A full-duplex, multi-channel transmit/receive module for an S-band satellite communications phased array

An S-band, full-duplex, multi-channel, transmit/receive (T/R) module has been designed, developed, and produced in large quantities for phased array satellite ground station applications. The satellites, in LEO, MEO, and GEO orbits, need a global network of such stations to serve as gateways for tracking, telemetry, and command (TT&C) operations and/or payload data routing. The array provides simultaneous multiple high gain transmit and receive beams within a hemisphere to communicate with satellites during the time when they are above the local horizon. The design, manufacturing, and testing processes were conducted to achieve a low-cost, highly reproducible T/R module, and with high reliability. This paper details the RF design, the control electronics, built in test capability, the mechanical design and cooling, fabrication processes, and RF testing of the T/R module. Fully automated small and large signal measurements systems were used for rapid testing of the module parameters.