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MIT 16 810 - Microwave Circuitry

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projDdhar2.pdfSheet116.810 IAP 2007 Engineering Design and Rapid Prototyping January 28, 2007 Version 1.3 Deliverable D Manufacturing Report System: MIT Space Elevator Team Beamed Ribbon Climber Component or Subsystem: Microwave Beaming System Team Name: The Rather-Naïve-About-Optics Team Team Member 1: Ethan Huwe Team Member 2: Arka P. Dhar Team Member 3: Chris Mandy 1. Microwave Circuitry Nearly all components of the waveguide circuitry will be purchased, so that manufacturing and assembly is rather limited. Waveguide components come equipped with 6 holes for 2.4mm diameter screws. Screws of 4cm length are long enough to protrude on both sides of the thick brass plate around the waveguide protrusions. All that is needed is to assemble the 12 Magnetrons 2-by-2 to beam combiners, combining four of these 6 pairings into two more pairings, and combining these new parings with another pair, so that the magnetrons are grouped in two groups of 6. Combining these two groups with the quadrature coupler yields a single beam source of appropriately polarized light. This source should now be connected to the 41cm waveguide, then attached to the first H-bend, second waveguide (61cm) and second H-bend (the radiation exiting from the second H-bend should be parallel to that of the first, directed in the opposite sense). The next item to be manufactured is the horn. A design template was generated from Paul Wade’s hdl_3b4 program, which can be copied onto the copper sheet with any punch. Cutting the copper sheet can be simply done by saw, followed by punching 12 holes in the indicated areas, finally folding along the necessary lines, and bolting the horn in its final shape. Connecting this horn to the third (14cm) waveguide occurs in the same manner as the previous two cases. This final microwave circuitry section should only be connected to the rest once the circuit is supported by the horn support. Schematical view: 1… 2. Dish Support The process is again quite simple, detailed here: 2• Cut steel tubing to desired length and angle with chop saw • Cut steel plates with band saw • Drill ½” holes in the plates • Weld plates to single end of tubing • Drill hole into frame of dish • Bolt legs onto the dish through these holes 3. Horn and Waveguide Support It will not be much challenging to craft the horn support. • Cut 4 40.3” and 63” tubing and angle with chop saw. • Bolt the main join together holding the longer side perpendicular to the 40.3” part. • Take the wigi-wigi tube and as designed attach them with the structure, so as to increase stability. • Put the waveguides through the tube cavity, and bolt the horn with the extended plate of the longer hand. • Bolt the leg with a 10” X 10” metal/polycarbonate base. 3Deliverable D: Cost EstimateM1 Team Naïve About Optics TeamEthan HuweArka DharChris MandyItem Price Unit Quantity CostRaw MaterialsDish SupportSteel Tubing 1" square 5 $/yard 12 60Steel Plates 4.73 $/sq. foot 2 9.46Bolts 2 $/25 1 2Screws 6 $/25 1 6Fasteners 4.2 $/100 1 4.2Horn SupportTubing 5 $/yard 13 65Bolts 2.5 $/25 8 20Nuts 2 $/25 8 16Wigi-wigi wire 3 $/yard 30 90Microwave CircuitMagnetrons 1170 $/unit 11 12870Waveguide 41.41cm 131.44 $/unit 1 131.44Waveguide 62.74cm 172.65 $/unit 1 172.65Waveguide 14.22cm 41.23 $/unit 1 41.23H-Bend 210.2 $/unit 2 420.4Horn Copper 2.2 $/sq. foot 1 2.2Bolts 2 $/25 2 4Screws 6 $/25 2 12Horn Backplate 0 Scrap 1 0Beam Combiner 301.5 $/unit 10 3015Quadrature Coupler 440 $/unit 1 440ManufacturingWelding 75 $/hour 2 150Cutting and Drilling 75 $/hour 1 75AssemblyAssembly 75 $/hour 4 300TestingNot quite yet…Total


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MIT 16 810 - Microwave Circuitry

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