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Article in The Journal of microwave power and electromagnetic energy: a publication of the International Microwave Power Institute · January 2010
DOI: 10.1080/08327823.2010.11689786 · Source: PubMed
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INTRODUCTION
The three-stub waveguide tuner [Collin 1966] is due to its simplicity the basic tool for
impedance matching of high-power industrial microwave applicators. It essentially consists
of three capacitive, often noncontacting stubs spaced apart along the waveguide broadwall
centerline by a quarter of guide wavelength λg. Only two neighboring stubs (1+2 or 2+3) are
used at a time for matching, each pair covering about half of the complete matchable area in
the Smith chart (Figure 1).
The tuner prime characteristic of interest is its matching performance, usually expressed
as maximum magnitude Mmax of load reflection coefficient that can be, regardless of phase,
perfectly matched. The quantity derives from maximum stub insertion depth hmax. Value of Mmax
can be as high as 0.9 in practical industrial tuners. In case of R-26 waveguides and generator
peak powers not exceeding about 1 kW this is indeed the only specification the user might be
concerned with. However, when the power increases, effects become important that can limit the
tuner performance or lead to its damage. The most severe of these effects is electric breakdown
that can develop in arc, able to melt the stubs. Also, increased input power proportionally
increases power dissipated in the tuning stubs, potentially leading to their overheating and
malfunction (arresting) or damage to softer surrounding parts (PTFE choke). Another limiting
factor is leakage of microwave energy through the microwave choke of a noncontacting stub.
The leaked radiation can interfere with built-in electronics and present hazard to personnel.
While the heat generated in stubs can in principle be conducted away by proper cooling and
leakage reduced by careful choke design there is little that can be done in tuner construction to
reduce the risk of arcing. It is therefore important to at least know safe limits of input power for
a given tuner design and stub insertion h. A systematic experimental investigation of breakdown
limits is difficult and can lead to tuner destruction. Fortunately, present-day electromagnetic
h
resonator. For a given frequency, resonance
Input
can take place only if the load reflection
coefficient has a certain phase. The two
critical areas are indicated as A, B in Figure 1. Figure 2. Model of the tuner for electromagnetic
Field strengths in such a resonating structure simulation.
Emax (kV/mm)
5
less time (minutes compared to hours). 4
Furthermore, a field distribution at any extra Ebr
3
frequency can be added without the need of 4 2
2
complete recomputation. Frequency range 5
1
was set to 2.4 – 2.5 GHz. Monitors of E-field and
surface current J at 2.45 GHz were engaged. 0
53 54 55 56 57 58
Tetrahedral mesh was used; it was refined z2 (mm)
such as to properly reproduce the sharpest 1-
mm radius edges. Trial computations proved Figure 3. Maximum E-field strength as a function of
distance z2 for input power Pin = 6 kW. Case 1: h = 25
that the results of FDS and TDS are in good
mm, re = 1 mm, |ΓL| ~1; Case 2: h = 25 mm, re = 7 mm,
agreement.
|ΓL|~ 1; Case 3: h = 28 mm, re = 7 mm, |ΓL| ~ 1; Case 4:
For different studied configurations h = 25 mm, re = 1 mm, |ΓL| = 0.95; Case 5: h = 25 mm,
the distance z2 was varied by means of re = 1 mm, |ΓL| = 0.9.
parametric sweep and, using postprocessing
macros, the following was evaluated: practically totally reflecting load. The results
have revealed that Emax rises sharply for certain
• Maximum value Em0 of E-field distances z2, exceeding more than 100 times
strength within the structure as the value in an empty matched waveguide.
function of z2 (the subscript 0 indicates Figure 3, curve 1, illustrates the case for a
that the input power is 1 W). moderate input power Pin = 6 kW, for which
• Maximum value Jm0 of stub surface Emax > 7 kV/mm at z2 = 54.3 mm, which more
current density as function of z2. than twice surpasses the dielectric strength
• Resonance distance z2 for of air (horizontal line). For comparison, in an
which Em0 is the highest; for this z2 also empty matched waveguide Emax = 59 V/mm.
coordinates where Em0 and Jm0 occur The resonance occurs within less than 1
were recorded. mm of the critical distance z2 (2º of reflection
coefficient phase); a potential hazard can
To acquire Emax and Jmax for arbitrary input therefore in many cases go unnoticed. The
power Pin, values Em0 and Jm0 obtained for P0 = input power to reach Ebr is 1 kW. Safe power
1 W have been multiplied by the square root level in this case is about 250 W, which is
of 2Pin/P0. The factor 2 appears because of our surprisingly low.
interest in amplitudes while MWS computes
effective values. Conversely, expressing Pin
and allowing Emax to reach the value Ebr/k
where Ebr = 3 kV/mm is dielectric strength of
air and k > 1 is a safety factor (typical value To load
2, see e.g. [Hewlett-Packard 1986]), the peak
input power for safe arc-free operation is
Emax
(1)
As the first case, an existing tuner (r = Figure 4. Distribution of E-field magnitude for h = 28
10 mm, re = 1 mm, h = 25 mm) was simulated mm, re = 7 mm, |ΓL| ~ 1. Maximum occurs at the stub
using vacuum as load fill material, yielding closer to the load.
Figure 5. Resonance exhibited as a loop in polar diagram and a dip in magnitude response of input reflection
coefficient at z2 = 54.3 mm.
40
times, i.e. about fifty times in terms of
hmax Mmax
35
power. Consequently, a slight uncertainty in
16 mm 0.27 determining |ΓL| can lead to great errors in
30
determining Pmax. In addition to the accuracy
25
and repeatability issues, experiments like
Pmax (kW)
20 18 mm 0.40
these can lead to damage of tuner under test
15
or other instrumentation used.
20 mm 0.53
10 Only pilot experiments with the
5 22 mm
24 mm
0.64
0.74
highest possible load reflection coefficient
0 26 mm 0.81 have been carried out. The tuner under test
0.8 0.85 0.9 0.95 1
(DUT) [S-Team 2009] with fully extended two
|Γ
ΓL|max
neighboring stubs (h = 25 mm) was terminated
Figure 6. Tuner working chart example. by a motorized noncontacting sliding short
may result in higher field intensities than with [Bilik and Bezek 2006]. Input reflection
more extended stubs. It should be noted for coefficient Γ of DUT was measured by a high-
completeness that while all the investigations power reflectometer (the same autotuner
assumed equal insertion of both stubs, it type as DUT). The system was fed from low-
cannot be excluded that in certain cases ripple magnetron source with input power
yet higher field strengths can occur with Pin settable from 1 kW to 7 kW. For a given
unequally inserted stubs, which could slightly power setting, the sliding short plunger was
modify the chart. moved, Γ recorded and occurrence of arcing
The usage of the chart is illustrated visually monitored. An example for Pin = 5 kW
on the following example. If, for instance, is illustrated in Figure 7, demonstrating the
the user wishes to safely apply input power situation on the verge of arcing. In Figure 7a,
Pmax = 15 kW and is able to secure applicator the shorting plunger was continuously slid
reflection coefficient below about 0.95, the with the speed 8 mm/s, hence x-axis (time)
stub insertion must not exceed hmax = 20 mm is also proportional to plunger distance zs =
(the circle in Figure 6). However, such stub z1 + z2 (see Figure 2). At z2 = 53 mm, sharp
insertion ensures perfect matching of only drop of |Γ| was observed to |Γ|min = 0.65,
loads with reflection coefficient magnitude corresponding to about 2.4 kW of absorbed
Mmax < 0.53 (VSWR < 3.23). power (in repeated experiments, |Γ|min varied
between 0.55 and 0.7). As the plunger moved
EXPERIMENTAL VERIFICATION on, the situation returned back to normal. In
Experiments involving investigation polar diagram (Figure 7b) the trajectory of
of electric breakdown limits and comparison the reflection coefficient represents a fast
with simulations are difficult. One reason is loop. Comparison with the corresponding
assuring constant conditions, corresponding simulation (z2 = 54.3 mm, |Γ|min = 0.72) shows
to simulation assumptions (e.g. low-ripple CW good agreement; also the size and position of
signal with stable frequency), in particular the resonance loops are similar (Figure 5).
for high powers. Even at apparently stable In Figure 7c, d the plunger was
conditions the breakdown occurrence is not stopped at the moment when the dip in |Γ|
exactly repeatable. But perhaps the most was observed. After four seconds, during
serious error source is the extreme sensitivity which |Γ| continued to fall, accompanied
of the breakdown threshold to load reflection by rapid heating of the sliding short walls,
coefficient magnitude |ΓL|. For example, breakdown occurred. This implies that the
the change of |ΓL| from 0.95 to 1, the breakdown limit is equal to or somewhat
difference commensurate with measurement less than 5 kW. The figure is higher than
accuracy, increases Emax more than seven the 1 kW predicted by the simulation; it is
1 1 1 1
Γ|
Γ|
Γ|
Γ|
|Γ
|Γ
|Γ
|Γ
Im Γ
Im Γ
Im Γ
0 0 0 0
Breakdown
Breakdown
-1 -1 -1 -1
-1 -1 0 0 1 1 -1 -1 0 0 1 1
Re Γ Re Γ b) b) Re Γ Re Γ d) d)
Figure 7.Tuner input reflection coefficient during electric breakdown experiments. a, b: arcing did not occur; c, d:
arcing occurred.
probably due to lower reflection coefficient the left-hand equation of the formula
of the sliding short compared to the nearly
total reflection assumed in the model. To
(2)
enhance measurement accuracy, a fixed short
with the critical length should be used. A
camera system to detect breakdown onset where ω is angular frequency, μ0 free space
and location would also add to credibility of permeability, and σ = 3.538 x 107 S/m aluminum
such experiments. conductance. The spatial distribution of |J|
for re = 7 mm is illustrated in Figure 8. The
SURFACE CURRENT “hot spot” (Jmax) always faces the load. A
Surface current is responsible for heating simplified approach to compute dissipated
the stubs by microwave power. The mean power was taken in that half of Jmax was
power dissipated in a stub can be estimated by somewhat arbitrarily chosen as effective
integrating the magnitude squared of surface value and applied on the whole exposed stub
current density J over the stub surface A using surface area A, as expressed by the rightmost
Port 2
Jmax Spindle
Body
To load
Choke
150
2
been used with re = 1 mm, h = 25 mm. The
100 distance zs of the shorting plate from stub axis
50 was varied (93.35 ÷ 253.35 mm, step 20 mm).
0 For each zs was computed the transmission
53 54 55 56 57 58 S21 from waveguide input (Port 1) to coaxial
z2 (mm) output formed by stub shaft (motor spindle)
Figure 9. Power dissipated in the stub closer to load passing through the choke body (Port 2). A
as a function of distance z2 for input power Pin = 6 kW. family of 17 frequency responses covering
Case 1: h = 25 mm, re = 1 mm, |ΓL|~ 1; Case 2: h = 25 one guide wavelength λg was thus obtained.
mm, re = 7 mm, |ΓL| ~ 1; Case 3: h = 28 mm, re = 7 mm, The simulation was also made for matched
|ΓL| ~ 1. load instead of the shorting plate.
-40
2 tuner was terminated by a noncontacting
-50
3 sliding short. Transmission responses S21 in
-60
the range 2.2 ÷ 2.7 GHz were measured
-70
using Agilent HP8753D network analyzer;
-80 distance zs was stepped by 2 mm from
2.2 2.3 2.4 2.5 2.6 2.7
f (GHz)
60.8 mm to 220.8 mm. The 81 obtained
responses covered more 0.7 λg even at the
Figure 11. Leakage transmission coefficient S21 lowest frequency. All the responses are
obtained by simulation. 1: Tuner terminated in overlaid as the gray lines in Figure 12.
matched load; 2, 3: Tuner terminated by a sliding short The configuration with matched load
with settings differing by 20 mm; 4: Envelope of the
transmission peaks.
was also measured (thick curve 1). Except for
frequency shift, the curve shape very closely
The results are shown in Figure 11. As agrees with that of the simulation. This is
expected, the matched load response (curve evident from curve 2, which is actually the
1) exhibits a single pole of attenuation. The simulated curve 1 from Figure 11 frequency-
pole was intentionally placed by the choke shifted by 148 MHz. For exactness, also a
dimensions to 2.29 GHz (6% lower than 2.45 configuration with a precision fixed short (zs =
GHz) because such choke when realized was 84.3 mm) was measured (curve 3); the pole of
tuned as desired. (This effect has occurred attenuation is located at 2.5 GHz as expected
systematically and in spite of much effort the (zs ~ 0.506 λg). The transmission peak is 13
cause has not been found.) dB above the matched-load response in
The presence of the short instead of good agreement with the simulation. The
the matched load introduces a second pole envelope of the family of the sliding short
of attenuation, position of which varies with responses closely follows the matched load
distance zs (curves 2 and 3, corresponding response upward-shifted by 12 dB (curve 4).
to zs = 163.35 mm and zs = 183.35 mm,
respectively). The pole appears nearly
exactly at the frequency for which zs is a
4
multiple of λg/2 and is caused by effectively
short-circuiting the waveguide at the stub
axis plane. Unfortunately, the pole is always 1
accompanied by a transmission peak at a higher
3
frequency; this is the effect that deteriorates
the choke performance compared to matched
2
termination. The peak is about 13 dB higher
than the matched-load response at the same
frequency, which is a typical figure. A margin
of this order (dashed line 4) must therefore Figure 12. Leakage transmission coefficient S21 obtained
be considered when designing and measuring by measurement. Gray curves: Tuner terminated in
a choke using a matched load only. sliding short with settsings stepped by 2 mm; 1: Tuner
In experiments, the stub stepper terminated in matched load; 2: Simulated matched
load response shifted on frequency axis by 148 MHz;
motor was replaced by a coaxial connector 3: Tuner terminated in a fixed short; 4: Curve 1 shifted
mounted on the choke body with the center 12 dB upwards copies the envelope of the sliding short
pin connected to the spindle. Thus the transmission peaks.
This substantially reduces the bandwidth of in close agreement. It was found that high-
the choke. For instance, the 40-dB isolation reflection loads can, compared to matched
bandwidth is reduced from 200 MHz to mere load, increase leakage level by as much as
47 MHz. 13 dB. This effect must be considered when
Generally, the following important designing and testing noncontacting stub
conclusions can be drawn. Electromagnetic tuners.
simulation yields realistic leakage levels; it The methodology developed in the
can therefore be applied also on structures paper can be applied on any waveguide type
which inherently do not contain measurement and stub construction.
ports suitable for direct comparison. A choke
can be designed and tested using matched REFERENCES
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CONCLUSIONS 1035.
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