produced by the TWT, and large specialized radiating surfaces to transfer this waste heat into space. The thermal requirements, as well as the associated satellite weight and size limitations for launch on a given vehicle, further limit the number of high power TWTs which can be carried on a satellite of a given size. Some TWTs are known to utilize one EPC for each pair of TWTs, this combination not only reduces overall power and amplifier weight but may provide other unrelated performance benefits. However, heat dissipation associated with TWTs remains a major limitation on the number of TWTs which each satellite is capable of carrying. This is generally true because the total heat dissipation capacity of a satellite is generally proportional to the size of the satellite. In the document "AIAA 8th Communications Satellite Systems Conference, 20-24 April 1980, Orlando, Florida, pages 171-177, Kreeb et A1. The Thermal Control System of the German Direct Transmitting Communication Satellite TV-SAT", there is described the configuration for heat dissipation for the TV-SAT A3 spacecraft. The three main heat dissipators (travelling wave tubes (TWT's), electrical power connectors (EPC's) and output multiplexor (OMUX)) are located at various points across the north and south panels of the spacecraft. In addition to self radiating collectors, extruded aluminium baseplates including four grooved heat pipe profiles are used to dissipate heat. The design includes redundant operating channels to ensure continued operation in the event that one of the channels fails. A method to increase the heat dissipation capacity of a satellite is to employ TWTs which radiate a portion of the waste heat directly to space. Early radiation-cooled TWT configurations were not efficient, and the number of operating TWTs that a given satellite could accommodate was limited to some small number, such as five. From the above, it can be envisioned that a TWT configuration which provides more efficient cooling, less weight, and higher power generation per transponder than prior art systems would be highly desirable. The present invention enables power enhancement of a communications satellite through thermal design. An improvement is the configuration of the travelling wave tube amplifiers such that a plurality (as e.g. two) radiation cooled TWTs are powered by a single EPC. This configuration provides higher transmitter power; a reduced overall mass of the satellite; and the ability to combine the power outputs of the two TWTs without an on board phase adjustment which may provide an improved conversion efficiency. The output of the two TWTs may be combined into a single high power output signal. Alternately, the output of each of the two TWTs may be a distinct signal. An improvement is also the use of an efficient radiator panel encasing a network of heat pipes. This becomes more significant in the configuration where two TWTs are applied to each EPC unit, since the amount of heat generated by the paired TWT units is high compared to the single TWT per EPC configuration, and requires a more effective cooling ability for the amplifiers. In order that the invention and its various other preferred features may be understood more easily, some embodiments thereof will now be described, by way of example only, with reference to the drawings, in which:- Figure 1 is a schematic illustration of one embodiment of a signal processing portion of the present invention; Figure 2 is a partial cross sectional view of one embodiment of a combined TWT, radiation panel with embedded heat pipes, and collector radiator, of the present invention, Figure 3A illustrates one embodiment of a travelling wave tube amplifier of the prior art; Figure 3B illustrates an alternate embodiment of a TWTA of the prior art; Figure 3C illustrates a third embodiment of a TWTA of the prior art; Figure 3D illustrates a fourth embodiment of a TWTA of the prior art; Figure 3E illustrates a first embodiment of a TWTA constructed in accordance with the present invention; Figure 3F illustrates a second embodiment of a TWTA of the present invention; Figure 4 illustrates an exploded cross sectional view of one of the heat pipes of Fig. 2; Figure 5 illustrates a partially broken away view of a segment of one of the radiation panels, with some of the heat pipes exposed; Figure 6 illustrates a top view of one embodiment of a full radiation panel; Figure 7a illustrates a radiative cooling element for a TWT, in which the radiative cooling element is formed with radiative fins; Figure 7b illustrates a radiative cooling element for a TWT, in which the radiative cooling element is formed with a radiative dome structure; Figure 7c illustrates a radiative cooling element for a TWT, in which the radiative cooling element is formed with a radiative cone structure; Figure 7d illustrates a radiative cooling element for a plurality of TWTs, in which the radiative cooling element is formed in two segments, each segment containing a plurality of radiative fins; and Figure 8 illustrates a headered heat pipe configuration which is not claimed but illustrates the application field of the invention. In this present disclosure the term "satellite" is intended to cover standard satellites, spacecraft, etc., and is considered as any device which is capable of travelling in space. The specific values described in the power and cooling descriptions of the present disclosure are intended to be illustrative in nature, and not limiting in scope. Elements which perform similar functions in different embodiments may be provided with identical reference characters. The present invention combines aspects of several technologies to provide an enhanced signal power output per satellite while also providing adequate cooling. The combination includes the utilization of two TWTs per EPC; the use of radiative cooling for the TWTs; and an efficient radiating panel utilizing a series of heat pipes. These technologies may appear at times to be distinct, but they are actually quite interrelated. Reference is now made to Figure 1. A satellite 10 (not illustrated except in general reference) contains a signal translation and amplification system 11. The signal translation and amplification system 11 includes a receiver portion 12, a signal amplification portion 13, and a transmitting portion 15. The receiver portion includes a receiving antenna 17, a feed element 16, a band pass filter 18, at least one R type switch 20a, 20b (R type switches are switches which are inserted in waveguides); a plurality of receivers 21a, 21b, 21c, 21d; at least one T type switch 22a, 22b; an input multiplexer 24; and an input switch ring 26. The receiving antenna 17 is a commercially available antenna which is used for satellite reception. The band pass filter 18 blocks out the effect of the signal generated by the transmitting portion 15 which is many times stronger than any signal which is likely to be received from any source external to the satellite. Since one of the primary functions of the satellite is to respond to external signals, the function of the band pass filter 18 becomes even more significant. As can be appreciated, the signal translation and amplification system 11 acts as a repeater which is carried by the satellite 10, to receive a signal, to amplify the signal, and to retransmit the amplified signal. The elements described in this and the next paragraph control which output group 30a, 30b, etc. of the signal processing portion 13 a specific signal will be transmitted through. The R type switches 20a, 20b control which of the receivers 21a, 21b, 21c, 21d is activated, and thereby which of the receivers is connected to the receive antenna 17 and the serially connected band pass filter 18. As a matter of illustration, the R type switch 20a can selectively apply a received signal to either of the upper receivers 21a, 21b. This selection is typically made depending upon which of the receivers 21a, 21b is functioning properly. The functioning of the receivers 21a, 21b can be monitored from the ground, since if a receiver is not functioning properly, there will be no output over the corresponding channel from the satellite. The position of the R type switch 20a is controlled from the ground, thereby controlling which receiver 21a, 21b is coupled to the input signal from antenna 17. If it is determined that neither of the upper receivers 21a, 21b is functioning properly, while both of the lower receivers 21c, 21d are functioning properly, then the R type switch 20a will divert its incoming signal to the lower R type switch 20b to apply the signal to one of the lower receivers 21C, 21d. The other lower receiver 21C, 21d will be connected to the antenna 17 via the lower R type switch 20b. This configuration enables the application of a filtered signal from the receiving antenna 17 to any receiver, 21a, 21b, 21c, 21d. The frequency of the received signal establishes which output group 30a, 30b, 30c, 30d processes a specific received signal. The plurality of receivers 21a, 21b, 21c, 21d are connected to the input multiplexers 24 by a plurality of T type switches 22. The receivers 21a, 21b, 21c, 21d function to receive, amplify, and down-convert the received signal to a desired frequency. The T type switches 22a, 22b, function similarly, but in a reverse sense, to the R type switches 20a, 20b described above to select any two of the four receivers 21a, 21b, 21C, 21d for connection to the input multiplexers 24. The input multiplexer 24 acts in a known manner to control which communication path 40a, 40b, 40c, 40d etc. (only communication paths 40a and 40b are illustrated, the other communication paths are identical) of the signal processing portion 13 the signal may be applied to within each output group; only output group 1 is illustrated in more detail for ease of display. The input switching ring 26 operates to select four specific communications paths from six available communication paths 40a, 40b, 40c, 40d, 40e, 40f within each output group. For example, if one (or more) of the selected communications paths becomes non-functional, the switching ring 26 is re-configured by ground command to select one of the unused (redundant) communications paths. The input multiplexer 24 and the switching rings 26 are both commercially available, and will not be further detailed herein. The signal amplification portion 13 of Figure 1 comprises a plurality of output groups 30a, 30b, 30c, 30d. Each output group contains a plurality of communication paths 40a, 40b (two communication paths are illustrated in the output group 30a of Figure 1, but there are 6 communication paths in each output group). Four of the output groups are active (selected) at any given time, and the remaining two are redundant. Each communication path includes a channel amplifier 45 and a TWTA 48. The channel amplifier 45 serves as a preamplifier for the signal to be applied to the TWTA 48. Each TWTA 48 of Figure 1 comprises an input hybrid 53, an output hybrid 55, and two TWTs 50a, 50b which are powered by one EPC 52. This TWTA configuration provides for improved power conversion efficiency as well as reduced mass. The use of a common-EPC 52 also provides the ability to combine the RF output power of the two TWTs 50a, 50b without requiring on-board phase adjustment. Each TWT is configured to contain a collector radiator 70 (see Figure 2) which is positioned to be exposed external to the satellite 10, and as such provides a primary path for heat rejection. The collector radiator 70 has a plurality of radiating fins 701. It is envisioned that each of the two TWTs in each of the communication paths could be applied to amplify signals of distinct channels, and thus act separately. Alternately, the two TWTs 50a, 50b could both be applied to the same channel, as shown in Fig. 1. When the TWTs are combined, the signal strength of the TWTs is nearly doubled (it is not actually doubled due to combining losses.) However, the total number of available satellite transmitter channels is also halved. The input hybrid 53 divides the signal strength applied to each TWTA 48 into two substantially even amounts, which are applied to each TWT 50a, 50b. The transmitter portion 15 includes an output switching ring 62, an output multiplexer 64, a feed element 67 and a transmitting antenna 68. The output ring 62 acts in a known manner, in combination with the input ring 26, to provide the suitable number of properly functioning communication paths from each output group 30a, 30b, 30c, 30d at any given time; and to eliminate non-functional communication paths. The output multiplexer 64 combines the transmissions of all of the signals applied from all of the communication paths within each output group 30a, 30b, etc., such that the signals will be transmitted over a single electrical conduit 66 to the antenna feed 67. Whatever signal is transmitted from the output-multiplexer 64 will be transmitted by transmitting antenna 68. Each satellite 10 may contain a plurality of transmitting antennas 68, 68' which are targeted to different locations (covering distinct land-masses, or other satellites, etc.) Each transmitting antenna 68, 68' receives output signals from one or more output groups 30a, 30b, etc. in the Figure 1 embodiment. The Figure 1 embodiment is intended to be illustrative in nature, and not limiting in scope. The radiation cooled TWTs 50a, 50b and EPCs 52 are mounted on high efficiency radiation panels 54 as illustrated in Figure 2, in which the bulk of each radiation panel is formed from an aluminum honeycomb with optical solar reflectors (OSR's) 71 on the radiating side. The OSRs 71 permit heat energy to pass from the radiation panels 54 into space, while reflecting a high percentage of ambient radiation back into space, as is well known in the art. Each radiation panel 54 employs a plurality of parallel embedded heat pipes 58 which are mounted substantially perpendicularly to a plurality of parallel embedded heat pipes 59. This configuration functions to substantially evenly dissipate heat generated by the TWTs and EPCs throughout the radiation panels 54 and into space. A cooling fluid such as ammonia is sealed in channels 60 formed in each embedded heat pipe 58, 59 and provides a heat sink for the heat applied to the radiation panel 54. It is preferable that the heat pipes 58, 59 be oriented in a crossed arrangement as illustrated. This configuration provides a very efficient heat radiator, permitting the development of a higher power, more energy efficient and lower mass satellite for a given volume than could be achieved otherwise. Heat energy passes by conduction from the TWTs 50a, 50b, via the radiation panel 54, to the heat pipes 58, 59. When the heat energy is in the heat pipes, it is distributed more evenly throughout the heat pipes, and through the radiation panel into space. To accommodate components of high concentrated heat loads, heat pipes are used to spread the heat efficiently over the entire OSR 71. The fixed-conductance, dual channel heat pipes 58, 59 are preferably formed with axially grooved aluminum tubing with anhydrous ammonia used as the working cooling fluid. Each dual channel heat pipe 58, 59 consists of the two independently operating channels 60. The components are arranged such that failure of a single heat pipe channel in a dual channel heat pipe will not overly limit the cooling capabilities of any of the heat pipes 58, 59; and thereby not impinge upon the overall operation of the satellite 10. The heat pipe layout for each radiation panel 54 (there are typically two radiation panels per satellite) is configured in a matrix arrangement (see Figures 5 and 6) with a total of 13 longer lateral heat pipes 59, and 6 header heat pipes 58 (only four of which are illustrated in Figure 6). The lateral heat pipes 59 are bonded to an inner communication panel faceskin 100, (Figure 2), and come in direct contact with as much of the TWTs 50a, 50b and the EPCs 52 as is possible due to design constraints. The header heat pipes 58 contact each crossing lateral heat pipe 59. Heat energy is transmitted effectively between the header heat pipes 58 and the lateral heat pipes 59. In Figure 6, a recess 120 is formed in the radiation panel to permit an arm for connecting to the solar array (not illustrated) to extend through. As can be observed from Figure 2, heat generated by the TWTs 50a, 50b (and also the unillustrated EPCs 52), can be transferred into space via either a collector radiator 70 or the radiation panel 54. The collector radiator 70 is typically integrally formed with the radiation-cooled TWTs, and provides a passage for heat energy directly into space. A thermal shield 72 is provided to limit the heat energy which has passed from the TWTs 50a, 50b to the collector radiator 70 from passing back to the TWTs. This combination promotes the passage of heat energy into space. While the prior art conduction-cooled TWTs utilize heat sinks as thermal spreaders to uniformly distribute the thermal energy, the radiation-cooled TWTs of the present invention utilize radiation panels, which contain heat pipes, to distribute at least a significant portion of the remaining TWT heat (the remaining heat is the total TWT heat less that radiated to space by the TWT radiating collector.) The radiation panels utilize the high thermal conductivity of the heat pipes to uniformly distribute the heat across the panel. Heat distribution with heat sinks and spreaders (thick panel face skins) is much heavier than radiation panels utilizing heat pipes. The collector radiators 70 combine with the radiation panels of the present invention to radiate sufficient heat energy into space so that the TWTs can produce the high energy level associated with the powerful signals while not overheating. Prior art satellites, limited in size, weight, and launch vehicle fairing envelopes can handle approximately 5000 watts DC, and less than 2000 watts RF radiated power. The present configuration permits 10,000 watts DC, or approximately 4200 watts RF radiated power. Table 1 is a comparison of the present invention and prior art TWTA performance and cooling characteristics. The prior art configurations are illustrated in Figures 3A to 3D, and correspond to each of the "prior art embodiments" illustrated in Table 1, as described therein. The present invention configuration is illustrated in Figures 1, 3E and 3F and corresponds to the "present invention embodiments" of Table 1. As evident from Table 1, the present invention provides a considerable improvement over the signal power generated compared to the prior art embodiments. The ground receivers (satellite dishes) which are configured to receive signals from the satellite of the present invention can be constructed to be smaller than the prior art satellite dishes due to the stronger signal generated by the satellites, while still receiving a comparable signal strength. This permits the use of less expensive, less obtrusive satellite dishes than those required with the present generation satellites. The use of smaller, less space consuming satellite dishes further enables a greater use of satellite communications in general. Figures 1, 2, 3E, 3F, 4, 5, and 6 illustrate different aspects of one embodiment of the present invention. It should be emphasized that there are several modifications which can be made to the above embodiment while remaining within the scope of the present invention. For example, the collector radiator 70 of Fig. 2 has radiating fins 701 to provide radiative cooling from the TWTs. Alternative embodiments of TWT radiation cooling surfaces are illustrated in Figures 7a - 7d. Figure 7a illustrates the TWT 50a with a plurality of radiating fins 701 which are similar to the Figure 2 embodiment. Figure 7b illustrates the TWT with a dome radiating cooling element 150. Figure 7c illustrates the TWT 50a with a cone radiating cooling element 151. Figure 7d illustrates a plurality of TWTs 50a which are both cooled by a distinct radiation portion 154, including fins 155; each radiation portion has a plurality of radiating fins 701 which are intertwined. Any other suitable radiating device which may be affixed to a TWT to radiate heat into space is within the scope of the present invention. Figures 5 and 6 illustrate one embodiment of heat pipes 58, 59 which are configured to be cross-hatched. The benefits of cross-hatching the heat pipes has previously been described. Figure 8 shows heat pipes 160 provided in a headered configuration which does not fall within the scope of the claims. The headered configuration has also been found to distribute heat energy effectively across a relatively large radiation panel 161. While several embodiments are disclosed in this specification, this specification is not intended to be limiting in scope, other configurations which are within the scope of the claims are intended to be included within the scope of the present invention.

Claims: A signal translation and amplification system (11), comprising at least one RF energy communication path comprising a plurality of radiation-cooled travelling wave tubes (TWTs) (50a, 50b) powered by electronic power conditioners (EPCs)(52), each TWT of the plurality of TWTs (50a, 50b) comprising a respective radiator component (70) that is thermally coupled to the corresponding TWT (50a, 50b) for providing a primary path of radiating heat into space, and a high efficiency radiation panel (54) that is thermally coupled along a first major surface thereof to each of the plurality of TWTs (50a, 50b) and to the EPC (52) for providing a separate path of transferring thermal energy therefrom, the radiation panel (54) comprising thermal transfer means for transferring the thermal energy from the first major surface to a second, opposite, major surface whereat the thermal energy is radiated into space, whereby the radiation panel comprises a cellular structural material and the thermal transfer means comprises a plurality of heat pipes (58, 59) embedded in the cellular structural material, whereby each embedded heat pipe (58, 59) contains a plurality of fluid-containing channels (60), whereby a plurality of said TWTs (50a, 50b) are powered by a single EPC (52) and in that the plurality of embedded heat pipes (58,59) define in the cellular structural material a cross-hatched network for approximately uniformly distributing the thermal energy over an area of the radiation panel (54). A signal translation and amplification system (11) as claimed in claim 1, wherein the embedded heat pipes (58, 59) comprise a first plurality of embedded heat pipes (58) disposed parallel to one another, and a second plurality of embedded heat pipes (59) disposed parallel to one another and orthogonal to the first plurality of embedded heat pipes (58). A signal translation and amplification system (11) as claimed in claim 2, wherein individual ones of the first (58) and second (59) plurality of embedded heat pipes are thermally coupled together at locations where the first (58) and second (59) plurality of heat pipes intersect. A signal translation and amplification system (11) as claimed in claim 2, wherein the first plurality of heat pipes (58) are disposed in a first plane, the second plurality of heat pipes (59) are disposed in a second plane that is parallel to the first plane, and wherein individual ones of the first (58) and second (59) plurality of heat pipes are thermally coupled together at locations where the first (58) and second (59) plurality of heat pipes intersect. A signal translation and amplification system (11) as claimed in any one of the preceding claims, wherein each of the channels (60) have axially grooved channel surfaces. A signal translation and amplification system (11) as claimed in any one of the preceding claims, wherein each channel (60) is sealed. A signal translation and amplification system (11) as claimed in any one of the preceding claims, wherein the respective fluid containing channels (60) contain a corresponding coolant comprised of ammonia. A signal translation and amplification system (11) as claimed in any one of the preceding claims, wherein the radiation panel (54) is further comprised of a solar radiation reflector (72) that is disposed over the second major surface for reflecting solar radiation energy impinging on the second major surface back into space. A signal translation and amplification system (11) as claimed in any one of the preceding claims, wherein the radiation panel (54) defines a portion of a spacecraft (10). A signal translation and amplification system (11) as claimed in any one of the preceding claims, further comprising at least one receive antenna (17) for receiving RF energy transmissions from a terrestrial station transmitter, the at least one receive antenna (17) having an output coupled to an input of each of the plurality of TWTs (50a, 50b), and at least one transmit antenna (68) for transmitting amplified RF energy transmissions to a terrestrial station receiver, the at least one transmit antenna (68) having an input coupled to an output of each of the plurality of TWTs (50a, 50b). A signal translation and amplification system (11) as claimed in any one of claims 1 to 8, further comprising at least one receive antenna (17) for receiving RF energy transmissions, the at least one receive antenna (17) having an output coupled to an input of individual ones of the plurality of TWTs (50a, 50b), at least one transmit antenna (68) for transmitting amplified RF energy transmissions, the at least one transmit antenna (68) having an input respectively coupled to a corresponding output of individual ones of the pair of TWTs (50a, 50b), the EPC (52) having outputs respectively coupled to individual ones of the pair of TWTs (50a, 50b), and a support assembly to which at least the individual ones of the pair of TWTs (50a, 50b) and the EPC (52) are mounted, the support assembly comprising the radiation panel that is thermally coupled along the first major surface thereof to the individual ones of the pair of TWTs (50a, 50b) and to the EPC (52) for providing the separate path of transferring thermal energy therefrom.

Inventors: AVELLINO WILLIAM R, BRIGGS DONALD C, COLLINS DANIEL E, TYNER RANDALL D, AVELLINO, WILLIAM R., BRIGGS, DONALD C., COLLINS, DANIEL E., TYNER, RANDALL D.
Applicants: LORAL SPACE SYSTEMS INC, SPACE SYSTEMS / LORAL, INC.
Application year: 1995
Main classification: B64G1
IPC codes: F28D15, H01P1, B64G1, H01J23, H04B7, H05K7