We describe the design and performance of Potter horns at millimetre and submillimetre wavelength employing a novel software package that we have developed, using Genetic Algorithm. The horn is easy to fabricate and exhibits excellent beam circularity and low cross polarization over a 15% bandwidth which is sufficient for many applications. Excitation of the required higher order modes is done by either a step or a flare discontinuity at the horn throat. In each case we provide design curves that give the optimum parameters of the horn geometry as a function of frequency and beamwidth. The range of values provided covers the parameters required for the design of horns for telescope feeds and various other instruments. The design curves show clearly that the flare-step performance is superior to the traditional groove-step Potter horn. The simulations for designing these horns were carried out at millimetre and submillimetre wavelengths but the results can be scaled to lower or higher frequencies. A key component in the design method is the optimization software that searches for the correct magnitude and location of the flare discontinuities. We have developed a software package based on the combination of modal matching, a genetic algorithm (GA) and downhill simplex optimization. The genetic code is first used to locate the proximity of the global minimum. The set of parameters obtained are then used as a starting point for the simplex method, which refines the parameters to the required accuracy.
Context. The use of large-format focal plane imaging arrays employing multiple feed horns is becoming increasingly important for the next generation of single dish sub-mm telescopes and cosmology experiments. Such receivers are being commissioned on both general purpose, common user telescopes and telescopes specifically designed for mapping intensity and polarisation anisotropies in the cosmic microwave background (CMB). Telescopes are currently being constructed to map the CMB polarisation that employ hundreds of feeds and the cost of manufacturing these feeds has become a significant fraction of the total cost of the telescope. Aims. We have developed and manufactured low-cost easy-to-machine smooth-walled horns that have a performance comparable to the more traditional corrugated feed horns that are often used in focal plane arrays. Our horns are much easier to fabricate than corrugated horns enabling the rapid construction of arrays with a large number of horns at a very low cost. Methods. Our smooth walled horns use multiple changes in flare angle to excite higher order waveguide modes. They are designed using a genetic algorithm to optimise the positions and magnitudes of these flare angle discontinuities. We have developed a fully parallelised software suite for the optimisation of these horns. We have manufactured prototype horns by traditional electroforming and also by a new direct drilling technique and we have measured their beam patterns using a far-field antenna test range at 230 GHz. Results. We present simulated and measured far-field beam patterns for one of our horn designs. They exhibit low sidelobe levels, good beam circularity and low cross-polarisation levels over a fractional bandwidth of 20%. These results offer experimental confirmation of our design technique, allowing us to proceed confidently in the optimisation of horns with a wider operational bandwidth. The results also show that the new manufacturing technique using drilling is successful, enabling the fabrication of large format arrays by repeatedly drilling into a single aluminium plate. This will enable the construction of focal plane arrays at a very low cost per horn. Conclusions. We have developed a new type of high performance feed horn that is fast and easy to fabricate. Having demonstrated the efficacy of our horn designs experimentally, we are building and testing a prototype focal plane array of 37 hexagonally close packed horns. This prototype array will be an important step towards building a complete CMB mapping receiver using these feed horns.
We present a design of a high performance horn operating at 700 GHz. The feed, which comprises three smooth-walled conical sections, is easy to machine and yet has comparable performance to a corrugated horn. The measured radiation patterns show high main beam circularity, low sidelobe level and good agreement with theoretical predictions. The cross-polar level is below −20 dB across a frequency bandwidth of 140 GHz. The new design allows the fabrication of high performance, large format feed arrays cheaply and rapidly.
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