Influence of the connecting tube at the cold end in a U-shaped pulse tube cryocooler

In some special applications, the pulse tube cryocooler must be designed as U-shape; however, the connecting tube at the cold end will influence the cooling performance. Although lots of U-shape pulse tubes have been developed, the mechanism of the influence of the connecting tube on the performance has not been well demonstrated. Based on thermoacoustic theory, this paper discusses the influence of the length and diameter of the connecting tube, transition structure, flow straightener, impedance of the inertance tube, etc. on the cooling performance. Primary experiments were carried out in two in-line shape pulse tube cryocoolers to verify the analysis. The two cryocoolers shared the same regenerator, heat exchangers, inertance tube and straightener, and the pulse tube, so the influence of these components could be eliminated. With the same electric power, the pulse tube cryocooler without connecting parts obtained 31 W cooling power at 77 K; meanwhile, the other pulse tube cryocooler with the connecting parts only obtained 27 W, so the connecting tube induced more than a 12.9% decrease on the cooling performance, which agrees with the calculation quite well.     

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.     

40 K single-stage coaxial pulse tube cryocoolers

Several 40 K single-stage coaxial high frequency pulse tube cryocoolers (PTCs) have been developed to provide reliable and low-noise cooling for GaAs/AlGaAs Quantum-Well infrared photodetectors (QWIPs). The inertance tubes together with the gas reservoir become the only phase shifter to guarantee the required long-term stability. The mixed regenerator consisting of three segments has been developed to enhance the overall regenerator performance. At present, the cooler prototype has achieved a no-load temperature of 29.7 K and can typically provide 860 mW cooling at 40 K with 200 W electric input power rejecting at 300 K. The performance characteristics such as the temperature stability and ambient temperature adaptability are also presented.     

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.     

Experimental study of the influence of cold heat exchanger geometry on the performance of a co-axial pulse tube cooler

Improving the performance of the pulse tube cooler is one of the important objectives of the current studies. Besides the phase shifters and regenerators, heat exchangers also play an important role in determining the system efficiency and cooling capacity. A series of experiments on a 10 W @ 77 K class co-axial type pulse tube cooler with different cold heat exchanger geometries are presented in this paper. The cold heat exchangers are made from a copper block with radial slots, cut through using electrical discharge machining. Different slot widths varying from 0.12 mm to 0.4 mm and different slot numbers varying from around 20–60 are investigated, while the length of cold heat exchangers are kept the same. The cold heat exchanger geometry is classified into three groups, namely, constant heat transfer area, constant porosity and constant slot width. The study reveals that a large channel width of 0.4 mm (about ten times the thermal penetration depth of helium gas at 77 K, 100 Hz and 3.5 MPa) shows poor performance, the other results show complicated interaction effects between slot width and slot number. These systematic comparison experiments provide a useful reference for selecting a cold heat exchanger geometry in a practical cooler.     

Condensation stage of a pulse tube pre-cooled dilution refrigerator

In our article, experiments with a pulse tube (PTR) pre-cooled dilution refrigerator (DR) are presented, where an upgraded ³He condensation stage has been tested. The DR had a ³He flow rate of up to 1.1 mmol/s. The ³He gas entering the refrigerator was first pre-cooled to a temperature of ～50 K at the first stage of the PTR. In the next cooling step, the ³He was run through a recently installed heat exchanger, which was attached to the regenerator of the second stage of the pulse tube cryocooler; at the outlet of this heat exchanger the temperature of the ³He was as low as ～4 K. Due to the non-ideality of the helium gas, the second regenerator of a two stage PTR has excess cooling power which can be made use of without affecting the base temperature of this stage, and it is this effect which was put to work, here. Finally, the ³He was further cooled in a heat exchanger, mounted at the second stage of the PTR, before it entered the dilution unit of the cryostat.The installation of a heat exchanger at the regenerator of the second stage of the PTR is especially important for the construction of DRs with high refrigeration capacities; in addition, it allows for a plain design of the subsequent Joule–Thomson (JT) stage, and herewith facilitates considerably the construction of “dry” DRs. The condensation rate of the ^3,4He mash prior to an experiment was increased. The pressure during condensation could be kept near 1 bar, and thus a compressor was no longer necessary with the modified apparatus.     

Second law based modeling to optimum design of high capacity pulse tube refrigerators

The optimum design of a high capacity double inlet pulse tube refrigerator based on second law of thermodynamics has been presented in this paper. Second law is applied to calculate the work loss in the regenerator and to optimize the cryocooler performance. To investigate the behavior of the pulse tube refrigerator, mass and energy balance equations are applied to several control volumes of the cryocooler cycle. A complete system of conservation equations is employed to solve the regenerator analytically. The proposed model reports the cooling capacity of 110 W at 80 K cold end temperature at frequency of 50 Hz, orifice conductance of 0.4 and double inlet coefficient of 0.6, with 2.4 kW net power delivered to the gas. In this case, the entropy generation in the gas phase is dominant which is contributing more than 85% of the total lost work in the regenerator. The optimum thermal efficiency of 99.1% was achieved at a proper mesh number. However, the second law efficiency is reported to have an inverse behavior at this mesh number.     

A two-stage Stirling-type pulse tube cryocooler with a cold inertance tube

A thermally coupled two-stage Stirling-type pulse tube cryocooler (PTC) with inertance tubes as phase shifters has been designed, manufactured and tested. In order to obtain a larger phase shift at the low acoustic power of about 2.0 W, a cold inertance tube as well as a cold reservoir for the second stage, precooled by the cold end of the first stage, was introduced into the system. The transmission line model was used to calculate the phase shift produced by the cold inertance tube. Effect of regenerator material, geometry and charging pressure on the performance of the second stage of the two-stage PTC was investigated based on the well known regenerator model REGEN. Experimental results of the two-stage PTC were carried out with an emphasis on the performance of the second stage. A lowest cooling temperature of 23.7 K and 0.50 W at 33.9 K were obtained with an input electric power of 150.0 W and an operating frequency of 40 Hz.     

High-capacity 60 K single-stage coaxial pulse tube cryocoolers

A high-capacity single-stage coaxial pulse tube cryocooler operating at around 60 K has been developed to provide the appropriate cooling for the next-generation very-large-scale long wave infrared focal plane arrays under development. The application background and cooler design process are described, and the performance characteristics are presented. At present, the cooler typically provides 4.06 W at 60 K with the input power of 180 W at 300 K reject temperature. 4.72 W can also be achieved when the input power increases to 200 W, and over 9.4% of Carnot efficiency at 60 K has been realized. The larger pulse tube diameter of 14.2 mm is used and the evident orientation sensitivity is observed in the range of 55–65 Hz. The experiments also observe the obvious reject temperature dependence.     

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.     

Study on a 10 W/90 K in-line pulse tube cryocooler

A Stirling-type in-line pulse tube cryocooler (PTC) has been designed, built and tested at Shanghai Institute of Technical Physics (SITP), Chinese Academy of Sciences. This PTC prototype can obtain a low-noise cooling capacity of more than 10 W at around 90 K cold head temperature and is used for cooling a space-borne infrared photo detector. In order to achieve a highly efficient PTC, a simplified numerical simulation model has been established for design and optimization. The simulation results of the regenerator, pulse tube and inertance tube are analyzed in detail. Besides, some key parameters of the PTC are listed in the paper. The PTC’s performances are tested at different operating frequencies from 42 Hz to 55 Hz and its reject temperature dependence is observed in the range of 290 K to 320 K. Furthermore, the map of the PTC’s performance characteristics is presented.     

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.     

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.     

10 W/90 K single-stage pulse tube cryocoolers

A single-stage 10 W/90 K coaxial pulse tube cryocooler has been developed for space-borne optics cooling. The design considerations are described, and the optimizations on the double-segmented inertance tubes are presented. The preliminary engineering model (EM) of the cooler has been worked out, which typically provides the cooling of 10 W at 90 K with the input power of 175.6 W at 310 K reject temperature, and achieves around 14% of Carnot efficiency at 90 K. The reject temperature dependence experiments on the EM show a smaller slope of 10.2 W/10 K and indicate a good adaptability to the reject temperature range from 290 K to 333 K.     

Numerical analysis on performance and contaminated failures of the miniature split Stirling cryocooler

A mathematical model based on thermodynamic theory of variable mass is developed for the split Stirling refrigerator, in which, the whole machine is considered by one-dimensional approach while the processes in the regenerator are simulated by two-dimensional approach. First, the influence of the ideal frost layer distributions on the flow and heat transfer in the regenerator and the performance of the Stirling cryocooler are simulated. Then, the distribution of the contaminated water vapor and its coagulated and deposited process is qualitatively analyzed. Finally, the lifetime of the refrigerator is evaluated based on the calculated data. The results show that when the refrigerator is operated at uniform distribution of the water vapor partial pressure in the regenerator, the cooling capacity is reduced over 10% at about 631 h, and the power consumption of compressor is increased over 20% at about 1168 h. However, for the linear distribution of water vapor partial pressure, the refrigerator can work properly because the frost never reaches the criterion of failure. Also, it is found that when the Stirling cryocooler restarts after a shutdown, the cooling capacity is reduced by 10% once the frost mass is over 7.05 mg, and there is no cooling capacity once the frost mass reaches 41.2 mg.     

Characterization of a thermoelectric/Joule–Thomson hybrid microcooler

Micromachined Joule–Thomson (JT) coolers are attractive for cooling small electronic devices. However, microcoolers operated with pure gases, such as nitrogen gas require high pressures of about 9 MPa to achieve reasonable cooling powers. Such high pressures severely add complexity to the development of compressors. To overcome this disadvantage, we combined a JT microcooler with a thermoelectric (TE) pre-cooler to deliver an equivalent cooling power with a lower pressure or, alternatively, a higher cooling power when operating with the same pressure. This hybrid microcooler was operated with nitrogen gas as the working fluid at a low pressure of 0.6 MPa. The cooling power of the microcooler at 101 K operating with a fixed high pressure of 8.8 MPa increased from 21 to 60 mW when the precooling temperature was reduced by the thermoelectric cooler from 295 to 250 K. These tests were simulated using a dynamic numerical model and the accuracy of the model was verified through the comparison between experimental and simulation results. Based on the model, we found the high pressure of the microcooler can be reduced from 8.8 to 5.5 MPa by lowering the precooling temperature from 295 to 250 K. Moreover, the effect of TE cooler position on the performance of the hybrid microcooler was evaluated through simulation analysis.     

Theoretical and experimental investigations on the cooling capacity distributions at the stages in the thermally-coupled two-stage Stirling-type pulse tube cryocooler without external precooling

The two-stage Stirling-type pulse tube cryocooler (SPTC) has advantages in simultaneously providing the cooling powers at two different temperatures, and the capacity in distributing these cooling capacities between the stages is significant to its practical applications. In this paper, a theoretical model of the thermally-coupled two-stage SPTC without external precooling is established based on the electric circuit analogy with considering real gas effects, and the simulations of both the cooling performances and PV power distribution between stages are conducted. The results indicate that the PV power is inversely proportional to the acoustic impedance of each stage, and the cooling capacity distribution is determined by the cold finger cooling efficiency and the PV power into each stage together. The design methods of the cold fingers to achieve both the desired PV power and the cooling capacity distribution between the stages are summarized. The two-stage SPTC is developed and tested based on the above theoretical investigations, and the experimental results show that it can simultaneously achieve 0.69 W at 30 K and 3.1 W at 85 K with an electric input power of 330 W and a reject temperature of 300 K. The consistency between the simulated and the experimental results is observed and the theoretical investigations are experimentally verified.     

Stirling-type pulse tube refrigerator (PTR) with cold compression: Cold compressor,colder expander

This research paper focuses on the performance prediction and its validation via experimental investigation of a Stirling-type pulse tube refrigerator (PTR) equipped with a cold linear compressor. When the working gas is compressed at cryogenic temperature, the acoustic power (PV power) can be directly transmitted through the regenerator to the pulsating tube without experiencing unnecessary precooling process. The required PV power generated by the linear compressor, furthermore, can be significantly diminished due to the relatively small specific volume of the working gas at low temperature. The PTR can reach lower temperature efficiently with higher heat lift at the corresponding temperature than other typical single-stage Stirling-type PTRs. Utilizing a cryogenic reservoir as a warm end and regulating the entire operating temperature range of the PTR will enable a PTR to operate efficiently under space environment.In this research, the experimental validation as a proof of concept was carried out to demonstrate the capability of PTR operating between 80 K and 40 K. The linear compressor was submerged in a liquid nitrogen bath and the lowest temperature was measured as 38.5 K. The test results were analyzed to identify loss mechanisms with the simple numerical computation (linear model) which considers the dynamic characteristics of the cold linear compressor with thermo-hydraulic governing equations for each of sub components of the PTR. All the mass flows and pressure waves were assumed to be sinusoidal.     

两级同轴型脉管制冷机回热器与脉管壁换热影响的模拟与实验

针对同轴型结构的两级脉管制冷机,采用热力学方法分析了回热器与脉管壁间换热作用对制冷机性能的影响。发现当脉管内热量通过壁面传向回热器时,脉管冷端焓流将增大,进而提升脉管冷指的制冷量。对设计的一台两级同轴型高频脉管冷指进行了数值模拟。模拟结果表明相同结构参数及输入下,引入回热器与脉管壁间的径向换热作用,低温级制冷量由原先的0.55 W@30 K提升至1.39 W@30 K,而对高温级的影响却小到可以忽略。     

Development of mechanical cryocoolers for the cooling system of the Soft X-ray Spectrometer onboard Astro-H

Astro-H is the Japanese X-ray astronomy satellite planned for launch in 2014. The Soft X-ray Spectrometer (SXS) onboard Astro-H, is a high energy resolution spectrometer utilizing an X-ray micro-calorimeter array, which is operated at 50 mK by the ADR with the 30-L superfluid liquid helium (LHe). The mechanical cryocoolers, 4 K-class Joule Thomson (JT) cooler and 20 K-class double-staged Stirling (2ST) cooler are key components to achieve a LHe lifetime for over 3 years in orbit (5 years as a goal). Based on the existing cryocoolers onboard Akari (2006) and JEM/SMILES (2009), modifications for higher cooling power and reliability had been investigated. In the present development phase, the Engineering Models (EMs) of these upgraded cryocoolers are fabricated to carry out verification tests for cooling performance, mechanical performance and lifetime. Nominal cooling power of 200 mW at 20 K for the 2ST cooler and 40 mW at 4.5 K for the JT cooler were demonstrated with temperature and power margin. Mechanical performance test for the 2ST cooler units proves tolerability for pyro shock and vibration environment of the Astro-H criteria. Continuous running of the 4 K-class JT cooler combined with the 2ST precooler for lifetime test has achieved over 5000 h without any degradation of cooling performance.