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3216 IEEE TRANSACTIONS ON MICROWAVE THEORY AND TECHNIQUES, VOL. 61, NO. 9, SEPTEMBER 2013 CAD Procedure for High-Performance Composite Corrugated Filters Fabrizio De Paolis, Member, IEEE, Rousslan Goulouev, Member, IEEE, Jingliang Zheng, and Ming Yu, Fellow, IEEE Abstract—The design of waveguide low-pass lters is accom- plished with a new method, where focus is on the upper stopband performance rather than passband or roll-off requirements. Using an efcient multimode variational formulation, composite lters are generated by direct optimization from an arbitrary number of partial corrugated subelements, each showing mutual -mode passband and different nonintersecting passbands corresponding to higher order modes. The exibility of this method leads to optimal lter solutions, having the designer full control over key dimensional features, i.e., minimum gap and cavity length. It is therefore possible to design low-pass lters exhibiting broad stopbands free of spurious propagation, without penalties of higher losses, lower power handling capability, larger size, and/or increased manufacturing complexity. Simulated and measured results demonstrate signicant advantages over lters designed with conventional methods. Index Terms—Computer-aided design (CAD), corrugated l- ters, microwave lters, optimization, periodic structures. I. INTRODUCTION L OW-PASS lters nd extensive use in microwave and millimeter wave systems for rejecting unwanted spectrum over broad frequency ranges. One area of particular interest is that of satellite communication systems, where far out-of-band rejection is required in addition to the narrowband ltering pro- vided by the multiplexing network. Broad stopband, low inser- tion loss, high-power handling capability, minimum size, and simple manufacturing are the key requirements in similar appli- cations. Unfortunately, these features are in conict when de- signing conventional lters, and a tradeoff has to be made. The ultimate consequence is the increasing difculty to meet tech- nical requirements of modern applications. Three categories of waveguide low-pass lters have been studied by microwave engineers: stepped-impedance (corru- gated), wafe-iron, and ridged lters. A. Limitations of Conventional Corrugated Filters Corrugated waveguide lters were rst introduced by Cohn [1] in the late 1940s. Later design methods using modern cir- cuit theory and synthesis techniques were developed by Levy [2] Manuscript received February 11, 2013; revised July 06, 2013; accepted July 16, 2013. Date of publication August 15, 2013; date of current version August 30, 2013. F. De Paolis was with COM DEV Ltd., Cambridge, ON Canada N1R 3P2. He is now with the European Space Agency, ESA-ESTEC, 2201AZ, Noordwijk, The Netherlands (e-mail: [email protected]). R. Goulouev, J. Zheng, and M. Yu are with COM DEV Ltd., Cambridge, ON Canada N1R 3P2 (e-mail: [email protected]). Color versions of one or more of the gures in this paper are available online at http://ieeexplore.ieee.org. Digital Object Identier 10.1109/TMTT.2013.2275451 and generalized for a wide class of tapered corrugated waveguide lters. The inconvenience of spurious passbands corresponding to high-order modes was reported in [2] and [3] and further in- vestigated in [4]. The spurious passbands cannot be eliminated, although their location can be predicted and eventually moved up or down the frequency axis by changing the width of the cor- rugated waveguide. The spurious bands are due to the E-plane symmetry of structure, which is the baseline of this design. Since most of the energy propagates in the dominant mode, usually only narrow spurious components or “spikes” occur. While Hauth in- troduced an efcient analysis method [5] and described modi- cations to the corrugated lter in order to use it as a bandpass lter [6], Levy’s work was later generalized to the inhomoge- neous case [7]. Although Levy’s latest approach improves the lter rejection performance, two separate points remain open: 1) high-order spurious spikes are quite difcult to control (see [7, p. 124]) and are not acceptable in many applications and 2) stan- dard closed-form formulas are used, requiring major tradeoffs among the stopband, insertion loss, and power handling (see [6, p. 526]) and limiting the design exibility. More recent studies proposing elaborate two-dimensional (2-D) proles have been published [8], [9], showing higher order mode suppression, but the methods do not show low insertion loss, compact size, and hardware simplicity as in this paper. Corrugated lters previously reported are based on wave- guide structures susceptible to propagation of high-order modes within the design stopband. Modes of order higher than the dominant mode are always present in any practical microwave systems due to discontinuities associated with both manufac- turing inaccuracies (e.g., asymmetries and misalignments) and external mode exciters (e.g., transformers, bends, and adapters). Since the lter out-of-band mode composition is, in principle, unknown, the worst case excitation must be taken into account if rejection specications are to be met without spurious effects. Design methods employed in the conventional lter types are based on distributed or lumped element circuits. The target of those design methods is the synthesis of an equi-ripple lter response by passband and roll-off requirements. As a result, the in-band frequency response may well reproduce ideal polynomials such as Chebyshev or Zolotarev. In practice, those lters may not meet the rejection requirements as well. In the out-of-band frequency range, the original model used for in-band synthesis is no longer valid. Therefore, conven- tional design methods ignore information about critical points corresponding to high-order modes, which form passbands or stopbands. However, the only effective method to design a spurious-free lter must be based on the proper distribution of those critical points over the required out-of-band frequency range, in order to guarantee full coverage of reection zeros by transmission zeros. 0018-9480 © 2013 IEEE

3216 IEEE TRANSACTIONS ON MICROWAVE …mingyu/publications/p201309.pdf3216 IEEE TRANSACTIONS ON MICROWAVE THEORY AND TECHNIQUES, VOL. 61, NO. 9, SEPTEMBER 2013 CAD Procedure for High-Performance

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Page 1: 3216 IEEE TRANSACTIONS ON MICROWAVE …mingyu/publications/p201309.pdf3216 IEEE TRANSACTIONS ON MICROWAVE THEORY AND TECHNIQUES, VOL. 61, NO. 9, SEPTEMBER 2013 CAD Procedure for High-Performance

3216 IEEE TRANSACTIONS ON MICROWAVE THEORY AND TECHNIQUES, VOL. 61, NO. 9, SEPTEMBER 2013

CAD Procedure for High-Performance CompositeCorrugated Filters

Fabrizio De Paolis, Member, IEEE, Rousslan Goulouev, Member, IEEE, Jingliang Zheng, andMing Yu, Fellow, IEEE

Abstract—The design of waveguide low-pass filters is accom-plished with a new method, where focus is on the upper stopbandperformance rather than passband or roll-off requirements. Usingan efficient multimode variational formulation, composite filtersare generated by direct optimization from an arbitrary number ofpartial corrugated subelements, each showingmutual -modepassband and different nonintersecting passbands correspondingto higher order modes. The flexibility of this method leads tooptimal filter solutions, having the designer full control over keydimensional features, i.e., minimum gap and cavity length. Itis therefore possible to design low-pass filters exhibiting broadstopbands free of spurious propagation, without penalties ofhigher losses, lower power handling capability, larger size, and/orincreased manufacturing complexity. Simulated and measuredresults demonstrate significant advantages over filters designedwith conventional methods.

Index Terms—Computer-aided design (CAD), corrugated fil-ters, microwave filters, optimization, periodic structures.

I. INTRODUCTION

L OW-PASS filters find extensive use in microwave andmillimeter wave systems for rejecting unwanted spectrum

over broad frequency ranges. One area of particular interest isthat of satellite communication systems, where far out-of-bandrejection is required in addition to the narrowband filtering pro-vided by the multiplexing network. Broad stopband, low inser-tion loss, high-power handling capability, minimum size, andsimple manufacturing are the key requirements in similar appli-cations. Unfortunately, these features are in conflict when de-signing conventional filters, and a tradeoff has to be made. Theultimate consequence is the increasing difficulty to meet tech-nical requirements of modern applications.Three categories of waveguide low-pass filters have been

studied by microwave engineers: stepped-impedance (corru-gated), waffle-iron, and ridged filters.

A. Limitations of Conventional Corrugated Filters

Corrugated waveguide filters were first introduced by Cohn[1] in the late 1940s. Later design methods using modern cir-cuit theory and synthesis techniqueswere developed by Levy [2]

Manuscript received February 11, 2013; revised July 06, 2013; accepted July16, 2013. Date of publication August 15, 2013; date of current version August30, 2013.F. De Paolis was with COM DEV Ltd., Cambridge, ON Canada N1R 3P2.

He is nowwith the European Space Agency, ESA-ESTEC, 2201AZ, Noordwijk,The Netherlands (e-mail: [email protected]).R. Goulouev, J. Zheng, and M. Yu are with COM DEV Ltd., Cambridge, ON

Canada N1R 3P2 (e-mail: [email protected]).Color versions of one or more of the figures in this paper are available online

at http://ieeexplore.ieee.org.Digital Object Identifier 10.1109/TMTT.2013.2275451

and generalized for awide class of tapered corrugatedwaveguidefilters. The inconvenience of spurious passbands correspondingto high-order modes was reported in [2] and [3] and further in-vestigated in [4]. The spurious passbands cannot be eliminated,although their location can be predicted and eventually movedup or down the frequency axis by changing the width of the cor-rugated waveguide. The spurious bands are due to the E-planesymmetry of structure, which is the baseline of this design. Sincemostof the energypropagates in thedominantmode, usuallyonlynarrow spurious components or “spikes” occur.While Hauth in-troduced an efficient analysis method [5] and described modi-fications to the corrugated filter in order to use it as a bandpassfilter [6], Levy’s work was later generalized to the inhomoge-neous case [7]. Although Levy’s latest approach improves thefilter rejection performance, two separate points remain open: 1)high-order spurious spikes are quite difficult to control (see [7,p. 124]) and are not acceptable in many applications and 2) stan-dard closed-form formulas are used, requiring major tradeoffsamong the stopband, insertion loss, and power handling (see [6,p. 526]) and limiting the design flexibility. More recent studiesproposing elaborate two-dimensional (2-D) profiles have beenpublished [8], [9], showing higher order mode suppression, butthe methods do not show low insertion loss, compact size, andhardware simplicity as in this paper.Corrugated filters previously reported are based on wave-

guide structures susceptible to propagation of high-order modeswithin the design stopband. Modes of order higher than thedominant mode are always present in any practical microwavesystems due to discontinuities associated with both manufac-turing inaccuracies (e.g., asymmetries and misalignments) andexternal mode exciters (e.g., transformers, bends, and adapters).Since the filter out-of-band mode composition is, in principle,unknown, the worst case excitation must be taken into accountif rejection specifications are to be met without spurious effects.Design methods employed in the conventional filter types

are based on distributed or lumped element circuits. The targetof those design methods is the synthesis of an equi-ripplefilter response by passband and roll-off requirements. As aresult, the in-band frequency response may well reproduceideal polynomials such as Chebyshev or Zolotarev. In practice,those filters may not meet the rejection requirements as well.In the out-of-band frequency range, the original model usedfor in-band synthesis is no longer valid. Therefore, conven-tional design methods ignore information about critical pointscorresponding to high-order modes, which form passbands orstopbands. However, the only effective method to design aspurious-free filter must be based on the proper distribution ofthose critical points over the required out-of-band frequencyrange, in order to guarantee full coverage of reflection zeros bytransmission zeros.

0018-9480 © 2013 IEEE

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DE PAOLIS et al.: CAD PROCEDURE FOR HIGH-PERFORMANCE COMPOSITE CORRUGATED FILTERS 3217

Fig. 1. Symmetric E-plane cavity. (a) The 2-D view. (b) Equivalent network.

B. Limitations of Waffle-Iron and Ridge Filters

Waffle-iron filters [10], [11] are susceptible to generationof spurious spikes in the passband, roll-off and stopband [11],[12]. These spikes are caused by excitation of waveguidemodes not considered by established design methods. Limitedpower handling is another major disadvantage. Waffle-ironfilters are therefore rarely employed in applications requiringboth spurious-free and high power performance.Evanescent-mode ridge waveguide filters [13], [14] require

quite small gap sizes in order to provide sufficient out-of-bandrejection in most applications. Therefore, the quality factor andpeak power-handling capability of the ridged filter are signifi-cantly lower than that of nonevanescent type of filters. Tuningcould also be required to compensate for the high sensitivity tomanufacturing tolerance. Therefore, ridged filters are not suit-able for those applications requiring very low losses or highpower-handling capability.

C. Alternatives to Conventional Synthesis Techniques forHarmonic Filter Design

In addition to rejection performance, conventional synthesistechniques limit the low-pass filter designer to control other im-portant features, such as insertion loss, power handling, size, andmanufacturability, which are not directly associated with filterprototypes. On the other hand, recent developments in computertechnologies have made possible direct optimization of wholefilter structures for specificrequirements.Aspreliminarilyshownin [15] and online,1 optimizationmethodswould allowone to by-pass the constraints of synthesis techniques, offering distinct ad-vantages in terms of (multimode) rejection performance and de-sign flexibility. An optimal practical low-pass filter could thenlookquitedifferent fromanyclassical prototype.

II. THEORY

A. Cavity Model and Transmission Zeros

The concept of direct-coupled cavities is the fundamentalmodel describing reflection and transmission properties of a cor-rugated filter as a nonuniform waveguide in multimode condi-tion of propagation. In order to illustrate the basic propertiesof a single cavity element as the building block of high-perfor-mance low-pass filters, a simple equivalent network is consid-ered first. Fig. 1(a) shows the symmetric corrugation composedby a T-junction loaded by a shorted waveguide stub, whereasthe equivalent network following a model from Marcuvitz [16]

1[Online].Available: http://www.goulouev.com/structures/newfil.htm

Fig. 2. Transmission response of a single cavity element.

is derived in Fig. 1(b). The -network admittance parametersare calculated as

(1)

where the admittance is zero for

(2)The reflection and transmission coefficients of the single

cavity can be expressed in elementary functions as follows:

(3)

in which

(4)

Simple inspection of (3) shows that when is zero, thetransmission coefficient is also zero. Each extracted cavitythen forms transmission zeros (Fig. 2) located between fre-quency bands of moderate transmission. Therefore the cavityelement can be used as a low-pass unit or high-pass unit. Inthe vicinity of a given transmission zero , we consider abandwidth where the transmission coefficient magnitudeshall be smaller than the corresponding specified value .There is also a plurality of frequency points where the reflectioncoefficient is approximately equal to zero. This happens atthe cut-off of each mode and at the frequency points whereis near infinity.

B. Composite Corrugated Filter

Composite corrugated filters are generated via direct connec-tion of quasi-periodic E-plane tapered waveguides (partialfilters), internally matched without intermediate transformingnetworks (Fig. 3). The composite structure is formed by

cavities in series, with coupling gap ,length and spacing . The cavity length is much shorter than

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3218 IEEE TRANSACTIONS ON MICROWAVE THEORY AND TECHNIQUES, VOL. 61, NO. 9, SEPTEMBER 2013

Fig. 3. Composite corrugated filter consisting of partial filters. (a) Side view. (b) Top view.

. The cavity height is gradually tapered from atthe ends to at the center of each partial filter.Although the structure of Fig. 3 physically resembles Levy’s

inhomogeneous filter, there is a substantial difference from theelectrical viewpoint. The filter considered is based on short ex-tracted cavities, realizing transmission zeros in the stopband(only first root for each cavity is used). The orderis not associated with the number of in-band reflection zerosand cannot be unambiguously associated with performance re-quired. Therefore, is a secondary parameter and can be ini-tially set to a value of 20 2 (for third-harmonic rejection). Thisapproach differs from classic corrugated filter theory where an-pole mode response is synthesized using a capacitive

iris or stepped-impedance transmission line model [2].Assuming a gap relatively smaller than the waveguide

widths , we can limit our consideration to only modesin the analysis of the stopband. An image frequency for the

mode of the th partial is predicted by

(5)

which is a generalized version of the formula given in [2] andwhere is a frequency point of the dominant mode and isthe waveguide width in inches of the th filter.The multimode transmission responses can be represented as

schematic graphs for the filters to generate mode charts. Se-lecting partial filters with different widths, the passbands corre-sponding to spurious modes can be positioned relativelyto each other in such a way that no mutual frequency pointsexist. In this case any of the modes carrying spurious fre-quency spectrum in one of the partial filters will be rejected bythe other partial filter. This condition is called “strong,” sinceit provides rejection of spurious frequency spectrum carried byall modes except the dominant one. When the position of spu-rious passbands corresponding to both partial filters intersectseach other and the intersecting modes have different symmetryindexes, the condition is called “weak.” A weak condition alsoguarantees that no spurious mode can propagate through theoverall filter provided that ideal symmetry is maintained. Bothconditions of spectrum superposition can be adopted for designusing (5). However, it shall be mentioned that the weak con-

dition, in practice, provides less rejection due to conversion be-tween symmetric and asymmetric modes when asymmetries areintroduced by manufacturing inaccuracies.The criterion used to select the dimension (expressed in

inches) is based on imposing the cross-polarized wave-guide mode to not propagate through the filter, i.e.,

(6)

where is the dominant mode cut-off frequency of the lowestpartial filter, is the highest frequency point of the spec-ified stopband and 0.5 is an empirical coefficient to account forthe cavity loading effect.The lengths define the cavity’s Q-factor at the transmission

zeros and are optimally selected using the empirical formula

(7)

where increasing the value enlarges the transmission zerosbandwidth , at the price of stronger spurious effects of higherorder resonances.The spacing between cavities is set to the minimum value

technologically feasible. Small values of widen the overallstopband, simultaneously reducing the filter loss and length. Inaddition, a minimum value of maximizes the ratio, ex-ploiting fringing-field effects to further increase the peak power-handling capability in vacuum [17].For each partial filter, the minimum cavity depth de-

pends on the highest specified frequency point of stopband, where rejection is required. The maximum value for

—related to the first root of when is avariable—can be approximately evaluated as the stub length atresonance frequency, including an empirical loading factor

(8)

The ideal composite corrugated filter presents optimal distri-bution of transmission zeros formed by each cavity so that anyfrequency point of the design stopband is within the rejectionbandwidth of at least one cavity. At the same time, the ta-pering function has to be adequately smooth in order to mini-mize the change of the scattering properties along the structure.

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DE PAOLIS et al.: CAD PROCEDURE FOR HIGH-PERFORMANCE COMPOSITE CORRUGATED FILTERS 3219

A good compromise is found choosing the sine distribution astapering function as

(9)

where .The parameter is linked to the filter roll-off and defines the

transmission zeros distribution from the roll-off, i.e., the trans-mission zeros cluster moves up in frequency when increasing. The smaller -values (between 1.0 and 1.5) lead to sharp butnarrowband rejection, which is recommended for rejecting upto the second harmonic. The larger -values (between 1.5 and3.0) lead to a smooth but wideband rejection and are better forthird-harmonic rejection. Imposing the value, the parameteris determined as a root of equation as

(10)

where, for a given partial filter,is the dominant mode transmission,is the vector of cavity heights, and is the characteristicfrequency where the filter dominant mode transmission equals

.The nonlinear equation system of (9) and (10) can be easily

solved with numerical methods.The use of extracted cavities with sinusoidal distribution

could result in nonideal passband return loss and near-band re-jection, because reflection zeros can appear around the roll-offrange. However, for low-pass filters, this is irrelevant whencompliance to specifications is considered: passband returnloss can be easily optimized (if required) as the initial structureis already internally matched; near-band performance is not alow-pass design driver, as its function is to provide far-bandand harmonic rejection.

III. OPTIMIZATION TOOLS AND DESIGN PROCEDURE

A. Mode Chart

Themode chart is the analytical tool from (5), used to performpreliminary spectrum superposition and determine the optimumwaveguidewidths and roll-off frequencies of each th filter.

B. Fast Multimode Simulator

The fast multimode simulator is a code that loads theschematic file with the filter design dimensions and outputsfrequency response data.The code model is based on a variational formulation

that takes both fundamental and higher order modes into ac-count. Fig. 4(a) depicts a cavity of length formed by twostep-junction discontinuities, in the general case of asymmetricrectangular-to-rectangular waveguide discontinuities withdifferent accessible modes. A rigorous formulation in terms ofY- and B-matrices is presented in [18], which can be used forcomputing of the multimodal -parameters of generic uniaxialwaveguide discontinuities. Although with such an approach the

Fig. 4. Single waveguide cavity. (a) The 3-D view. (b) Equivalent network.

cavity element of Fig. 4(a) can be characterized by a cascadeof -matrices of two step-junctions, using an independentmodel for the double discontinuity gives the advantage of amore efficient computational algorithm. The expressions of theY-matrix members are expressed as

(11)

where the -values are the aperture integrals on both accessibleports and as

and , , and are the wave admittances, propagation con-stant and transverse electric fields for the th mode in the largerwaveguide. and are the transverse electric fields for theth and th mode of both accessible waveguides. The analyticalformulation is given in the Appendix. The case of a single-stepdiscontinuity can also be solved using a similar formulation.The rigorous model introduced above is used for fast and ac-

curate modeling of a generally non-uniform corrugated wave-guide using sequential cascading of multi-modal -matrices.The process of simulation takes about 2 s on a standard PC fora typical filter structure with 20 corrugations, using one acces-sible mode and approximately 200 localized modes swept over600 discrete frequency points.

C. Transformer Synthesizer

The transformer synthesizer is a code based on conventionalmatching techniques, which loads simulation file with initialspecification and generates a partial filter matched around thecentral frequency of passband via step transformer. Such tech-niques are widely known and therefore not repeated here. Theprogram outputs schematic file with design dimensions. Time ofthe synthesis process takes less than one second on a standardPC, when applied to typical filters with 20 corrugations.

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3220 IEEE TRANSACTIONS ON MICROWAVE THEORY AND TECHNIQUES, VOL. 61, NO. 9, SEPTEMBER 2013

D. Optimization

For design optimization, an error function to be minimized isconstructed with the cavity spacing and transformer lengthsas optimization variables as

(12)

where and are the sample frequencies within the passbandand the stopband, and are the reflection and transmissiontargets and is the vector of the filter lengths to be optimized.Only waveguide lengths are used to tune the passband response,thus the procedure is very fast since only a step characterizationis required all over the optimization process. Time of the opti-mization process normally takes less than 10 min on a standardPC when applied to typical filters with 20 corrugations. Thisstep can be often omitted, particularly in all cases where stan-dard return loss level (around 20 dB) are required.

E. Summary of the CAD Procedure

The design procedure comprises the following steps.Step 1) Filter widths and roll-off frequencies are selected

using the mode chart generated from (5).Step 2) With the aid of the multimode simulator, initial pa-

rameters of each partial filter are determined usingthe design formulas (6)–(10).

Step 3) The partial filters are first matched individually usingthe transformer synthesizer and then directly con-nected into a composite filter.

Step 4) With the aid of the multimode simulator, check thatspecified stopband is clear from spuriousspikes.

Step 5) If required, fine-tune the passband return loss andverify performance.

The procedure requires runningmany simulations of differentwaveguide modes for several design iterations. Anymodal anal-ysis technique can be in principle employed, being the proce-dure completely general. However, it is found that the approachbecomes particularly fast using the multimode variational for-mulation of Section III, where most of complex matrix manip-ulations are replaced by 2-D sums. The overall design processis then a matter of few minutes, including optimization.The fundamental difference of this method with respect to

synthesis emerges now in its full extent. Here, the multimodestopband performance is determined before the passband im-plementation, imposing the largest and the smallest values,then tapering the corrugation heights. As near-band transmis-sion zeros rely on selected -values, the filter steepness is con-trolled well independently of the order or gap size . Theadvantages resulting from this approach are the broad rejec-tion free of spurious bands and the optimal dimensionalfeatures. Previous methods proceed somewhat backwards: anequi-ripple passband is synthesized as a first step, losing in-formation about spurious modes and leading to small-gap andlengthy structures associated with filter prototypes.Similarly to [7], bandwidth limitation is the disadvantage of

using composite filters. The maximum bandwidth is limited bythe mode cut-off frequency of the waveguide of smallestwidth and the lowest roll-off frequency (actual limitation can

Fig. 5. Mode chart for the first four modes: , , , and.

be easily estimated with the mode-chart). Using this approachfractional bandwidths up to 20% are typically achieved. Theseencompass the majority of applications.

IV. DESIGN EXAMPLE: -BAND OUTPUT FILTER

A. Specification Review and Mode-Chart—Step 1)

In the frame of a recent -band space flight program, alow-pass filter was required after high-power amplification in aremote location of the spacecraft. The filter must provide broadrejection free of spurious bands, according to the fol-lowing specifications:

Passband 11.2 to 12.5 GHz;

Insertion loss over passband 0.12 dB;

Return loss over passband 26 dB;

Rejection:

from 17.3 to 18.1 GHz 80 dB ( -band Rx);

from 22.4 to 25.0 GHz 60 dB (second harmonic);

from 33.6 to 37.5 GHz 60 dB (third harmonic);

Power handling(multipactor)

6205 W;

Length 6 in;

Waveguide interface WR75.

Note: good performance over a broader frequency rangewould be desirable as a design target. Specifically, the filtershould feature a passband between 10.7 and 12.7 GHz withreturn losses greater than 26 dB. Moreover, a clean rejectionlevel should be maintained for frequencies between 17.3 and40.0 GHz. Although not formal requirements, these targetswould lead to a more generic design suitable to a variety of-band high-power applications.Fig. 5 shows the mode chart, where both strong and weak

conditions are used for spurious suppression ( 0.805 in,0.595 in).

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DE PAOLIS et al.: CAD PROCEDURE FOR HIGH-PERFORMANCE COMPOSITE CORRUGATED FILTERS 3221

Fig. 6. Multimode simulator frequency response of the first four modes: (a) , (b) , (c) , (d) , and (e) .

B. Multimode Design and Simulation—Steps 2)–4)

Using (6) and (7) at the highest specified frequency point37.5 GHz and imposing , the first set of design

dimensions was determined ( 0.08 in, ,0.09 in). The minimum cavity height was calculated from (8)

0.08 in . Setting the order of the two partial filters, then selecting and

solving the two resulting nonlinear equation systems (for bothcases: , 0.22 in), the other elements of theheight vector are calculated. The two partial filters are matchedto WR75 via two-step transformers at one end and then con-nected together without any transformer at the other end.It can be noted how (6)–(10) provide very good initial values,

so that the fast multimode simulator is only used for minoradjustments of while monitoring the spurious perfor-mance (Fig. 6).

C. Fine Tuning and Performance Verification—Step 5)

The passband performance of Fig. 6(a) shows good matchingwithout any full-wave global optimization. In order to meetthe stringent return loss requirement, minor optimization ofthe cavity spacing and transformer lengths was necessary inthis example. Final lengths are within 0.010 in of the startingvalues.The final RF performance, including insertion loss and peak

voltages, was verified via commercial numerical tools (CSTMi-crowave Studio). Fig. 7 depicts a 3-D view of the final structurehalf-shell ready for manufacturing.The filter response in Fig. 6(a) may look nonoptimal in terms

of polynomial prototypes: there is no correspondence betweennumber of poles and number of cavities and one reflection ap-pears in the roll-off range around 15 GHz. However, the filterstructure looks really optimal from amore practical perspective:

Fig. 7. 3-D mechanical model of the fabricated filter (one half-shell shown).

the large gap size shows promise of high power handling, lowloss, and low sensitivity to mechanical tolerance; the short cav-ities and simple matching networks results in a compact size(length is less than 6 in); the filter body is straightforward fromthe manufacturing viewpoint and can be realized using conven-tional clamshell techniques.

D. Experimental Results

The filter was built from two aluminum body halves usingindustry standard machining process, silver-plated and fastenedby mounting screws.Figs. 8 and 9 show the low-power -parameters measured

results, without any tuning. The in-band performance (Fig. 8)shows a return loss greater than 28 dB and an insertion lossaround 0.10 dB. The measurement of Fig. 9 was carried out overthe out-of-band frequency range from 13.0 to 40.0 GHz dividedinto three subbands, i.e., 13.0 to 20.0 GHz, 20.0 to 30.0 GHz,and 30.0 to 40.0 GHz. The filter WR75 waveguide interface is

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3222 IEEE TRANSACTIONS ON MICROWAVE THEORY AND TECHNIQUES, VOL. 61, NO. 9, SEPTEMBER 2013

Fig. 8. Measured in-band performance. (a) Return loss. (b) Insertion loss.

Fig. 9. Measured out-of-band performance over several frequency ranges. (a) Rejection from 13.0 to 20.0 GHz. (b) Rejection from 20.0 to 30.0 GHz. (c) Rejectionfrom 30.0 to 40.0 GHz.

connected to the dominant mode waveguide corresponding toeach subband through waveguide tapers, ensuring the measuredsignal is converted into the mode. In order to achieveworst case excitation of both symmetric and asymmetric modeswithin the specified stopband, special mode exciters (H-planebends) are placed at the filter input and output ports [4]. The re-sulting multimode standing wave between tapers is reduced byattenuating sections installed before the exciters and calibratedout. As can be seen in Fig. 9, the out-of-band range is free ofspurious bands beyond the third harmonic. Only minornarrowband spikes are observed. Such spikes are mainly due tothe mode, in agreement with simulation of Fig. 6(b). It isimportant to remark that a “clean” out-of-band rejection—simi-larly to the plots of Fig. 6(a)—is obtained when the filter is usedin a symmetric waveguide system, where high-order modes areconsiderably lower [4].The filter was high-power tested for multipactor breakdown.

The setup consisted of an RF pulsed source (power level6205 W, test frequency 11.717 GHz, duty cycle 2 ),a thermal-vacuum chamber (control temperature 82 C,pressure 5 10 torr) and a Cesium radioactive source forelectron seeding. Close-to-carrier noise, third harmonics, ande-probe were used as detection methods [19]. No multipactorevents occurred up to the maximum power level required.

TABLE I-BAND FILTER PERFORMANCE SUMMARY

Simulated with CST Microwave Studio.

No breakdown detected.

Table I summarizes the predicted and measured filter perfor-mance versus the technical requirements. It was possible not

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DE PAOLIS et al.: CAD PROCEDURE FOR HIGH-PERFORMANCE COMPOSITE CORRUGATED FILTERS 3223

only to meet the stringent specifications, but also to providegood rejection (between 55 to 80 dB approximately) overa much broader range than required. Similar rejection levelscannot be guaranteed by conventional corrugated filters and arenormally achievable only using waffle-iron or ridged filters,possibly with the approach recently reported in [8] and [9];however, the price is reduced power handling, higher loss,and/or increased manufacturing complexity. To the best ofthe authors’ knowledge, using previously published designmethods, it is not possible to simultaneously fulfill similar setsof requirements.

V. CONCLUSION

Computer-aided design based on multimode variational tech-niques takes minutes and leads to optimal solutions meetingmodern requirements for waveguide low-pass filters. It is shownthat composite corrugated structures can be utilized to forma multimode cluster of transmission zeros through fast designand optimization of the cavity heights. The designer then hasfull control over key dimensional features (gap , length , andspacing ) that can be optimally preselected at the beginning ofthe design process. The following improvements are introducedwith respect to previous techniques.1) Rejection of harmonic spurious bands: it is possible to ef-fectively design low-pass filters with spurious rejection forboth fundamental and higher-order modes, irrespective ofthe excitation conditions of the system.

2) Enhanced design flexibility: it is possible to design low-pass filters with large gap size and short lines, without jeop-ardizing the harmonic spurious performance. This leads toa number of distinct benefits in parallel:• low insertion loss;• high-power handling capability;• small length;• simple industrialization (no tuning, low sensitivityto mechanical tolerance, and standard manufacturingprocess)

Many designs have been successfully built for low and highpower applications, ranging from the -band to -band. Sim-ulation and measurement results of a -band example demon-strated the feasibility of the method, in particular when rejectionspecifications up to the third harmonic are to bemet without spu-rious. In many practical cases, out-of-band rejection, insertionloss, power handling capability, size, and manufacturing com-plexity no longer need to be traded off.

APPENDIX

With reference to Fig. 4(a), transverse electric and magneticfields of a smaller waveguide on junction areas or can berepresented in terms of Harrington’s voltage and current factors[18] as follows:

(13)

(14)

where and correspond respectively to the sumand difference of incident and reflected wave amplitudes of theth mode at the accessible waveguides 1 and 2. isthe cross-section electric field of the th mode in the smallerwaveguide normalized on or .Electric and magnetic fields in the larger waveguide cavity

are expressed as superposition of standing waves as

(15)

(16)

where represents the modal amplitude of the th standingwave shorted at and , respectively.Projecting on eigenfunction basis the boundary condi-

tions for electric fields at the junction planes ( is the wall areaof the larger waveguide at the junction)

forfor

(17)

forfor

(18)

we obtain

(19)

Substituting

(20)

then

(21)

Projecting on eigenfunction basis the continuity con-ditions of magnetic field at apertures

for (22)

for (23)

and manipulating the resulting equations, we obtain

(24)

where

(25)

Substituting (21) into (24) and introducing the index for theth mode in the smaller waveguide, we obtain the expressions(11) of the Y-matrix.

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3224 IEEE TRANSACTIONS ON MICROWAVE THEORY AND TECHNIQUES, VOL. 61, NO. 9, SEPTEMBER 2013

REFERENCES

[1] S. B. Cohn, “A theoretical and experimental study of a waveguide filterstructure,” Office Naval Res., Cruft Lab., Harvard Univ., Cambridge,MA, ?SA, Rep. 39, Apr. 25, 1948.

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[3] C. G. Matthaei, L. Young, and E. M. T. Jones, Microwave Filters,ImpedanceMatching Networks, and Coupling Structures. NewYork,NY, USA: McGraw-Hill, 1964.

[4] K. L. Wu and G. McDonald, “Coping with hidden spurious harmonicmodes in design of low-pass corrugated waveguide filters,”Microw. J.,vol. 44, no. 11, pp. 180–183, Nov. 2001.

[5] W. Hauth, R. Keller, and U. Rosenberg, “CAD of waveguide low-passfilters for satellite applications,” in Proc. 17th Eur. Microw. Conf.,Rome, Italy, 1987, pp. 151–156.

[6] W. Hauth, R. Keller, and U. Rosenberg, “The corrugated band-passfilter—A new type of waveguide filter,” in Proc. 18th Eur. Microw.Conf., Stockholm, Sweden, 1988, pp. 945–949.

[7] R. Levy, “Inhomogeneous stepped-impedance corrugated waveguidelow-pass filters,” in IEEE MTT-S Int. Microw. Symp. Dig., Jun. 2005,pp. 123–126.

[8] I. Arregui, F. Teberio, I. Arnedo, A. Lujambio, M. Chudzik, D. Benito,R. Jost, F.-J. Görtz, T. Lopetegi, and M. A. G. Laso, “High-power low-pass harmonic waveguide filter with TEn0-mode suppression,” IEEEMicrow. Wireless Compon. Lett., vol. 22, no. 7, pp. 339–341, Jul. 2012.

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[19] “Multipaction design and test,” Eur. Space Agency, Noordwijk, TheNetherlands, ECSS-E-20-01A, May 5, 2003.

Fabrizio De Paolis (S’04–M’12) received the Laureadegree in electronic engineering from “La Sapienza”University of Rome, Rome, Italy, in 2004.In 2005, he joined COM DEV, Cambridge, ON,

Canada, as an Advanced Member of Technical Staff,where he was involved with the electromagneticmodeling and design of filters and multiplexers forspace applications. Since 2009, he has been with theEuropean Space Research and Technology Centre(ESTEC), Noordwijk, The Netherlands, where heis responsible for industrial and R&D activities in

the area of RF payload equipment and technologies. His current interestsencompass the areas of filters and multiplexers, nonlinear effects in passive

microwave devices, high-power amplification, and satellite communicationsystems.

Rousslan Goulouev (M’02) was born in Nebit-Dag, USSR, on February 9,1961. He received the Engineer-Physicist Diploma from the Moscow Instituteof Physics and Technology, Moscow, Russia, specializing in RF and electronicdevices.Currently, he is with COM DEV, Cambridge, ON, Canada, where he is a Se-

nior Member of Technical Staff designing microwave filters for space applica-tions. His interests are microwave filtering structures, design process automa-tion, numerical methods and boundary problem solving.Dr. Goulouev is a Professional Engineer of Ontario.

Jingliang Zheng received the B.S. degree from Bei-jing University of Posts and Telecommunications,Beijing, China, in 1982, and the M.S. and Ph.D.degrees in electrical engineering from TsinghuaUniversity, Beijing, China, in 1984 and 1988,respectively.For one year, he was with the Beijing Design In-

stitute of Telecommunications, Beijing, China, wherehe was involved with wireless communication. From1989 to 1993, he was involved with electromagneticfield simulation with the Swiss Federal Institute of

Technology, Zurich, Switzerland. From 1994 to 1998, he was involved with an-tenna and antenna array design with DSO National Laboratories, Singapore. Hewas then an Engineer with GHz Technologies Inc., Montreal, QC, Canada, fortwo years. In 2000, he joined the Research and Development Department, COMDEV., Cambridge, ON, Canada, where he is currently a Principal Member ofTechnical Staff, involved with the development of computer-aided design soft-ware for design, simulation, and optimization of microwave circuits for spaceapplications.

Ming Yu (S’90–M’93–SM’01–F’09) received thePh.D. degree in electrical engineering from theUniversity of Victoria, Victoria, BC, Canada, in1995.In 1993, while working on his doctoral disser-

tation part-time, he joined COM DEV, Cambridge,ON, Canada, as a Member of Technical Staff, wherehe was involved in designing passive microwave/RFhardware from 300 MHz to 60 GHz for both space-and ground-based applications. He was also aprincipal developer of a variety of COM DEV’s core

design and tuning software for microwave filters and multiplexers, includingcomputer-aided tuning software in 1994 and a fully automated robotic diplexertuning system in 1999. His varied experience also includes being the Managerof Filter/Multiplexer Technology (Space Group) and Staff Scientist of Cor-porate Research and Development (R&D). He is currently the Chief Scientistand Director of R&D. He is also an Adjunct Professor with the University ofWaterloo, Waterloo, ON, Canada. He holds an NSERC Discovery Grant from2004–2015 with the University of Waterloo. He has authored or coauthoredover 100 publications and numerous proprietary reports. He holds eight patentswith six more pending. At COM DEV, he is responsible for overseeing thedevelopment of company R&D Roadmap and next-generation products andtechnologies, including high-frequency and high-power engineering, elec-tromagnetic-based computer-aided design and tuning for complex and largeproblems, and novel miniaturization techniques for microwave networks.Dr. Yu is a IEEE Distinguished Microwave Lecturer from 2010 to 2012. He

is MTT Filter committee Chair (MTT-8) since 2010 and also served as Chair ofTPC-11. He is an associate editor of the IEEE TRANSACTIONS ON MICROWAVETHEORY AND TECHNIQUE. Hewas the recipient of the 1995 and 2006COMDEVAchievement Award for the development a computer-aided tuning algorithmsand systems for microwave filters and multiplexers.