2024-05-17 Filter Design

Introduction

Table of Contents

Research

Filter Design

Our System

First Pass

Parameters

  • Minimum Pass Band: 1236MHz - 1286MHz

  • Minimum Bandwidth = (1286-1236)/2 = 25 MHz

  • Target Center Freq = 25 +1236 = 1261 = 1260 MHz

  • Center Freq Wavelength = 299 792 458 / 1 260 000 000 = 0.2379 m = 23 cm

  • Center Freq Quarter Wavelength = 0.05948 = 6cm = 2.4 inch

  • Target Bandwidth = 40 MHz

  • Target Pass Band: 1220Mhz - 1280 MHz

Ideal Dimensions

  • Using the table from https://lea.hamradio.si/~s53mv/cavity/cavity.html for the initial dimensions.

    • “Fingers” are the three rods installed in the tube

    • “Probe” is the piece connected to the SMA

  • Tube Size

    • Ideally one dimension is 1/4 wavelength, will do my best

    • Targeting 2.4inch for one dimension based on above calculations

  • Finger Spacing

    • From table this is pretty clear I need to go with 40mm spacing

    • The distance between the “Fingers” is used to set the center frequency of the filter

  • Tube Length

    • From table 180mm seems optimal with this finger spacing so 7 inch

  • Finger Diameter

    • 10mm from table so 0.39 inch = 0.4 inch

    • 8mm also seems fine in table so = 0.31 inch

  • Finger Length

    • this seems to matter a lot based on center frequency

    • I will be able to sand these down worst case though this is also tunable

    • 48mm on all of them seems reasonable so 1.9inch

    • 2inch is 50.8mm so it’s kind of a lot but could sand it down

Materials

  • I am rushing this because machine shop closes for three day weekend!!

  • Getting connectors for this via 2024-05-15 Digikey Order

    • ensured they have the dielectric on the output to keep the 50 ohms

    • went with ones with just two bolts hoping easier to secure

  • Box Tubing

  • Finger pieces

  • End Cover

    • 0.6mm sheet aluminum was used (could be thinner tho if they have?)

    • as thin as possible at EMS

    • Dimension options to cover 1x3inch tube with an extra 1/2 inch (reference used 0.4inch on each end so 0.8inch total) on bent part gives

      • 1.5x3

        • this one seems preferable

      • 1x3.5

    • https://ems-stores.uwaterloo.ca/ems-site/aluminum-sheets

      • Alum Sheet - 5052 H32 20 GA. - .032

  • Fasteners

    • 4x for SMA conn bolts M3X3

    • 3x tuning bolts M3X15

    • 3x tuning counternut and lockwasher

    • 3x finger bolts

    • 8x end cover bolts M3 (M3X6 ?)

    • 8x end cover nylock nuts M3

  • copper/brass rod for probe

    • EMS doesn't have anything good for this, will need to get inventive here, not sure where to get brass rods or thin copper tube. guide uses UT-085 semirigid shield but I don’t have any of that

    • We have steel rods that are for little red yard flags

      • I can solder to these easily

      • Can easily cut myself with wire cutters

      • width should be close enough hopefully

EMS Purchase

Website and sign says they close 4:30pm friday, but 3:45pm they were closed. This means not gonna happen for competition.

  • Alum Rect Tube 3 x 1 x .125 Wall

    • 7 inches

    • 1x

  • Alum Solid Rounds 1/4 - 6061

    • 3x

    • 1.9 inch (2inch ok)

  • Alum Sheet - 5052 H32 20 GA. - .032

    • 1.5x3 inch

    • 2x

  • Metric Steel Socket Head Cap Screw 3X10MM X 0.5

    • 20x

  • Metric Steel Socket Head Cap Screw 3X20MM X 0.5

    • 10x

  • Metric Steel Socket Head Cap Screw 3X16MM X 0.5

    • 10x

  • MET NUTS M3 X 0.5

    • 20x

  • MET LOCK/SPRING/WASHERS M3

    • 20x

Actual Dimensions

  • measure and sharpie it out

Simulation

Assembly

  • taps from EMS?

  • should be able to drill with stuff in the bay and measure it out myself mostly

  • soldering rod to SMA connector

Tuning

  • Borrowing VNA from university

  • https://lea.hamradio.si/~s53mv/cavity/cavity.html

    • Screwing in the tuning screws should decrease the resonant frequency of each finger by approximately 5%.

    • “The useful tuning range of the complete filter is approximately +/- 3% around its nominal center frequency.”

  • using epoxy or hotglue to secure the tuning bolts once done as I don’t have the recommended paint

  • sharpie on parameters

Conclusion

No VNA yet, no materials, low on time to simulate. Will save this for later. It is good fun, cost effective, and useful so seems worth pursuing.