FREQUENCY ELECTRONICS, INC.freqelec.com/space/space-fei_capabil_07-06.pdfFREQUENCY ELECTRONICS, INC....

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FREQUENCY ELECTRONICS, INC.

World Leader in High Precision Time & Frequency Control Technology for Space Applications

Olie Mancini 07-06

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Frequency Electronics, Inc.U.S. Headquarters

• ISO 9001 Registered• Strong Balance Sheet• Website: www.freqelec.com• NASDAQ: Stock Symbol FEIM

Founded in Founded in 19611961Modern FacilityModern Facility–– 100,000 sqft: Laboratory, Engineering and Production Space100,000 sqft: Laboratory, Engineering and Production Space

Mitchel Field, New YorkMitchel Field, New York275 Employees275 Employees–– Professional and Technical Staff: 150Professional and Technical Staff: 150

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More Than:More Than:5,000 Systems in Space5,000 Systems in Space2,000 Cesium Primary 2,000 Cesium Primary StdsStds

10,000 RF/Microwave & Other 10,000 RF/Microwave & Other AssembliesAssemblies50,000 Quartz Clocks50,000 Quartz Clocks100,000 Rubidium Clocks100,000 Rubidium Clocks10,000 Sync Systems10,000 Sync Systems4,000 GPS Units4,000 GPS Units

PROVEN PERFORMANCEOver 150,000 Fielded Products

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RUBIDIUM STANDARDSfor Commercial, Military and Space

33””

Model FEModel FE--5650A5650A

Model FEModel FE--5680A5680A

.98.98””

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Precision Crystals and OscillatorsFrom Raw Materials

For For Commercial Telecommunications and Military ApplicationsCommercial Telecommunications and Military Applications

5 MHz 55 MHz 5th th

Overtone Overtone CrystalCrystal

10 MHz 310 MHz 3th th

Overtone Overtone CrystalCrystal

““FEFE--205A Series205A Series””StateState--ofof--thethe--artart

Super Precise OscillatorsSuper Precise Oscillators(Poor Man(Poor Man’’s Rubidium!)s Rubidium!)

ShockShock--Mounted Mounted Precision Oscillator Precision Oscillator for Aircraft for Aircraft ApplicationsApplications

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Master ClockQuartz orRubidium

Frequency Generation,

Synthesis andDistribution

5 MHz to 42 GHz

Digital Systems Etc.

Up/Down Converters,Receivers

DC to DCConverters

To Transmitter

GPS ReceiverWith Low Phase Noise Quartz or

RubidiumOscillator

Frequency Distribution Amplifier

fo

OtherFrequency Generation

And Synthesis

Ground Station

Satellite

Provided by FEI

Space Technologies and Capabilities

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Space Technologies

KU BAND UP/DOWN CONVERTER

DC TO DC CONVERTER MODEL FE-302A

Triple Redundant Quartz based Clocks and Frequency Distribution

HybridsHybrids

FEFE--4220A Series OCXO4220A Series OCXO

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FREQUENCY ELECTRONICS, INC. SPACE CUSTOMER BASE

• Alcatel• Alenia Spazio• Aerojet• Astrium• Ball Aerospace• Boeing/Hughes Space• ITT• JPL

• Lockheed Martin• NASA• Raytheon• Space Systems

Loral• Northrop-

Grumman/TRW• DoD/MILITARY

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Alcatel KoreaSat 5; Syracuse I,II Telephony 1 & 2; Intelsat 9, MTSat; Worldstar;XM Radio 1,2,3,4

Alenia SICRAL 1, 1B; ARTEMIS; EMSJPO-GPSIII ATAFS-GPS III RbHughes/Boeing WGS 1,2,3,4,5,6

Milstar, UHF, AnikNothrop-Grumman/TRW AEHF 1,2,3; NPOESSS/Loral TerreStar, ICO,

GlobalstarISRO NSAT 2Raytheon DefenseDoD Secure Com JPL Mars Mission Orbital Sciences GCCS (WAAS)COM-DEV CascadeBall Aerospace Kepler

RECENT SPACE ACTIVITIESFREQUENCY REFERENCE UNITS and SYNTHESIZERS (1 MHz to 44GHz)

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RECENT SPACE ACTIVITIES

• Frequency Translators / ReceiversCTI IndostarSS/Loral EutelsatOrbital Sciences GCCS (WAAS)

• DC/DC ConvertersAerojet SSMISSS/Loral N-Star, Thaicom, YamalAlcatel Syracuse, XM Radio,

Numerous Other

• HybridsHughes VariousSS/Loral Various

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FREQUENCY = 1 MHz to 44 GHz

TYPESDirect = Multiply, Divide, MixIndirect = Phase Locked, VCXO, DRO

LOW NOISE = 170 dBc / Hz NOISE FLOOR

LOW SPURS = -110 dBc

CROSS-STRAPPED CONFIGURATIONS

OTPUTS: High Isolation 1 to 60

Frequency Reference Units and Synthesizers

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Generalized Block DiagramGeneralized Block Diagram

N x 8 Redundant Frequency GeneratorN x 8 Redundant Frequency Generator

(Architecture assures no single point failure)(Architecture assures no single point failure)

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Triple Redundant Ultra Stable Oscillator (USO) and Triple Redundant Ultra Stable Oscillator (USO) and Distribution AssemblyDistribution Assembly

Syracuse and Syracuse and KoreaSatKoreaSat Programs: 60 Isolated Programs: 60 Isolated OutputsOutputs

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Local Oscillator, Eutelsat II

Model FE-5140A

Triple Redundant Quartz Master Oscillator

WGS, WORLDSTAR, XM Radio and numerous other space programs


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Frequency Range 20MHz to 145 MHz

Low Phase noise

Excellent Temp. Stability < +2 x 10-7

-100C to +600C Operating

Low Aging +1 ppm for life

Radiation Immunity 100 Krads

Highly Reliable: Over 20 years of space service with zero failures

Small size and light weight


OCXO Model FE-4220A

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Triple Redundant Precision Master Oscillator

Flying on numerous Military and NASA satellites

MILSTAR, UHF/EHF, POLARSAT, and numerous other programs

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ACTS

Frequency Generator FE-5150A

5 MHz to 6.8 GHz; Fully Redundant; Includes DC / DC Converter

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DROs

16 GHz DRO Phased Locked to 100 MHz Input

(1/N sampling Phase detector N = 160)14 GHz DRO

8.8 GHz Phased Locked DRO8.8 GHz Phased Locked DRO

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Typical Phase Noise 14 GHz DRO

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• PHASE LOCKED DRO– Output Frequency: 14.16GHz– Reference Frequency: 80MHz– Multiplication: 177– Output Power: +13 dBm, Dual Outputs– Spurious Signals: -80 dBc– DC Current: 300 mA at +15V– Phase Noise: -112 dBc/Hz (TYP) @ 1KHz to 100KHz– Qualified on space station– 15 year life– MMIC, MIC and SMT Technology

DRODRO

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• FREE RUNNING DRO– Frequency: 13.775GHz– Stability: ±30 ppm/yr– Output Power: 0dBm– Spurious Signals: -60 dBc– Phase Noise (dBc/Hz): -105 at 100kHz

-120 at 1MHz– DC Current: 50mA at +15V

• Qualified on Space Station• Switchable Output, -90dB Isolation• MIC Construction

DRO

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• DRO’S AND CRO’S– SPACE STATION 14.16 GHz DRO

13.78 GHz DRO

– EUTELSAT 1.0 GHz CRO1.5 GHz CRO1.8 GHz CRO2.05 GHz CRO2.55 GHz DRO3.3 GHz DRO

– GLOBALSTAR 2.5 to 7.8 GHz DRO

DRO and CRO

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•Delivered and qualified package contains: DRO, Synthesizer and EPC

•Assembly has been qualified over the frequency range of 700 MHz to 18.2 GHz

•The DRO section remains identical except for scaling the actual “puck/resonator” and loop parameters to match requested frequencies

Multiple Frequency SourcesPackaging Configurations

f0 Input

RFI Filter DC/DC Converter Regulator

RF Output

35V to 100V DC Bus Input

Synthesizer DRO

EPC

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SMAFEMALE

4.20 [106.7]

3.70 [94.0]

.60 [15.2]

2.48 [62.9]

4.95 [125.7]

1.88 [47.6]

4.35 [110.5]

5.50 [139.7]

•Dual DC/DC Converters

•Dual Frequency Synthesizer

•Dual DRO

•Output frequencies from 1GHz to 17GHz

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•Dual Ultra Stable 50 MHz OCXO

•Dual DC/DC Converter

•Multiple Frequency Generation: 100MHz to 8GHz

•Telemetry and Command

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•Seven output frequencies 1GHz to 18GHz generated from 10 MHz

•DC/DC Converter

•Telemetry and Command

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THESE ASSEMBLIES, DESIGNED FOR CUSTOM APPLICATIONS, COMBINE MANY TECHNOLOGIES TO PERFORM A COMPOSITE

COMPLEX FUNCTION. USED IN BOTH SPACE AND GROUND ENVIRONMENTS, UNITS OFTEN

INCLUDE POWER SUPPLIES, FREQUENCY GENERATORS AND SYNTHESIZERS, INTERFACE COMMAND AND TELEMETRY

CAPABILITY, SUBASSEMBLIES, AND REDUNDANT OPERATION.

FREQUENCY TRANSLATORS / RECEIVERS

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UPCONVERTERS

DOWNCONVERTERS

PIN ATTENUATORS

GAIN CONTROL

TEMPERATURE COMPENSATION

CUSTOM TELEMETRY AND CONTROL

Frequency Translators/ReceiversRF to Ka-Band

Example of µWave Assembly Used in Up/Down Converters

•Up-Converters and Down-Converters available form RF to Ka-Band

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REDUNDANT CONFIGURATIONS

INTERNAL/EXTERNAL LO

CONSTRUCTIONDISCRETE

MMIC

SMT ON ALUMINA SUBSTRATES

SMT ON SOFT BOARD

Frequency Translators/Receivers

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Examples of Receiver components

8.8 GHz Phased Locked DRO8.8 GHz Phased Locked DRO

Low Noise AmplifiersLow Noise Amplifiers

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INDOSTAR X-BANDRECEIVER

••INPUT FREQUENCY: 8.8 GHzINPUT FREQUENCY: 8.8 GHz••OUTPUT FREQUENCY: 2.2 GHzOUTPUT FREQUENCY: 2.2 GHz••BANDWIDTH: 150 MHzBANDWIDTH: 150 MHz••NOISE FIGURE: 1.6 dBNOISE FIGURE: 1.6 dB••INTERCEPT POINT: +30 dBmINTERCEPT POINT: +30 dBm••DC POWER: 11 WATTSDC POWER: 11 WATTS••WEIGHT: 3.2 kgWEIGHT: 3.2 kg

THIS IS A REDUNDANT UNIT OPERATING DIRECTLY THIS IS A REDUNDANT UNIT OPERATING DIRECTLY FROM THE SPACECRAFT BUS. IT IS FULLY CROSS FROM THE SPACECRAFT BUS. IT IS FULLY CROSS STRAPPED AND COMPUTER COMMANDABLE.STRAPPED AND COMPUTER COMMANDABLE.

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BLOCK DIAGRAMC to S-BAND RECEIVER

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DSP SHF RECEIVER

PIN:PIN: --48 THRU 48 THRU --117 dBm117 dBmRF INPUT FREQUENCY:RF INPUT FREQUENCY: 5.5 5.5 ±± 1.1 GHz1.1 GHzLOCAL OSCILLATORSLOCAL OSCILLATORS

XX--BANDBAND 9.18 GHz9.18 GHzCC--BANDBAND 3.696 GHz3.696 GHzOTHEROTHER 53.3/13.3 MHz53.3/13.3 MHz

OUTPUTSOUTPUTSCHANNEL ACHANNEL A 7.7 kHz 7.7 kHz ±± 900 Hz @ 1V PEAK900 Hz @ 1V PEAKCHANNEL BCHANNEL B 14.4 14.4 kHz kHz ±± 900 Hz @ 1V PEAK900 Hz @ 1V PEAK

DC POWER:DC POWER: +15V, +15V, --15V @ <7.3W15V @ <7.3W

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DSP SHF RECEIVERBLOCK DIAGRAM

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GCCS (WAAS) RECEIVER

L-band payload

• Part of the U.S FAA Geostationary Communications and Control Segment (GCCS) program.

•Galaxy 15 relays GPS navigation to in-flight aircraft, providing highly accurate guidance to pilots at airports and airstrips

Galaxy 15

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GCCS (WAAS) RECEIVERBLOCK DIAGRAM

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GCCS (WAAS) Receiver Subsystem

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GCCS (WAAS) RECEIVERBLOCK DIAGRAM

• INPUT FREQUENCY (GHz) 6.6• NOISE FIGURE (dB) 1.2• RECEIVER GAIN (dB) 67 – 82• LNA GAIN (dB) 52• BANDWIDTH MHz 75• TEMPERATURE RANGE 0C -25 TO +67• DC POWER (WATTS) 27 (1 LNA)• RELIABILITY 1250 FITS (15

years)• GROUP DELAY (nsec) 0.40• OIP3 (dBm) +22

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FREQUENCY TRANSLATORSFREQUENCY TRANSLATORS

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TDRSS Frequency Converters

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SATCOMSATCOM

Receiver FamilyReceiver Family

Ka Ka –– BandBand

Up and Down Up and Down ConverterConverter

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Other Building Blocks for Space Applications

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• Rubidium Clock System on board MILSTAR Space Craft since 1994 – All frequencies and timing for the MILSTAR

satellites are derived from the RMO – Low Drift < 3 x 10-14 / day– Inherently insensitive to radiation effects– Designed for low single event upset

• Rubidium Clock System and Synthesizer on board AEHF

Rubidium Clocks in Space

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MILSTARMILSTAR

Rubidium Master Oscillator SN 003 Rubidium Master Oscillator SN 003

••Total of 19 systems delivered to MILSTARTotal of 19 systems delivered to MILSTARExcellent Excellent

performance performance

in spacein space

Aging Rate:Aging Rate:

≈≈ 3x103x10--1414/day/day

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On Orbit Data, Milstar RMO

y = 3E-14/day-2E-10

-1E-10

0

1E-10

2E-10

3E-10

Nov-95

Nov-96

Nov-97

Nov-98

Nov-99

Nov-00

Nov-01

Time

Freq

uenc

y O

ffse

t (d

elta

f/f)


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AEHFAEHF

Advanced EHF Space System consisting of:

– Triple Redundant Rubidium Atomic Standards

– Triple Redundant Precision Quartz Oscillators

– Double Redundant Multiple Frequency RF Synthesizers

– Triple Redundant DC/DC Converters

– Triple Redundant Mil-Std-1553B Serial Interface

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GPS IIIFEI has been awarded a contract from the Air Force for Advanced Technology Atomic Frequency Standard (ATAFS) for GPS III

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TYPES– Crystal 1MHz to 150MHz

– SAW 200 MHz to 1100 MHZ

– Helical 100MHz to 2GHz

– Cavity 1GHz to 39GHz

– Stripline 1GHz to 15GHz

FILTERS

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TYPICAL PERFORMANCE

ORDERINPUT(MHz)

OUTPUT(MHz)

SPURIOUS(dBc) TYPE

X10 125 1,250 -65 Transistor,Efficient

X5 100 500 -40 Balanced,Low Noise

X5 1,120 5,600 -70 SRDX3 13,000 39,000 -30 Varactor

Designed for low noise spacecraft applications. These devices are available as integrated subassemblies incorporating Amplifiers, Isolators, and Filters. Active and step-recovery Diode techniques are used.

FREQUENCY MULTIPLYERS

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DC /DC POWER CONVERTERS

ModelModel

FEFE--302A302A

3.53.5””

AeroAero--jetjet AMSUAMSU

100W 18 outputs100W 18 outputs

MTSAT 2MTSAT 2

20W, +20V, +15V, 20W, +20V, +15V, --15V15V

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POWER OUTPUTS UP TO 200W

BUS INPUTS = 20V TO 100V

BASE-PLATE OPERATING TEMPERATURE UP TO 80C

STANDARD HYBRID DESIGNS FOR CONVERTER CONTROLLER AND LINEAR REGULATORS

CUSTOM MAGNETIC ELEMENT IN-House CAPABILITY

RADIATION HARDENED COMPONENTS AND CIRCUITS

ISOLATED AND NON-ISOLATED TELEMETRY SIGNALS AVAILABLE FROM INPUT AND/OR OUTPUT BUS.

DC /DC POWER CONVERTERS

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• FEI has a long history of producing high reliability space-qualified dc-dc converters for numerous applications.

• FEI designs and manufactures dc-dc converters as:– stand-alone product – for integration into a total system solution. – Standard products are customized to an application’s specific requirements.

• Ability to adapt product to meet most customers’ requirements because of ;– modular pc board designs – hybrid building blocks

• Vertically integrated design and manufacturing process for total quality and reliability control

– power magnetics are custom designed and manufactured – proprietary hybrids in-house designed and manufactured to deliver superb,

proven and repeatable performance • 90 - 95% of all critical control and power circuitry is located inside the hybrid

DC-DC CONVERTER OVERVIEW & HERITAGE

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DC-DC CONVERTER BLOCK DIAGRAM

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DC-DC CONVERTER

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The package measures 3.9 x 1.56 x 0.63 in. which includes a built-in EMI filter, multi-stage output filters, input undervoltage and output short circuit protection, regulation to 1%, is radiation hardened and has a power density of 6.7 watts per cubic inch.

DC-DC CONVERTER OUTLINE DRAWING

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DC-DC CONVERTER PACKAGING DETAIL

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DC-DC CONVERTER PACKAGING PHOTO

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• FEI’s converters are radiation hardened – use of components such as radiation hardened switching power mosfets. – components are further protected by internal hybrid package (all of control

circuit and most power components)– the outer chassis.

• Package design(s) insure protection and guaranteed performance over mission life from:

– accumulated low dose radiation, – single event upset, – single event burnout etc.

Radiation Hardening

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• Converters designed with – multiple stages of output filtering to achieve lowest noise possible while adhering

to size and weight constraints. – filters are designed to reduce switching fundamental frequency noise as well as

switching spike noise which contains many harmonics– Feed-thru filters may be additionally employed to eliminate switching spike noise.

• FEI’s chassis designs are optimized to allow the converters to meet the most stringent radiated emissions and susceptibility criteria

– use of pot-core magnetics which provide inherent shielding by design.

• In lower power converters, the aluminum chassis is designed to be emission “tight” by utilizing a laser welded chassis.

• In higher power converters, the chassis consists of hollowed out tub design with a recessed cover.

• These designs minimize gaps which could “leak” causing a radiated emission failure. The same design coupled with the use of spot shielding when required allows FEI to meet radiated susceptibility specification without difficulty.

EMI CAPABILITIES

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RELIABILITY

• All designs are proven by analysis and test.

• Among the analyses which are performed on all converter designs include but are not limited to:

– electrical component stress– parametric worst-case analysis– thermal stress– radiation– reliability– mechanical – FMECA

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BUILD TO SPECIFICATION OR BUILD TO PRINT

ANALOG, RF AND MicroWave FUNCTIONS

LOW AND HIGH POWER

THIN FILM AND THICK FILM TECHNOLOGY

EUTECTIC AND EPOXY CHIP AND SUBSTRATE MOUNTING

WIRE AND RIBBON BONDING

CUSTOM HYBRIDS

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CUSTOM HYBRIDSHYBRIDS

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WHY FEIFor Space Programs

• LEGACY: Extensive statistical data on performance of products in space– 5000 Systems in Space– Over 120 Satellite Programs

• PRODUCTS: Deep product line of Space Products

• HERITAGE: Clocks on board space craft since 1964

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• LOW RISK AND PERFORMANCE COMPLIANCE

– All critical components e.g. SC-cut, AT-cut, FC-cut crystals, hybrid assemblies, and magnetic are manufactured at FEI from raw material to finished products

– Usage of “Premium Q Swept Quartz” or radiation hardened quartz material

– Usage of crystals exhibiting monotonically-positive aging slope (radiation offsets the positive aging trend of quartz)

– All critical components e.g. glass lamps, resonance cells, RF cavities and magnetic for Rubidium Atomic Standards are manufactured at FEI from raw material to finished products.

WHY FEIFor Space Programs

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Statistical Data AnalysisAssures Mission Success

• Clocks on board numerous space craft since 1963 have accumulated millions of hours of data and have provided extensive statistical data in terms of: – reliability, – performance, – radiation effects, – corrections, – drift rates and other important parameters

• Quartz, Rubidium and Cesium Clocks have been supplied in various forms and in various redundant modes

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Statistical Data AnalysisAssures Mission Success

• Examples of Quartz Clocks aging on-orbit:– Argos (6 clocks) ≈ 6 – 9 x 10-12/day after 5 years – Voyager (2 satellites) ≈ 3.4 x 10-12/day after 10 years (not in Earth’s orbit)– Fleet Sat Com (13 sat) ≈ 2 – 4.4 x 10-12/day after 15 years – MILSTAR ≈ 2 x 10-13 / day after 8 years

• Rubidium Atomic Standards aging on-orbit:Rubidium Clocks have been flying on MILSTAR since 1994 with continuous gathering and analysis of statistical data.– The estimated drift / day for Rb is < 3 x 10-14 / day

• Cesium clocks and other space products have also been flying fornumerous hours and relevant data has been tabulated and analyzed

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SPECIAL EXPERTISE

• ISO 9001 REGISTERED.• QUALITY SYSTEMS AND FEI PROCESS

AND PROCEDURES HAVE BEEN APPROVED BY MANY U.S. AND EUROPEAN COMPANIES.

• REQUIRED ANALYSIS: WORST CASE, THERMAL, RADIATION, ETC.

• PARTS AND MATERIAL SELECTION, SCREENING, QUALIFICATION AND AQUISTION

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Quality, Technology, Performance

QUALITYQUALITY - First and foremost priority in the Frequency First and foremost priority in the Frequency Electronics Corporation Electronics Corporation

–– ISO 9001 certified ISO 9001 certified

––Integrated Corporate Wide Quality Awareness Program Integrated Corporate Wide Quality Awareness Program

––On time deliveriesOn time deliveries

TECHNOLOGYTECHNOLOGY -- Frequency Electronics Inc. has set a Frequency Electronics Inc. has set a benchmark for highly reliable precision Quartz Oscillators benchmark for highly reliable precision Quartz Oscillators Rubidium and Cesium Atomic Standard.Rubidium and Cesium Atomic Standard.

PERFORMANCE PERFORMANCE -- Unmatched by any competitor for Unmatched by any competitor for precision time/frequency systems in applications for land, precision time/frequency systems in applications for land, sea, air and space.sea, air and space.

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Over Forty Years of Hi-Rel Space Experience

FEI has produced and installed over FEI has produced and installed over 100,000 precision clocks in all operating 100,000 precision clocks in all operating environments from deep space to deserts environments from deep space to deserts to underseato undersea

––Over 1000 years of combined experience in space Over 1000 years of combined experience in space products resides with its key scientists and technologistsproducts resides with its key scientists and technologists

–– FEIFEI’’s extensive experience minimizes single event upset s extensive experience minimizes single event upset in timing systems and provide long life in space in timing systems and provide long life in space environmentsenvironments

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Examples of Examples of over 100+ over 100+ accoladesaccolades

FREQUENCY ELECTRONICS, INC.freqelec.com/space/space-fei_capabil_07-06.pdfFREQUENCY ELECTRONICS, INC....

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