A cryogen-free Vuilleumier type pulse tube cryocooler operating below 10 K

Vuilleumier (VM) type pulse tube cryocooler (PTC) utilizes the thermal compressor to drive the low temperature stage PTC. This paper presents the latest experimental results of a cryogen-free VM type PTC that operates in the temperature range below 10 K. Stirling type pre-coolers instead of liquid nitrogen provide the cooling power for the thermal compressor. Compared with previous configuration, the thermal compressor was improved with a higher output pressure ratio, and lead and HoCu₂ spheres were packed within the regenerator for the low temperature stage PTC for a better match with targeted cold end temperature. A lowest no-load temperature of 7.58 K was obtained with a pressure ratio of 1.23, a working frequency of 3 Hz and an average pressure of 1.63 MPa. The experimental results show good consistency in terms of lowest temperature with the simulation under the same working condition.     

Opposed piston linear compressor driven two-stage Stirling Cryocooler for cooling of IR sensors in space application

A two-stage Stirling Cryocooler has been developed and tested for cooling IR sensors in space application. The concept uses an opposed piston linear compressor to drive the two-stage Stirling expander. The configuration used a moving coil linear motor for the compressor as well as for the expander unit. Electrical phase difference of 80 degrees was maintained between the voltage waveforms supplied to the compressor motor and expander motor. The piston and displacer surface were coated with Rulon an anti-friction material to ensure oil less operation of the unit. The present article discusses analysis results, features of the cryocooler and experimental tests conducted on the developed unit. The two-stages of Cryo-cylinder and the expander units were manufactured from a single piece to ensure precise alignment between the two-stages. Flexure bearings were used to suspend the piston and displacer about its mean position. The objective of the work was to develop a two-stage Stirling cryocooler with 2 W at 120 K and 0.5 W at 60 K cooling capacity for the two-stages and input power of less than 120 W. The Cryocooler achieved a minimum temperature of 40.7 K at stage 2.     

Vibration reduction of pulse tube cryocooler driven by single piston compressor

The development of pulse tube coolers has progressed significantly during the past two decades. A single piston linear compressor is used to in order to reduce the size and mass of a high frequency pulse tube cryocooler. The pulse tube achieved a no-load temperature of 61 K and a cooling power of 1 W@80 K with an operating frequency of 80 Hz and an electrical input power of 50 W. By itself, the single piston compressor generates a large vibration, so a set of leaf springs with an additional mass is used to reduce the vibration. The equation relating the mass, the elasticity coefficient of leaf spring and the working frequency is obtained through an empirical fit of the experimental data. The vibration amplitude is reduced from 55 mm/s to lower than 5 mm/s by using a proper leaf spring. This paper demonstrates that a single piston compressor with vibration reduction provides a good choice for a PTC.     

Experimental study of one-stage VM cryocooler operating below 8 K

The Vuilleumier (VM) refrigerator, known as heat driven refrigerator, is one kind of closed-cycle Stirling type regenerative refrigerator. The VM refrigerator with power being supplied by liquid nitrogen was proposed by Hogen and developed by Zhou, which shows great potential for development below 10 K. This paper describes the experimental development of a VM cryocooler operating below 8 K, which was achieved by using liquid nitrogen as a heat sink of middle cavity. The regenerator was optimized by using a part of metallic magnetic regenerator material Er₃Ni to replace the lead sphere and a no-load temperature of 7.8 K was obtained. Then all the lead spheres were replaced by Er_0.6Pr_0.4 material and a no-load temperature of 7.35 K was obtained, which is the lowest temperature for this kind of refrigerator reported so far. The cooling power at 10 K is about 500 mW with a pressure ratio near 1.6 and a charge pressure of 1.8 MPa. Especially, the magnetic material Er_0.6Pr_0.4 was found to be a potential substitution for the conventional lead.     

A novel coupled VM-PT cryocooler operating at liquid helium temperature

This paper presents experimental results on a novel two-stage gas-coupled VM-PT cryocooler, which is a one-stage VM cooler coupled a pulse tube cooler. In order to reach temperatures below the critical point of helium-4, a one-stage coaxial pulse tube cryocooler was gas-coupled on the cold end of the former VM cryocooler. The low temperature inertance tube and room temperature gas reservoir were used as phase shifters. The influence of room temperature double-inlet was first investigated, and the results showed that it added excessive heat loss. Then the inertance tube, regenerator and the length of the pulse tube were researched experimentally. Especially, the DC flow, whose function is similar to the double-orifice, was experimentally studied, and shown to contribute about 0.2 K for the no-load temperature. The minimum no-load temperature of 4.4 K was obtained with a pressure ratio near 1.5, working frequency of 2.2 Hz, and average pressure of 1.73 MPa.     

Study on cold head structure of a 300 Hz thermoacoustically driven pulse tube cryocooler

High reliability, compact size and potentially high thermal efficiency make the high frequency thermoacoustically-driven pulse tube cryocooler quite promising for space use. With continuous efforts, the lowest temperature and the thermal efficiency of the coupled system have been greatly improved. So far, a cold head temperature below 60 K has been achieved on such kind of cryocooler with the operation frequency of around 300 Hz. To further improve the thermal efficiency and expedite its practical application, this work focuses on studying the influence of cold head structure on the system performance. Substantial numerical simulations were firstly carried out, which revealed that the cold head structure would greatly influence the cooling power and the thermal efficiency. To validate the predictions, a lot of experiments have been done. The experiments and calculations are in reasonable agreement. With 500 W heating power input into the engine, a no-load temperature of 63 K and a cooling power of 1.16 W at 80 K have been obtained with parallel-plate cold head, indicating encouraging improvement of the thermal efficiency.     

Study on the phase shift characteristic of the pneumatic Stirling cryocooler

Due to entire pneumatic connection between free piston and free displacer, the motion parameters of them including amplitude and phase shift can actually impact the cooling capacity and overall performance of cryocooler obviously. In this study, the procedure of design and manufacture pneumatic free piston and free displacer (FPFD) Stirling cryocooler had firstly been described in details. Then in order to accomplish study, the experimental bench has been set up based on 80 K@1 W Stirling cryocooler. The effect of the thermodynamic and pneumatic parameters including charging pressure, natural frequency of displacer, damping coefficient of displacer, working frequency on the pressure, displacement and displacer phase shift has been investigated, respectively by means of experimental and theoretical method. In particular, the variation of damping is realized by adjusting the width of clearance cut on the additional damping component, which is screwed on the displacer rod. Similarly, natural frequency of displacer is changed by the extra mass connected on the displacer. Due to the results of experimental study, the optimum working conditions of this Stirling cryocooler for 80 K cold tip temperature are as follows: charge pressure 15 bar, natural frequency of displacer 46 Hz, width of clearance 300 μm and working frequency 43 Hz. In agreement with the optimum working conditions, neighborhood interval of 90° is the ideal working domain for displacement phase shift. Meanwhile, the displacer phase shift should approach to 0°as near as possible and pressure phase shift should also be as small as possible, which have linear relation with non-dimensional damping characteristic of compressor. In view of theoretical study, the expressions of three phase shifts deduced from thermodynamic equation of piston and displacer respectively are expressed as the functions of working parameters, which are verified by the experimental data and consequently can be used as the powerful guidance to optimum seeking.     

Investigation on a thermal-coupled two-stage Stirling-type pulse tube cryocooler

Multi-stage Stirling-type pulse tube cryocoolers with high frequency (30–60 Hz) are one important direction in recent years. A two-stage Stirling-type pulse tube cryocooler with thermally coupled stages has been designed and established two years ago and some results have been published. In order to study the effect of first stage precooling temperature, related characteristics on performance are experimentally investigated. It shows that at high input power, when the precooling temperature is lower than 110 K, its effect on second stage temperature is quite small. There is also the evident effect of precooling temperature on pulse tube temperature distribution; this is for the first time that author notice the phenomenon. The mean working pressure is investigated and the 12.8 K lowest temperature with 500 W input power and 1.22 MPa average pressure have been gained, this is the lowest reported temperature for high frequency two-stage PTCS. Simulation has reflected upper mentioned typical features in experiments.     

Operating characteristics of a single-stage Stirling cryocooler capable of providing 700 W cooling power at 77 K

High cooling capacity Stirling cryocooler generally has hundreds to thousands watts of cooling power at liquid nitrogen temperature. It is promising in boil-off gas (BOG) recondensation and high temperature superconducting (HTS) applications. A high cooling capacity Stirling cryocooler driven by a crank-rod mechanism was developed and studied systematically. The pressure and frequency characteristics of the cryocooler, the heat rejection from the ambient heat exchanger, and the cooling performance are studied under different charging pressure. Energy conversion and distribution in the cryocooler are analyzed theoretically. With an electric input power of 10.9 kW and a rotating speed of 1450 r/min of the motor, a cooling power of 700 W at 77 K and a relative Carnot efficiency of 18.2% of the cryocooler have been achieved in the present study, and the corresponding pressure ratio in the compression space reaches 2.46.     

Innovative phase shifter for pulse tube operating below 10 K

Stirling type pulse tubes are classically based on the use of an inertance phase shifter to optimize their cooling power. The limitations of the phase shifting capabilities of these inertances have been pointed out in various studies. These limitations are particularly critical for low temperature operation, typically below about 50 K. An innovative phase shifter using an inertance tube filled with liquid, or fluid with high density or low viscosity, and separated by a sealed metallic diaphragm has been conceived and tested. This device has been characterized and validated on a dedicated test bench. Operation on a 50–80 K pulse tube cooler and on a low temperature (below 8 K) pulse tube cooler have been demonstrated and have validated the device in operation. These developments open the door for efficient and compact low temperature Stirling type pulse tube coolers. The possibility of long life operation has been experimentally verified and a design for space applications is proposed.     

Air Liquide space cryocooler systems

After successful developments these last 3 years, AL/DTA is now in position to propose two pulse tube cryocooler systems for space applications in the 40–80 K temperature range. The two pulse tube cryocoolers are yet qualified against stringent thermal and mechanical environmental constraints. AL/DTA also develops associated Cooler Drive Electronic at QM level implementing launch locking and vibrations cancellation. This paper presents these complete cryocooler systems available for space applications.     

Raytheon long life cryocoolers for future space missions

Over the last several years, Raytheon has made significant advances on two long-life cryocoolers designed for efficient operation on space platforms. The first is the Low-Temperature Raytheon Stirling/Pulse Tube 2-stage (LT-RSP2) hybrid cryocooler, which is capable of providing simultaneous cooling at 55 K and 10 K nominal first and second stage temperatures. The LT-RSP2 design was finalized in mid-2009, with fabrication of the prototype unit taking place in late 2009 and early 2010 and execution of the production program in 2011–2015. During this period the LT-RSP2 has undergone extensive characterization testing and has successfully been integrated with an optical bench. The second cryocooler is the Raytheon Advanced Miniature (RAM) cryocooler, a flight packaged single stage pulse tube cooler with an integrated surge volume and inertance tube. It has been designed for high frequency operation and has been fully optimized to make use of the Raytheon Advanced Regenerator, resulting in improved efficiency relative to previous Raytheon pulse tube coolers. In this paper, aspects of both the LT-RSP2 and RAM mechanical and thermodynamic designs will be presented as well as information regarding their capabilities and performance.     

Operating characteristics of a three-stage Stirling pulse tube cryocooler operating around 5 K

A Stirling pulse tube cryocooler (SPTC) operating at the liquid-helium temperatures represents an excellent prospect for satisfying the requirements of space applications because of its compactness, high efficiency and reliability. However, the working mechanism of a 4 K SPTC is more complicated than that of the Gifford McMahon (GM) PTC that operates at the relatively low frequency of 1–2 Hz, and has not yet been well understood. In this study, the primary operating parameters, including frequency, charge pressure, input power and precooling temperature, are systematically investigated in a home-developed separate three-stage SPTC. The investigation demonstrates that the frequency and precooling temperature are closely coupled via phase shift. In order to improve the cooling capacity it is important to lower the frequency and the precooling temperature simultaneously. In contrast to the behavior predicted by previous studies, the pressure dependence of the gas properties results in an optimized pressure that decreases significantly as the temperature is lowered. The third stage reaches a lowest temperature of 4.97 K at 29.9 Hz and 0.91 MPa. A cooling power of 25 mW is measured at 6.0 K. The precooling temperature is 23.7 K and the input power is 100 W.     

Theoretical and experimental investigations on the partial scaling method for the Oxford-type moving-coil linear compressor

This paper puts forward the partial scaling method of the Oxford-type moving-coil linear compressor for pulse tube cryocoolers and analyzes the related principles. The systematic experimental investigations are further made to verify the analyses. One of the typical compressors developed in the authors’ laboratory is chosen to be scaled, and then coupled with the original pulse tube cold finger. At the typical operating temperature of 80 K for the pulse tube cold finger, the scaled compressor’s maximum input electric power increases from 236.7 W to 370.0 W, and the cooling power is enhanced from 10.0 W to 15.0 W. The motor efficiency decreases from 78% to 73%, but the average cooling efficiency slightly increases from 11% to 12% of Carnot efficiency due to a better match between scaled compressor and original cold finger. The rationality and feasibility of the partial scaling method have been verified by the theoretical analyses and experimental investigations.     

Investigation on phase shifting for a 4 K Stirling pulse tube cryocooler with He-3 as working fluid

He-3 is generally recognized for its ability to provide more excellent thermophysical performance than He-4, especially in the 4 K temperature range. However, this was not always the case in our preliminary experiments on a three-stage Stirling-type pulse tube cryocooler (SPTC). Our ongoing studies, as reported in this paper, demonstrate that the different working fluids also affect the performance through their phase shifting capability. This feature has been passed over in large part by researchers considering refrigerant substitution. Unlike previous theoretical analyses that focus primarily on regenerator losses, this report investigates the effects of the working fluid on the phase angle at the cold end in order to quantitatively reveal the relationship between the lowest attainable temperature and the cooling capacity. The analysis agrees well with our experimental results on a three-stage SPTC. While running with the operating parameters optimized for He-3, the lowest temperature of the SPTC decreased from 5.4 K down to 4.03 K. This is the lowest refrigeration temperature ever achieved with a three-stage SPTC.     

Experimental results on V-M type pulse tube refrigerator

This article mainly introduces experimental results on a new type pulse tube refrigerator named as V-M type pulse tube refrigerator. The main difference from Stirling type or G-M type pulse tube refrigerator is that thermal compressor similar to that of a V-M cryocooler is used instead of mechanical compressor. By using temperature difference between room temperature and liquid nitrogen, pressure wave with high to low pressure ratio around 1.2 is obtained. This pressure wave is used to generate cooling effect at the cold end. With a 20 K pre-cooler, this machine reaches lowest temperature 5.25 K by using helium⁴ at 0.77 Hz, 19 bar charge pressure. DC flow plays an important role in our system. It not only influences the final obtainable lowest temperature, but also is used to increase cold end cool-down speed. Total volume of the V-M type pulse tube refrigerator is around 3.3 l. However, dead volume inside rotor housing occupies about 2.8 l and can be much reduced.     

18.6 K single-stage high frequency multi-bypass coaxial pulse tube cryocooler

A single-stage high frequency multi-bypass coaxial pulse tube cryocooler (PTC) has been developed for physical experiments. The performance characteristics are presented. At present, the cooler has reached the lowest temperature of 18.6 K with an electric input power of 268 W, which is the reported lowest temperature for single-stage high frequency PTC. The cooler typically provides 0.2 W at 20.6 K and 0.5 W at 24.1 K with the input power of 260 W at 300 K ambient temperature. The cooperation phase adjustment method of multi-bypass and double-inlet shows its advantages in experiments, they might be the best way to get temperature below 20 K for single-stage high frequency PTC. The temperature stability of the developed PTC is also observed.     

Intermediate cooling from pulse tube and regenerator in a 4 K pulse tube cryocooler

This paper introduces intermediate cooling by thermally attaching heat exchangers on the second stage pulse tube and regenerator in a commercial 4 K pulse tube cryocooler. Due to the large enthalpy flow in the 2nd stage pulse tube and regenerator, both intermediate heat exchangers on the pulse tube and regenerator can provide cooling capacities in the temperature range of 5–15 K without or with minor effect on the performance of the 4 K stage. Extracting cooling capacity from the pulse tube or regenerator reduces the 1st stage cooling performance in the present study. The joint intermediate heat exchanger on the pulse tube and regenerator has demonstrated promising results for applications.     

A closed-cycle 1 K refrigeration cryostat

A 1 K closed-cycle cryostat has been developed to provide continuous cooling to a photon detector below 2 K. A two-stage 4 K pulse tube cryocooler is used to liquefy evacuated vapor from a 1 K pumping port to form a closed-cycle refrigeration loop. A 1 K instrumentation chamber, attached to the 1 K cooling station, is designed to operate with helium inside and provide more uniform cooling. The design of the cryostat has no direct mechanical contact between the pulse tube cryocooler heat exchangers and the 1 K cooling station resulting in almost no vibration transfer to instrumentation chamber. The cryostat can reach a no-load temperature of 1.62 K and provide 250 mW cooling power at 1.84 K.     

CFD modeling and experimental verification of a single-stage coaxial Stirling-type pulse tube cryocooler without either double-inlet or multi-bypass operating at 30–35 K using mixed stainless steel mesh regenerator matrices

This paper presents the CFD modeling and experimental verifications of a single-stage inertance tube coaxial Stirling-type pulse tube cryocooler operating at 30–35 K using mixed stainless steel mesh regenerator matrices without either double-inlet or multi-bypass. A two-dimensional axis-symmetric CFD model with the thermal non-equilibrium mode is developed to simulate the internal process, and the underlying mechanism of significantly reducing the regenerator losses with mixed matrices is discussed in detail based on the given six cases. The modeling also indicates that the combination of the given different mesh segments can be optimized to achieve the highest cooling efficiency or the largest exergy ratio, and then the verification experiments are conducted in which the satisfactory agreements between simulated and tested results are observed. The experiments achieve a no-load temperature of 27.2 K and the cooling power of 0.78 W at 35 K, or 0.29 W at 30 K, with an input electric power of 220 W and a reject temperature of 300 K.