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Recent progress toward the development of light weight, long life coolers is presented. In particular, programs underway in the United States to develop Stirling cycle coolers and pulse tube coolers are described. The potential availability of reliable, long lifetime coolers for space applications is discussed.
This short paper describes work in progress on the conceptual design of a control system for a cryogenic cooler intended for use aboard spacecraft. The cooler will produce 5 watts of cooling at 65 K and will be used to support experiments associated with the following: earth observation; atmospheric measurements; infrared, x-ray, and gamma-ray astronomy; and magnetic field characterization. The cooler has been designed and constructed for NASA/GSFC by Philips Laboratories and is described in detail. The cooler has a number of unique design features intended to enhance long life and maintenance free operation in space including use of the high efficiency Stirling thermodynamic refrigeration cycle, linear magnetic motors, clearance-seals, and magnetic bearings. The proposed control system design is based on optimal control theory and is targeted for custom integrated circuit implementation. The resulting control system will meet the following mission requirements: efficiency, reliability, optimal thermodynamic, electrical, and mechanical performance; freedom from operator intervention; light weight; and small size.
Acquiring cheap, moving video was impossible in a vacuum environment, due to camera overheating. This overheating is brought on by the lack of cooling media in vacuum. A water-jacketed camera cooler enclosure machined and assembled from copper plate and tube has been developed. The camera cooler (see figure) is cup-shaped and cooled by circulating water or nitrogen gas through copper tubing. The camera, a store-bought "spy type," is not designed to work in a vacuum. With some modifications the unit can be thermally connected when mounted in the cup portion of the camera cooler. The thermal conductivity is provided by copper tape between parts of the camera and the cooled enclosure. During initial testing of the demonstration unit, the camera cooler kept the CPU (central processing unit) of this video camera at operating temperature. This development allowed video recording of an in-progress test, within a vacuum environment.
Two sorption coolers using hydrogen as the working fluid are currently being fabricated and assembled for flight delivery by the Jet Propulsion Laboratory (JPL). Being vibration free, scalable and with the capability for the cold end to be remotely located from the warm spacecraft are the major advantages of this class of cryo-coolers. These systems have been designed to provide a total cooling capacity (per cooler) of 1 W at a cold end temperature less than 19 K. They will be used for the Planck surveyor mission (2007 launch). In this paper we present the level Of maturity of the hydrogen sorption cooler technology at JPL by describing the design and how it has been validated at the subsystem and system levels.
The Cryocooler for the Mid Infrared Instrument (MIRI) on the James Webb Space Telescope (JWST) provides cooling at 6.2K on the instrument interface. The cooler system design has been incrementally documented in previous publications [1][2][3][4][5]. It has components that traverse three primary thermal regions on JWST: Region 1, approximated by 40K; Region 2, approximated by 100K; and Region 3, which is at the allowable flight temperatures for the spacecraft bus. However, there are several sub-regions that exist in the transition between primary regions and at the heat reject interfaces of the Cooler Compressor Assembly (CCA) and Cooler Control Electronics Assembly (CCEA). The design and performance of the test facility to provide a flight representative thermal environment for acceptance testing and characterization of the complete MIRI cooler subsystem are presented.
Previously, we reported two-phase capillary-based cooling using narrow (200 to 1000 ..mu..m) heater bridge copper inverse opal (CIO) wicks with heat flux level of 1400 Wcm -2 and superheat ~ 10 degrees C. Here, we demonstrate the area scaling of the proposed technology to a large-area micro-cooler for high-heat-flux cooling of microprocessors and power electronics. We developed a hybrid single/two-phase micro-cooler that relies on capillary-wicking in a 25-..mu..m-thick CIO with an open silicon microchannel 3D-manifold for liquid delivery and vapor extraction, achieving a high heat flux ~ 400 Wcm -2 over a heated area of 10 x 10 mm 2 . For a range of inlet water flowrates from 5 to 60 g(min) -1 , we achieved total thermal resistances and vapor qualities of 0.68 cm 2 degrees CW -1 to 0.2 cm 2 degrees CW -1 and 0.55 to 0.12, respectively. The flowrates are 10x smaller than those of conventional single- or two-phase microchannel cooling technology. The corresponding two-phase thermal resistances ranges from 0.05 to 0.02 cm 2 degrees CW -1 with temperature superheat of 8 to 6 degrees C, respectively. While the overall performance of the large-area (10 x 10 mm 2 ) capillary-based micro-cooler degraded compared to the previous demonstration of the technology for a heated area of 5 x 5 mm 2 , however, preliminary CFD modeling indicates that an improved manifold design will be able to achieve comparable performance.
The Electron Ion Collider (EIC) requires cooling of protons at the injection energy to obtain emittances needed to achieve the design luminosity. The low energy cooler (LEC) provides such a capability. The LEC is an electron cooler utilizing a non-magnetized, RF-based electron cooling. This approach to cooling was successfully used in Low Energy RHIC Electron Cooler (LEReC).
This project addressed a major gap in supercritical CO 2 (sCO 2 ) power cycle research by focusing on the pre-cooler, a component that had received little attention despite its significant impact on cycle efficiency and plant economics. The team developed a compact dry cooler using brazed/diffusion-bonded microchannel passages paired with formed air-side fins, advancing the technology from TRL-2 toward commercial readiness. Compared to conventional fin-tube coolers, the design cuts installation footprint by roughly half for 10+ MWth systems while achieving better heat transfer and lower approach temperatures, translating into a projected LCOE reduction from 6.04 ¢/kWh to between 5.85 and 5.94 ¢/kWh. While fabrication of an aluminum MW-scale prototype revealed brazing and sealing challenges at larger scales, lessons learned informed a subsequent 1 MWth unit that was successfully built and delivered for integration into Sandia's Gen3 Particle Pilot Plant, advancing the technology to TRL-7 with a path toward TRL-8 pending successful testing.
Summaries of the thermal design, analysis, and testing of a radiative cooler for the Near Infrared Mapping Spectrometer (NIMS) for the Galileo Jupiter Orbiter are presented. The radiative cooler rejects approximately 120 milliwatts of heat at a temperature of 75K when operating in the worst-case thermal environment. The cooler is designed to operate against a relatively hostile thermal environment which varies over 145 deg of instrument scan angle and which includes planetary radiation, solar radiation, and emissions from warm spacecraft surfaces (some of which rotate periodically through the radiator field of view).
Magnetic bearings and noncontacting seals let cooler operate unattended at 65 K for more than 3 years. New cooler uses magnetic bearings, small piston/cylinder clearance seals, and linear motors. Cooler consists of compression and expansion sections connected end-to-end. Compression section houses reciprocating hollow piston driven by linear motor.
A cryogenic cooler is provided for use in craft such as launch, orbital, and space vehicles subject to substantial vibration, changes in orientation, and weightlessness. The cooler contains a small pore, large free volume, low density material to restrain a cryogen through surface tension effects during launch and zero-g operations and maintains instrumentation within the temperature range of 10 to 140 K. The cooler operation is completely passive, with no inherent vibration or power requirements.
An 80-K Joule-Thomson (J-T) cooling system designed for the Probe Infrared Laser Spectrometer (PIRLS) proposed for the Huygens Titan Probe of the Cassini Saturn orbiter mission is presented. The cryogenic cooling requirements of the PIRLS instrument are listed, and the cooler system design including details of a J-T cryostat, cold head, and dewar design is described along with the results of a thermal modeling effort and lab cooler performance testing. It is shown that by using active feedback temperature control of the cold head in combination with the self-regulating action of the J-T cryostat, a temperature stability of less than 0.1 mK/min is achieved by the cooler weighting 1.8 kg.
Free-piston Stirling power converters are candidates for high capacity space power applications. The Space Power Research Engine (SPRE), a free-piston Stirling engine coupled with a linear alternator, is being tested at the NASA Lewis Research Center in support of the Civil Space Technology Initiative. The SPRE is used as a test bed for evaluating converter modifications which have the potential to improve the converter performance and for validating computer code predictions. Reducing the number of cooler tubes on the SPRE has been identified as a modification with the potential to significantly improve power and efficiency. Experimental tests designed to investigate the effects of reducing the number of cooler tubes on converter power, efficiency and dynamics are described. Presented are test results from the converter operating with a reduced number of cooler tubes and comparisons between this data and both baseline test data and computer code predictions.
An existing operational low-earth-orbit radiative cooler is being upgraded for use on the Mars Observer polar-orbiting mission, using the Landsat Thematic Mapper cooler as a basis for upgrading. Significant improvements were achieved in the design of the thermal performance and vibration endurance, and in the mass minimization design. The cooler provides about 18 mW of useful refrigeration power in Mars orbit at its equilibrium operating temperature. The detector operating temperature for the worst-case orbital environment is about 73 K.
Three-stage regenerative sorption cooler produces no measurable vibration, highly reliable, and exhibits efficiency comparable to that of less-reliable mechanical Stirling-cycle cooler. Represents improvement over two-stage sorption cooler described in "Regenerative Sorption Refrigerator" (NPO-17630).
This paper describes the design of a digital control system for control of magnetic bearings used in a spaceborne cryogenic cooler. The cooler was developed by Philips Laboratories for the NASA Goddard Space Flight Center. Six magnetic bearing assemblies are used to levitate the piston, displacer, and counter-balance of the cooler. The piston and displacer are driven by linear motors in accordance with Stirling cycle thermodynamic principles to produce the desired cooling effect. The counter-balance is driven by a third linear motor to cancel motion induced forces that would otherwise be transmitted to the spacecraft. An analog control system is currently used for bearing control. The purpose of this project is to investigate the possibilities for improved performance using digital control. Areas for potential improvement include transient and steady state control characteristics, robustness, reliability, adaptability, alternate control modes, size, weight, and cost. The present control system is targeted for the Intel 80196 microcontroller family. The eventual introduction of application specific integrated circuit (ASIC) technology to this problem may produce a unique and elegant solution both here and in related industrial problems.
We have developed a calculational model that treats all the components of an orifice pulse tube cooler. We base our analysis on 1-dimensional thermodynamic equations for the regenerator and we assume that all mass flows, pressure oscillations and temperature oscillations are small and sinusoidal. Non-linear pressure drop effects are included in the regenerator to account for finite pressure amplitude effects. The resulting mass flows and pressures are matched at the boundaries with the other components of the cooler: compressor, aftercooler, cold heat exchanger, pulse tube, hot heat exchanger, orifice and reservoir. The results of the calculation are oscillating pressures, mass flows and enthalpy flows in the main components of the cooler. By comparing with the calculations of other available models, we show that our model is very similar to REGEN 3 from NIST and DeltaE from Los Alamos National Lab. Our model is much easier to use than other available models because of its simple graphical interface and the fact that no guesses are required for the operating pressures or mass flows. In addition, the model only requires a few minutes of running time allowing many parameters to be optimized in a reasonable time. A version of the model is available for use over the World Wide Web at http://irtek.arc.nasa.gov. Future enhancements include adding a bypass orifice and including second order terms in steady mass streaming and steady heat transfer. A two-dimensional anelastic approximation of the fluid equations will be used as the basis for the latter analysis. Preliminary results are given in dimensionless numbers appropriate for oscillating compressible flows. The model shows how transverse heat transfer reduces enthalpy flow, particularly for small pulse tubes. The model also clearly shows mass recirculation in the open tube on the order of the tube length. They result from the higher order Reynolds stresses. An interesting result of the linearized approach is that the steady mass streaming does not affect the enthalpy flow at second order. The major effect of recirculating mass streaming is to increase transverse temperature gradients, which leads to higher entropy production and reduced efficiency.
A bootstrap configuration has been proposed for multistage pulse-tube coolers that, for instance, provide final-stage cooling to temperatures as low as 20 K. The bootstrap configuration supplants the conventional configuration, in which customarily the warm heat exchangers of all stages reject heat at ambient temperature. In the bootstrap configuration, the warm heat exchanger, the inertance tube, and the reservoir of each stage would be thermally anchored to the cold heat exchanger of the next warmer stage. The bootstrapped configuration is superior to the conventional setup, in some cases increasing the 20 K cooler's coefficient of performance two-fold over that of an otherwise equivalent conventional layout. The increased efficiency could translate into less power consumption, less cooler mass, and/or lower cost for a given amount of cooling.