PRELIMINARY REVERSE CRYOGENIC Phase

DESIGN

FOR CYCLE

BRAYTON

COOLER

I Final Report

U
Contract #NAS5-31281 Period of Performance: September 1990 - December 1992

'T

Walter Create
E_ m

Swift Inc.

V_ w

CREARE HANOVER,

INC. NH 03755 December

TN-508 10, 1993

@reare
TN-508 TABLE
w

OF CONTENTS 4 5 6 6 7 9 l0 10 10 13 18 18 18 20 21 28 28 34 40 45 47 47 53 54 58 62 63 68 71 75

LIST

OF FIGURES

......................................................................................................... ....................................................................................................... .................................................................................................... Objectives and Workscope ............................................... I Technical

TABLES

.......................................................................................................................... 1.1 Background 1.2 Phase

I. INTRODUCTION

1.3 Scope of this Report ....................................................................................... 2. SYSTEM DESCRIPTION AND ANALYSIS ............................................................ 2.1 Cycle 2.2 System Design Point ........................................................................................ ........................................................................................ Analysis Predictions Predictions Predictions Load .............................................................................. ................................................................................ ............................................................................. .......................................................................... ............................................................................... ........................................................... Description

2.3 Thermodynamic 2.4 Performance 2.4.1

= =

Design Variable

Point

2.4.2

2.4.3 40 K Modeling 2.5 Component 3. CRITICAL 3.1 Component 3.2 Facility 3.3 Instruments 3.4 Contamination 4. TEST RESULTS 4.1 June 4.2 September 4.3 December 5. DISCUSSION
_i _m

............................................................................................ DEVELOPMENT

Descriptions Testing

COMPONENT Description

........................................................................................ ........................................................................................ .................................................................. .................................................................................. Turbine .............................................. Turbine Turbine ..................................... .....................................

and Data Acquisition Control

......................................................................................................... - 3.18 mm Diameter 1992 Tests 1992 Tests MODEL - 2.38 mm Diameter - 3.18 mm Diameter

1992 Tests

OF TEST

RESULTS

...........................................................................

6. ENGINEERING

........................................................................................... ............................................................................................ Model Cryocooler ..............................................................

6.1 The Components 6.2 The Engineering

w

7. REFERENCES APPENDIX I APPENDIX

.............................................................................................................

...... """"'""'"'"'"............... ...... .,....... .... ...................................................72 II ..................................................................................................................

H N

= w

m m

REPORT

DOCU MENT, .TIOH .

PAG E"

Fort. Approved OMB No. 0704-0188

Public reporting burden for this collect on of nforrnation is est mated to average 1 hour per response including the lime for reviewin instructions searchln and maintain ng the data needed and com_letin_ and revi....... _^ _,,.............. ..... g , " g existing daaa sources, gatherln , ,..,,. _ _w,._ .,v _.u._ut_. u_ inJorrnal_on. _eno commenls regaramg this ouroen estimate or an other as g information including suggestions for reduc no ths burden to Washln-,_u^.. ....... ,.................. Y _ of this colleclion of ' =. , _._- ,,o=uHua.ur:= ,aulvJt._s, ulreczorale rot mlorma[lon uperations and Reports, 1215 Jet.son Davis Highway Su#e 1204, Arhn_lton, VA 22202-4302, and to the Ofhce of Mana_lemant and Budget, Paperwork Reduction Project/0704-0188), Washing on, DC 20503.

1. AGENCY USE ONLY (Leave blank) 4. TITLE AND SUBTITLE Preliminary 6. AUTHOR(S) Walter L. Swift Design for a Reverse

2. REPORT DATE December 1993

3. REPORT TYPE AND DATES COVERED Contractor Report 5. FUNDING NUMBERS

Brayton

Cycle Cryogenic

Cooler NAS5-31281

7.

PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES) Creare, Inc, P.O. Box 71 Etna Road Hanover, NH 03755

8.

PERFORMING ORGANIZATION REPORTNUMBER

9.

SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES) National Aeronautics and Space Administration Washington, D.C. 20546-0001

10. SPONSORING/MONITORING AGENCY REPORTNUMBER CR-189341

11.

SUPPLEMENTARY NOTES

12a.

DISTRIBUTION/AVAILABILITY STATEMENT Unclassified-Unlimited Subject Category 31

12b. DISTRIBUTION CODE

13. ABSTRACT (Maximum 200 words) A long life, single stage, reverse Brayton cycle cryogenic system is designed to provide 5 W of cooling at a temperature cooler is being developed for applications in space. The of 65 Kelvin with a total cycle input power of less than 200 an all metal, high performance, compact the

watts. Key features of the approach include high speed, miniature turbomachines, heat exchanger and a simple, high frequency, three phase motor drive. In Phase I, a preliminary design of the system was performed. Analyses

and trade studies

were used to establish

thermodynamic performance of the system and the performance specifications for individual components. Key mechanical features for components were defined and assembly layouts for the components and the system were prepared. Critical materials and processes were identified. Component and brassboard system level tests were conducted at cryogenic temperatures. The system met the cooling requirement of 5 W at 65 K. The system was also operated over a range of cooling loads from 0.5 W @ 37 K to 10 W at 65 K. Input power to the system was higher than target values. The heat exchanger and reverter met or exceeded their respective performance targets. The compresssor/motor assembly was marginally below its performance target. The turboexpander met its aerodynamic efficiency target, but overall performance was below target because of excessive heat leak. The heat leak will be reduced to an acceptable value in the engineering model. The results of Phase I indicate that the 200 watt input power requirement can be met with state-of-the-art technology system which has very flexible integration requirements and negligible vibration levels. Subsequent work will focus on further optimization of component performance and the design and demonstration of the Engineering Model. 15. NUMBER OF PAGES 76 16. PRICE CODE 18. SECURITYCLASSIFICATION 19. SECURITYCLASSIFICATION OF THIS PAGE OF "B,_TPA_T Unclassified Uncl_o:ifie'_ 20. LIMITATIONOF ABSTRACT Unlimited Standard Form 298 (Rev. 2-89)
Prescribed by ANSI Std. 239-18, 298-102

in a

14. SUBJECT TERMS cryocooler, Reverse-Brayton turboexpander, compressor Cycle, gas bearings,

17. SECURITYCLASSIFICATION OF REPORT Unclassified NSN 7540-01-280-5500

_,,_--_,,,_ t. Rop&_ .,.

Report

Documentation
No.

Page
3. Recip_nt's Cetelog No.

2. Governn_nt AcceM_"

4. Title and

Subtitle

5. Report Date DECEMBER 1O, 3.993

PRELIMINARY CRYOGENIC

DESIGN COOLER

FOR

REVERSE

BRAYTON_E

6. Performing Organization Code

7. Authorlsl
m

8. Performing Organization Report No. L. SWIFT TN-508 10, Work Unit No.

WALTER

9. Performing OrgsnlzatJon Neme end Addrem4m Creare,

IL=I

Inc. Box 71 NH Etna _ 03755 Road

11. Conuect o Grsnt No. NAS5-31281 13. Type of Report and Pe,_d Covered

P.O.
m

Hanover,
a==,

12. S_an_Age_Nmmee_ NASA Code

_mm_.

Add.m Space Flight Center

PHASE

FINAL

REPORT

Goddard 713.1 Road

14. Span_ting

Agency Code

Greenbelt

Greenbelt r _ tS. Supplen_ntlry Notes

20771

16. Abmlfect'
i

system

A long life, single is designed to provide

stage, reverse Brayton cycle cryogenic cooler is being developed for applications in space. The 5 W of cooling at a temperature of 65 Kelv|n wl_il_ a total Cycle input power of less than 200 watts. high speed, miniature turbomachines, three phase motor drive. of the system was performed. an all metal, high performance, compact heat

Key features of the approach include exchanger and a simple, high frequency, In Phase I, a preliminary

design

Analyses

and trade

studies

were used

to establish

the

thermodynamic performance of the system and the performancespec_fications for individual components. Key mechanical features for components were defined and assembly layouts for thecomponents and the system were prepared. Critical materials and processes were identified. Component and brassboard syste_ level tests Were conducted at cryogenic temperatures. The

H
m

system met the cooling requirement of 5 W at 65 K. The system was also operated Over a range of cooling 37 K to t0 W at 65 K. Input power to the system was higher than target values. The heat exchanger exceeded their respective performance targets. The compressor/motor assembly The turboexpander met its aerodynamic efficiency target, but overall performance leak. The heat leak will be reduced to an acceptable value in theengineedngmodei. The results of Phase I indicate that the 200 watt input power requi_rnent which has very flexible integration requirements and negligible vibration of component performance and the design and demonstration

loads from 0.5 W @ and inverter met or

was marginally below its performance target. was beiow target because of excessive heat :_ can be met with state of the art technology in levels. Subsequent work will focus on further Model.

a system

optimization

0_ngineering

t7. Key Words (Suggested by Authoris)) CRYOCOOLER, GAS BEARINGS, COMPRESSOR REVERSE-BRAYTON TURBOEXPANDER, CYCLE,

18, Distribution Stetemenl

19. Security Classd. (of this reporll UNCLASSIFIED I_'ASA FORM 1E2BOCT _,

_"

20. Secutily Cla_l.' (of this page) = UNCLASSIFIED .... "-

21. /_o. of pages 76

22. P'rice

'reare
The key technical The below results achieved during Phase I include the following: and reliably to temperatures more brassboard the design system point, operated of capacities demonstrated successfully a cooling

TN-508

well than 0.5

demonstrating

capacity

of slightly

W at 37 K, and a range
m

from 4 W to i0 W at 65 K. that design designs. duration steady state tests at cryogenic targets can be met with only

The

performance changes series

tests

modest Several
= u =

to the individual of cooldown and

component moderate

temperatures The
z_

demonstrated tests provided

the robustness excellent data

of the system. for detailed characterization of each of

system

the components.

The

tests and hardware

analyses

performed

during

Phase with

I provided The design the expectation 1994.

key and

information fabrication that system

confirming performance life tests

that tests with

the on the

overall Model

objectives

of the program is currently Model Model

can be met. by early

of the Engineering tests at Create,

proceeding

the Engineering the Engineering goal of monitoring

will be completed is to be delivered behavior

Following

performance for extended

to Phillips

Laboratory

system

for a period

of five years..

'reare
PROJECT SUMMARY

The

objective

of this program The cryocooler

is to develop

and test a Reverse

Brayton

Cycle

Cryogenic

Cooler

for use in space.

will be designed

to meet the following

requirements:

5 years years,

continuous with System, of cooling

operation launch

on orbit with 0.95 and abort landing

reliability,

an operating for

goal the

of 10 Shuttle

compatibility Transport 5 watts

environments

at 65 K, and efficiency (electrical input power < 200 W DC).

high thermodynamic

The technical heat exchanger Specifically, performance

approach in a the design

is to combine reverse of Brayton the

miniature cycle reverse-Brayton

turbomachines configuration Cryocooler

and a high performance, to meet relies the on goals the listed

all metal above. high

following

components:

a miniature a miniature an all-metal, an innovative

turboexpander centrifugal

with gas bearings, compressor with gas bearings, and heat exchanger,

high performance motor controller.

The program Fabrication Prototype

consists and Test,

of four phases: Phase and Test.

Phase

I - Preliminary Test of the

Design,

Phase

II - Engineering Model, and Phase

Model IV -

HI - Endurance

Engineering

Cooler

Fabrication

The

technical

objective

of Phase

I has been

to establish

the preliminary

design

of the cryocooler

and Ground of a closed System loads design results establish and down

Support Equipment (GSE) and demonstrate loop system incorporating brassboard level component to 37 K. performance System data were obtained and component modeling

critical component performance. Tests components were conducted in Phase I. at over was a range of temperatures the effects and of performed to assess

modifications at the component were used to verify component the designs of Engineering

level and to predict overall system performance. The test and system models. These results were also used to hardware.

Model

'reare
LIST OF FIGURES
w

TN-508

2.1 2.2 2.3 2.4 2.5

u

Schematic

of Reverse Cycle

Brayton

Cryogenic Brayton

Cooler Cooler Diagram

ii 12 14 16 17 - Engineering Model 19 20 22 23 24 27 27 29 & Spiral (1) Groove Thrust Face 30 30 31 33 34 35 36 39

Thermodynamic

for Reverse

Cryogenic Cooler Thermodynamic Model Thermodynamic Cycle Model Flow Chart Summary of Component Block Models Predicted Design Point Operating Cycle Performance Schematic Simplified 0.254 0.152 Three Diagram Circuit of Input Diagram Wall Power

2.6 2.7 2.8 2.9 2.10 2.11a

Characteristics Conversion

of Inverter ShelI Shell

Turboexpander

Heat Leak Thickness

mm (0.010")

2.11b 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 4.1 4.2 4.3 4.4 4.5 4.6 5.1 5.2 6.1 6.2a 6.2b 6.3 6.4 6.5

mm (0.006") Wail Thickness Phase Inverter Test Article Impeller Hole and Shaft, Impeller Compressor

Compressor Original

Tilt Pad Bearing (r) and Bladed

The Brassboard Drilled

Assembly Impeller

Disk Ring Pair for Brassboard Heat Exchanger Turboexpander Housings and Two Turbine Shafts Generalized Detailed Brassboard Schematic Mounting Brassboard Temperature Warm Thermal Test Facility Schematic Cold End and Support Systems Thermometers - 3.18mm During during Turbine, System June 1992 at the and Low Pressure Cooldown Gas Streams Cooldown Test Facility Schematic Facility

Diagram of Data Acquisition Detail for Platinum Resistance Cooldown Differences and Steady Between of the Heat

42 44 48 49 50 53 54 Brake) 55 59 60 63 65 65 67 69

Test Matrix the High Exchanger

and Cold Ends of the Recuperator

Effectiveness

Turbine Efficiencies During Steady State Tests (3.18mm Turbine). Cooldown and Steady State Tests with the 2.38mm Turbine Cooldown and Steady State Tests with 3.18mm Turbine (Reduced Comparison between Brassboard Effects of Heat Leak and Turbine Engineering Model Inverter Outline Cross Drawing Section of Engineering Assembly Model Model Design Compressor and Modified Speed on Efficiency Model Compressor Model Compressor Compressor

of Engineering

Engineering Engineering Preliminary

Heat Exchanger Turboexpander of Engineering Model Cryocooler

70

H
u

4
w

'reare
TN-508 TABLES. 2.1 2.2 2.3 3.1 4.1 4.2
i

Design Thermal Single

Point Stage

and System Input Reverse

Specifications, for Design Cryocooler

Summarized Point Prediction Performance and Mass

10 19 21 43 52

Model

Values Brayton

Instruments in the Brassboard Test Facility Steady State Tests - June 1992 September Comparisons and December, Between 1992, Steady State Tests and Model Predictions Predictions Heat Exchanger Test Results Test Results

5.1 5.2 6.1 6.2 6.3

57 6O 62 64 66 67 70

Comparison Between Inverter Characteristics

and System

Engineering Model Compressor Heat Exchanger Features Engineering Model Turboexpander

Features Features

_m

6.4

F_

reare
TN-508 1. INTRODUCTION

This report Cryogenic Cooler.

F_ .H

presents the results of Phase I of a program to develop a Closed Phase I was performed during the period September 1990 - December during this time focused on preliminary design of the cryocooler,

Cycle 1992.

The technical

effort

modeling

and analysis of the system, and critical component testing to support the design and analysis efforts. The work was performed by Create under contract #NAS5-31281 to NASA/GSFC.
!

Funding

was provided The initial

by SDIO, of work system K.

with Program for Phase tests report

Management I focused level.

through

Phillips

Laboratory. Design effort in

scope for to 40

on a six month This effort the results was of the hardware

Preliminary expanded at cryogenic Phase

supported scope
== u

by limited down

testing

at the component level This

and extended temperatures including I work

to provide

of brassboard presents

extending

---=4

performance analyses for the system, a description level test results for a wide range of test conditions, 1.1 Background

of the Engineering Model design, and system including two separate turboexpanders.

= =

There refrigeration Temperatures watts

is a critical need for mechanical cryogenic coolers to sensors and associated equipment in space over can vary from about depending 100 K down either to below on the application. Within coolers the broad In some spectrum

that can reliably extended periods varying there loads, from cases, external

provide of time. tens of

10 K, with loads

to tens of milliwatts, cooling attributes at several for colder

are requirements or to provide there are some

to provide cooling common

temperatures,

to accommodate

--2

stage refrigerators. for all mechanical

of requirements, for space applications:

that are desirable

--=

high reliability, long life, high thermodynamic very low vibration, flexibility in packaging low weight, and simplicity and robustness. efficiency, and integration,

A significant cryocoolers that of the desirable

amount listed

of effort above

has

been

invested

in the

development while

of mechanical as many currently of systems

will meet features

various

temperature

and load requirements Among

exhibiting

as is possible.

the candidate

being pursued, the turbomachine-based reverse meeting each of these requirements for a broad The counterflow basic steady flow, basic elements heat exchanger. may fluid loop.

Brayton cryocooler (TRBC) offers range of temperatures and loads.

the promise

of the TRBC include a centrifugal compressor, a turbine, and a Depending on temperatures and loads, one or more of each of these within is highly the cycle. modular, The components are connected within a allowing for heat absorption and rejection

components

be required The system

@reare
TN-508
m

at locations configuration,

that are relatively remote from the components. packaging and integration is very flexible. cooling loads for most space applications

Because

of this distributed

system

Because
!

are relatively

low

(typically

less

than

10 W), the turbomachines electromagnetic bearings. reduced, simplifying size, high detectable features

are very small. Shaft speeds are high, requiring If self acting gas bearings are used, electronics and enhancing reliability as a result. The gas bearings results in machines that the need for vibration compensation The cost is in thermodynamic (reduce input performance power) performance are required. operate devices. and reduce

the use of gas or and controls are of small with virtually no These desirable mass. advances In mass,

the system

combination

_4

speed and precision vibration, eliminating at some cost.

come

and system

order to increase thermodynamic in precision fabrication techniques

For the past fifteen years, Creare has been working actively to reduce increase the performance of the basic components of the TRBC, the turbomachines exchanger. Laboratory This and work activities discharge work Wright was focused has been Laboratory), funded supported SDIO through These by internal and the Small research Business fabrication funds, Much methods, Innovation the Air NASA/GSFC. of the early

the size and and the heat Force (Phillips program. in the area key system blading at a at a diameter on the component

development Technical of electric

Research principally to produce

on developing

advanced

machining.

advanced

methods

were then used

components with high precision in small sizes. Turbine rotors diameter of 2 mm, solid compressor impellers with aerodynamic
g

with aerodynamic swept back blades

of 15 mm, and perforated plates for heat exchangers the order of 0.1 mm in size are now possible. thermodynamic improved. capacities. with other This In other approaches performance has extended words, of the the basic practical capacities use

with thousands The result of of the type the reverse of this

of precision perforations these advances is that have been significantly refrigeration competitive and to lower cryocooler power

components have made

TRBC system Brayton

these advances

at low cooling

from the standpoint

of input

system

mass.

This
w

program and confirm built

is focused the status to supply architecture,

on

a specific

set

of

operating

requirements of an operating However, power

in

order

to The

demonstrate hardware because An eventual

of the technology power lends for these itself

in the form conditions

system.

is being goal

5 W of cooling

at 65 K, with a limit on input is desired. to the use of other components

of 200 W. the system, slightly

of 150 W input

of its modular

to meet

different operating requirements (different loads and temperatures), technology that will improve the overall system performance, weight portions 1.2 of the current Phase The tests that existing Modeling program focus on the how the cycle and Workscope I was to establish meet were convincing

or to incorporate new or reliability. As a result, operating conditions.

can meet other

I Technical overall objective

Objectives of Phase

data

through cooler. predict

analysis In Phase configuration. system

and I,

the and

system

specifications hardware at the

could component

eventually individually level

in a prototype performed to

(brassboard)

was tested

and in a closed

loop system

analyses

level

reare
m

TN-508 The test results were used to corroborate In the next and correct Phase during tests the models and and to guide long the life

performance. design
=

of the Engineering

Model

hardware.

of work,

the Engineering demonstrate

Model

system is expected to meet performance requirements behavior during extended endurance testing. At the start of Phase I, the basic components already existed. These four basic components an inverter frequency a compressor pressurize that converts DC input

cooler

that make included:

up a single

stage

reverse

Brayton

power

to three phase

AC power

at variable

to drive the motor that consists and circulate

and compressor, motor and centrifugal compressor to

of a drive

the flow through that precools and

the cycle, the high pressure gas flowing

a counterflow heat exchanger, to the cold end of the cooler, a turboexpander that provides

the net refrigeration

for the cycle.

F_ i

Each of these components had been developed and demonstrated at some level. In general, the important operational features of each had been verified by testing. In Phase I, each was carried to the next level of maturation. Important improvements robustness were implemented and evaluated by test. Inverter. The brassboard tested inverter had been developed load motor tests. (resistor used in performance or in mechanical

under and

an SBIR

program that

Fq. It had simulated used used to to

been

successfully

by driving levels during

a dummy those

inductor

circuit) was

the electrical
M

characteristics generation

of the induction version

in the compressor. Phase I, this inverter

It met or exceeded first then

expected drive
=

performance

During

an early

of the compressor

with pressurized

gas bearings,

demonstrate incorporated the workhorse Important the relationship motor.

startup capability and normal control self acting gas bearings and modified driver between for all compressor and performance voltage, current, operational

capability of later generation compressors that aerodynamics. During Phase I, it was used as and for all cryogenic in Phase operation system with level tests. I that allowed for optimizing the induction

development frequency

data were gathered

and slip during

m_ i

Compressor. original assembly

The compressor consisted

had also been

developed hole

under impeller

an SBIR

program shaft

{2]. The that was

of a low efficiency,

drilled

on a solid

supported by pressurized journal used to develop the three phase,

m

bearings and a magnetic thrust bearing. solid rotor induction motor up to speeds for the solid was shaft were part improved, and of this swept-back successfully A major aerodynamic integrated,

This assembly had been that would be required. a self acting the impeller gas bearing and diffuser the and involved Operational

During system,

Phase

I, fabrication the thrust were

methods bearing

including

aerodynamics fabrication

significantly impeller

improved. incorporating

improvement blades.

of a solid

@reare
performance data cryogenic tests. Heat Phase I. fabrication fabricated exceeded model were obtained during benchtop open loop testing and during

TN-508 system level

Exchanger.

The all metal,

slotted

plate

heat exchanger

was built

and tested

during

The design had evolved from an SBIR contract during which key methods development were performed I31. A reduced scale test article and tested test expected during article the SBIR program was built and tested reflect levels to verify that the models temperatures. effectiveness behavior from a prior were at cryogenic the actual design existed The

modeling and had also been In Phase slightly The losses. device

accurate.

I, a full scale

performance

in both thermal

and in pressure of the device. several SBIR prior project

was upgraded Turboexpander.

to more accurately The

turboexpander test article

dates from

independent in which

and it had

related

machines.

The

brassboard

been tested at cryogenic machine was physically over a range that temperatures of the warm is was program. for this system also temperature assembly turboexpander development not optimized cooling capacity

temperatures to characterize modified to increase its speed that extended end tested system in determining in the closed designed at these machines the of the machine

its performance [21. During Phase I, the and improve efficiency. It was also tested data heat for the A machine. thermal second, existed The Finally, modeling low from data The for data the of the capacity a prior was a low base of the to corroborate leak. This

performance was varied parasitic loop system. but

important

machine

It had been

for operation

in helium it provided

at 4.2 K. valuable

machine

temperatures, provided

(of the order

of ! or 2 watts,

between important

65 K and guidance

40 K).

obtained from the tests on both designs for higher performance. In addition programs techniques, methods provided Model. supplied data

on optimization

to the data obtained useful acquisition experience and

and improvements at the system methods level. and

made overall

at the component preparation, operation system

level, gas and

the test cleaning control

System

reduction

were developed and improved. This early experience valuable information that can be reflected in the design

with brassboard hardware and test of the Engineering

1.3

Scope

of this Report above, Phase I focused could on characterizing be met, and the system, developing from the developing and components design tests. This to

As noted assure that Engineering also focuses The system

system

requirements

a preliminary analyses

of the report

Model that incorporates the information on these three broad topics. first portion of the report and individual describes requirements

the system: of the

the design components.

point

requirements, performance of

the of the the

hardware

configuration,

thermodynamic

description.

Overall

cycle is related to the components are provided.

Descriptions

@reare
The components. middle portion This includes of the report discusses development analyses and several series of tests. carried out in Phase

TN-508 I on the

The final sections of the report describe the preliminary design of the Engineering Differences between Engineering Model and the brassboard components are discussed.

Model.

2.

SYSTEM This section

DESCRIPTION describes

AND operational

ANALYSIS requirements of the cryocooler configuration system and overall of and the overall are loads presented. are design The

of the modeling

system. that of

The is used cycle

thermodynamic to predict performance

cycle component over

and

hardware

and features

performance

is discussed. presented. model are

Predictions Descriptions also given. 2.1

u

a range

temperatures are incorporated

of the components

and how their

in the system

Cycle

Design

Point is designed temperature to meeting to provide 5 W of refrigeration goals, at a temperature input power the most important of 65 K. design The

The cryocooler nominal than heat rejection power and 200 W. In addition

for the system

is 280 K, and electric

is to be less drivers

life and reliability

are system specifications extracted

and mass. operational

Each is to be reduced to the extent possible. More detailed requirements are summarized in Table 2.1. These have been
[4].

from the specifications

Table Performance
g

2.1 Design Load

Point

and System

Specifications_

Summarized 5W 65 K <200 W

Refrigeration Load Input Power Rejection

Temperature Temperature

Heat Weight Cooidown

225 K - 275 K + 30C gradient To be Minimized < 24 hr. from ambient 0.95 for 10 yr, 50,000 33,000 50,000 hr. operation

Reliability Mission

hr Non-Operative hr. Operatin_

2.2

System The

Description is based on the reverse Brayton cycle. Miniature, of heat The high speed the high strategy for

cryocooler provide end.

turbomachines at the cold pressure

for pressurization gas streams

of the gas at the warm provides as they flow through

end of the cycle

and expansion

A counterflow

heat exchanger

for exchange the system.

between driving

and low pressure

10
!

reare
TN-508 the system - configured design is to use features which have the highest potential to achieve the highest practical level of performance. 2.1 is a schematic compressor of the system and Figure 2.2 for robustness and reliability

Figure cycle. reject exchanger heat

illustrates flows through through through

the

thermodynamic an aftercooler to heat turbine

A centrifugal where

pressurizes bus.

gas (neon) flow.

which

of compression it is cooled

to a thermal

The gas then continues The gas expands

a counterflow a radial flow

by the return

which produces useful the low pressure side

refrigeration. of the heat

The gas absorbs exchanger, cooling and pressures are

heat from the load, then returns through the high pressure stream. The flow is steady state when at the normal

continuous, and all temperatures operating conditions.

relatively

Power first converted In the inverter,

to the system to controlled the regulated

is supplied as unregulated DC power at 28 V, +/- 7 V. This power is 28 VDC +/- 0.2 V to match the input requirements of the inverter. 28 VDC power is converted to three phase high frequency regulator power to and the inverter

drive the induction motor in the compressor. Losses from the voltage are rejected as heat by a conduction path to the heat rejection interface.

Qrej
m

Qrej

rej
_-2. m

Fluid Loop
m

DC Supply Power
==

Turboexpander

Qload
:=

Inverte_

ontroller

MotorlCom

p ressor

Heat Exchanger

H m

Figure The motor and and

2.1.

Schematic

Of Reverse are contained housing

Brayton in and an

Cryogenic integral

Cooler assembly. rejection The heat of by a The loop.

compressor through

compression combination
m

heat due to motor for the system uses a combination

losses the called

can be transmitted for rejection

to the heat through

interface fluid this.

of conduction design

convection of all heat

an aftercooler.

original

specification

to an undefined to accomplish

The current

of convection

and conduction

11

@reare
turbine Heat must also be rejected from the turboexpander. produces shaft power that is absorbed and dissipated assembly. site. The brake circulates is heated design warm is based The gas in the brake heat rejection circuit by the brake the turboexpander fluid loop. a suitable neon through a separate, rejection

TN-508 The expansion of the gas through the by a brake wheel in the warm end of but connected heat to at the this at a into occurring and then cooled by rejecting

The current

on this heat

temperature of the interface with the fluid loop. However, heat at a separate, isolated radiator at lower temperatures. lower temperature, less heat is conducted from the warm the cold end. This parasitic heat leak is a relatively of the system virtually to 3000 Shutdown important

there are advantages to rejecting If the brake heat can be rejected end of the turboexpander cycle penalty. defined. the In testing power switch. assembly

Start and stop operation the compressor about about 3000 6500 frequency off. Both procedures Engineering has been started Hz (corresponding is then increased rps to 7500 rps).

has not yet been then simply

totally throwing (which requires

to date, to The

instantaneously revs/second), operating of the system

by presetting

the inverter has varied

frequency

to the desired

condition

during

tests from be switched and stop for the

that the power

machines coast down to a stop without incident. may evolve as testing and system integration Model.

More complex start issues become defined

HEAT _i_ EJECTED 2

2/

COMPRESSOR

!J
= =

HEAT EXCHANGER

-iN

AVAILABLE COOUNG 4q--_ Entropy (S) TURBINE 5 COOLING

[,d

Figure Because control

2.2.

Thermodynamic

Cycle

For Reverse

Brayton

Cryocooler

r_J n

precise

of the thermal mass and high effectiveness of the load temperature by adjusting either is basically designed to run open

of the heat exchanger, rapid and the compressor or turbine speed is frequency that could be

impractical.

The system

loop at a fixed

_-_-_-_:

adjusted on command signal to provide for speed changes to the system operation. Rapid and precise control of the load temperature will be better accomplished by means of either a thermal stabilizing mass and/or a small have not yet been defined. incrementally adjustable heater. Details for these components

IBm=

12

reare
g

TN-508 Analysis model of the features section. and cycle was variables. are discussed Since the developed Details original have been that were to provide predictions are presented of the to The used. of in

2.3

Thermodynamic A thermodynamic as a function document are detail in [5], presented several

performance a separate predictions discussed additional

of important in the next

operating

of the model formulation

r._l,but important variations

in this section.

Results

from system model provide model

improvements or assumptions

incorporated initially

or to correct

simplifications

will continue to evolve in the direction of increased accuracy, mainly in the form of improved component modeling resulting from test data. The generic cycle model is formulated in a Lotus 123 spreadsheet. optimization code Supplementary in which system performance analyses were also performed are related individual using a Creare-proprietary details of the to designs in order characteristics to refine to geometric

components. These analyses were used optimize the overall system performance. The cycle load makes and and input use model consists to the cycle

component

of a methodology for operating and

for calculating conditions variables, thermodynamic empirical

(among such variables data and

other

things) The

cooling model thermal from a of

power pressure to yield

selectable

by the user. as efficiency, are relations

of component

performance loss coefficients, results. The models,

characterization standard component non-proprietary used

effectiveness, expansion This combination analysis.

for compression obtained methods

performance

of proprietary section variables

standard

discusses

the equations is provided

in the analysis.

A discussion

of the values

used for performance

in the descriptions was intended

of the components. for predicting cooler performance for

The original formulation the following conditions: cooling loads from 0 to 10 W

of the model

load temperatures heat rejection

from 55 K to 90 K, from 260 K to 325 K. The range of load has been formulated temperatures has in which a load off design the design

temperature

The model has been subsequently modified in two ways. been extended to 35 K. And a second version of the model versus temperature curve for fixed input power performance of the turbine and heat exchanger value of 65 K.

can be predicted _61. This incorporates as the load temperature varies from

Input

A diagram illustrating the features relevant and output nodes for individual components are referred to later in the list of equations

to the system are identified

model is shown in Figure 2.3. in the figure. The numbers at

the nodes

used in the model.

13

@reare
TN-508

m m

i I
/

_=_
m

\
m

7 c,
t4
L

i4
r_

'reare
TN-508 In addition to the primary heat load interfaces for the cryocooler, the load and the heat by the to the to the to the rejection interface, there are several subsidiary parasitic heat loads that are considered model. Radiation to the cold end of the cycle is accommodated in three ways. Radiation heat exchanger, is included within the thermal effectiveness for that component. Radiation cold end tubing is determined by off-line calculations, and input as heat loads. Radiation cold end of the turboexpander is accommodated within the total The total parasitic heat leak from the warm end of the turboexpander by detailed thermal models of that component, depending on the brake temperature and the cold also accommodates load. This parasitic thermal bus to which The
i

heat leak in that component. to the cold end is calculated by a first order equation in the machine. The model

and characterized end temperature

the heat load from a separate, non-operating cryocooler interfacing at the heat load is calculated off-line and input as a numerical value. The external all cycle heat is rejected model is assumed overall to be at a constant cooler performance temperature from Trej.

thermodynamic

cycle

calculates

conventional

models of the individual components. the conversion of input power to useful

For the inverter, motor, compressor and power is characterized as an efficiency: power) / (input power) performance parameter

turboexpander,

rl = (net output For the aftercooler effectiveness: and heat exchanger, the

component

is the

thermal

E - (heat Parasitic effects

transferred) losses

/ (maximum

possible

heat transfer) calculation. in Figure Model factors calculates also and 2.4. inputs such produces analyses. of The to as

such as pressure structure

are accommodated and method

by separate of solution

The general
t

of the model

is outlined

study case variables are selected by the user for a steady state operating point. the calculation include gas properties, component dimensions, performance efficiency and other effectiveness pressures, results that values, refrigeration are useful and parasitic and effects. input with data The power. model The then model modeling temperatures, various capacity for correlating

cycle

H
I

or offline

The gas properties in the model illustrating some of the equations,

I

are real gas properties ideal gas relationships

from [71. However, for the purpose are substituted in this report. by the model. of the overall pressure, and

tl
H i

Figure 2.5 summarizes the functional calculations used in the figure is a schematic representation of the main elements

Each of the blocks calculation. temperature at the

I) For the compressor,

starting

with

mass

flow

rate,

inlet, the model uses compressor speed, compressor diameter, compressor efficiency, motor efficiency, inverter efficiency, and aftercooler effectiveness to calculate electric input power and pressure and temperature at the aftercooler exit.

15

'reare
E_ = :

TN-508

"-2 MODEL INPUTS STUDY CASE VARIABLES

Gas properties Component d[mensions Performance factom efficiencies effectiveness Parasitic effects ressure drop eat Inputs

Load temperature Rejection temperature Moss flow rate Compressor Inlet pressure Compressor rotational speed

I
fi CALCULATIONS ] Compressor inlet temperature impeller velocity input power pressure ratio exit temperature exit pressure

Aftercooler exit temperature

node temperatures I Heat Exchancjer I

Turboexpander inlet pressure exit pressure expansion heat leak ratio inlet temperature exit temperature expander rotational power speed

Cold inlet

Load

temperature

Summary cold load input power thermal load

cycle efficiency

Figure

2.4.

Thermodynamic

Cycle

Model

Flow

Chart

16

'reare
TN-508

2) In the counterflow
=

and

low

pressure

heat exchanger, temperatures at the inlet and exit ports for the high streams are related by a functional relationship between thermal pressure

effectiveness and mass flow rate. Another functional relationship between loss and flow rate is used to calculate the pressure loss in each stream.

K,J

3) In the

turboexpander,

an

adiabatic

efficiency

relates

exit

temperature

to

inlet

temperature and pressure ratio. Internal heat leak is applied of the temperature of the gas at the inlet to the turbine.

as an equivalent

increase

4) At the load, parasitic

net
m

radiation, from

the heat load from the redundant the cycle are gas applied. exiting The from cold the

cooler load cold

and the actual temperature plate where is

useful

refrigeration

assumed to be the temperature of the refrigeration is supplied to the load.

1

5) Pressure
two end.

losses These

in the tubing at the warm of tubing losses therefore at the cold are roughly been pressure

and cold ends have end and into two the 10 % of the

been

estimated lengths losses

assuming at the warm in the heat loss

1 meter

lengths and have

1 meter pressure heat

exchanger calculation.

lumped

exchanger

pressure

t 1 m

_3
i

qp,qm

,qc, E.c m' Po,To

ill, PT' T6

--I
/

Cold Plate

rn, Ps, T8
_ Qredundant

Q radiation

I_,

p31,__3[ Heat

Exchangerl_---i_, p4, T4 A Phlgh

Qleak/Ws

APh.

Comp Plow

rh'P4'T-_41Turbexpanderqt
Tubing

Figure

2.5.

Summary

of Component

Block

Models

17

@reare
m

TN-508 Predictions

2.4
=

Performance

Performance predictions for the cycle were conditions. The model results presented in this section Model Study Description Design

carried out are tabulated

for several below.

basic

operating

U
u

Point Operation Input Power (200W) System Variable (40 K Case) the design flow rate, speeds, Load Capacity

Steady Reduced

The operating temperatures

first study conditions.

was used to define These parameters and component

the system parameters required to meet include system conditions such as characteristics such as efficiencies,

and pressures,

operating

and internal Engineering the system

component sizes. In the second study, design performance characteristics of the Model hardware were extended to off design conditions to simulate the behavior of over a range of temperatures. The output from this study was predicted load and

temperature for the Engineering Model if operated at a steady input power of 200 W over a range of load temperatures. The third study was used to evaluate the performance that could be
u

achieved 2.4.1

with hardware Design Point

that was smaller Predictions

(or the same)

in a system

designed

for 2 W at 40 K.

L_ u

The design

point

operating

conditions

were predicted Important

using

expected and

performance parameters

values are

for the Engineering summarized in Table

m

Model 2.1.

hardware.

assumptions

system

[]

The results of the model predictions are shown schematically in Figure 2.6. The figure predicted temperatures and pressures at several locations within the system. Cooling parasitic from loads and input power point prediction at these conditions were used are also summarized the expected and turbine conditions. speeds, in the figure. performance flow rates the design to finalize points

shows load, for the

The results and pressure

components. I.e., the model establishes compressor rise that will be required to meet the design operating 2.4.2 Variable Load Predictions

The design performance compressor reduced from

basic

features

of the

design of the

point

model

were could

retained

and

expanded to establish

so that off

off

performance

characteristics

components

be used

design

of the cycle. For example, calculations input power (hence, the compressor speed) 5 W to 0 W. Under these conditions,

were performed assuming that the is constant and the cold end load is will decrease as the and therefore net result is a As the

the cold end temperature

load is reduced. This will reduce reduce the enthalpy drop through reduction in turbine speed

the temperature at the inlet to the turboexpander the turbine (for the same pressure ratio). The a change in the flow rate through the turbine.

and hence,

18

'reare
Table 2.2. Thermal Model Input Values For Design J/g-K Point Prediction 1.035 0.412 1.667 Diameter, cm cm 1.524 0.318 0.01 0.01 0.15 (W) 0.17 0.90 0.51 0.70 0.32 0.95 0.993 Gas Properties Specific Specific Heat Heat Rotor Capacity, J/g-K Ratio Impeller Diameter,

TN-508

Gas Constant, Geometry Parasitic

w

M m

Compressor Turbine Effects Pressure Pressure Radiation Redundant

Loss, high side - dP/P Loss, low side - dP/P Heat Load (W) Cooler Load

Design

Variables

Power Motor

Conditioner Efficiency

Efficiency

Compressor
m

Efficiency Power Train Efficiency Effectiveness Effectiveness

m =-2

Combined Aftercooler Recuperator

20W

88.2W

89.2W

8.1W

1.02 gls

378.5K 1.73 at
m

1.73 at

0.32W

O-------O-------

ir::_ m

200W

180W

_9988K

'

615._K t

_ O.15W

_ 5W

k
p-

Figure conditions flow

2.6.

Predicted

Design change,

Point

Operating will

Characteristics tend to operate accompanied

- Engineering at a reduced by a slight

Model The in the

at the turbine the heat

the turbine

efficiency. decrease

rate through

exchanger

will also change,

m_

thermal effectiveness of this component. The total effect of these changes efficiency will decrease (relative to Carnot efficiency) as the low temperature moves away from 65K.

is that the system end of the cycle

19

reare
w i J

TN-508 compressor fits through and heat exchanger data for each component perIbrmance relationships were in the form of suitable dimensionless and was

The characterized parameters effectiveness

turbine, in curve

(e.g. flow coefficient, head coefficient and flow rate for the recuperator).

and efficiency for the two turbomachines, A FORTRAN version of the model

developed and integrated with an optimizing computer code iteration to solve for system conditions with variable component was then used to predict system the input power and compressor The results the expected rejection power should cycle temperature of these input power as a function speed remained constant. are shown capacity is the nominal

that allows for the necessary characteristics I61. The model assuming that

of load and temperature

H
D- tl i

calculations

in Figure design

2.7. point

The

curve

in the figure The K. that The

relates thermal input

net refrigeration for the system

as a function

of load

temperature. value of 280 show

for this prediction be able to achieve

is 195 W from the electric bus. The a no-load temperature of about 35 K.

predictions

the cycle

= i

o
u

o o
O
O O

-__:=-__ I

o
3 O

o
/-

/
0 3O * ,O,'/,

o
I .... 40 I 50
i i i i [ i , , , | , , , ,

60 (K)

70

80

Load Temperature

Figure 2.4.3 40 K Modeling Studies (Baseline design scaled point were performed were For sizes without for three

2.7. Cycle

Performance

additional cycle

design

points

[81. Two for the

generic mass

system for each Model each For

models of the were design studies

and Advanced) conditions.

used to predict studies, to reflect

performance

and system

the Baseline and speeds incorporating

the components the designs advances

Engineering

to different condition

that would

be used to meet

technology

tt)at may be available.

20

@eare
TN-508 using
z

the

Advanced to reflect three values

system,

some

modifications changes

to the design to the designs power and and lower

of individual that could mass

components be incorporated.

were

incorporated The 2.3. The

the effects points in the

or realistic and predicted Table

design listed

system upper

are summarized for input following

in Table power and paragraphs

provide

bounds The

= m

cryocooler summarize

mass for each the assumptions

of the design operating conditions. used for each of the systems.

Table
I

2.3. Load

Single

Stage

Reverse

Brayton 35 K 0.25 W 0.2W

Cryocoo!er

Performance 35 K 2.75 W 0.2W 386W 15.5 kg 260W I1 k_

and Mass 35/65 0.25/2.5 0.2W 337W 18.7 kg 230 W 12.5 ku K W

Temperature(s) Capacity Load

Cooling Parasitic Baseline System Electric Advanced

z

Input

Power

2oow
15.5 kg 160W I1 kg

Cryocooler
m

Mass Power

System Input Mass

Electric
=

C_ocooler
M

7 m

The the and predictions design

performance listed speeds were

of each above. varied

of the Engineering to provide optimum

Model

components

was and

used rates,

as a basis pressures

for sizes and

For the Baseline

studies,

the tuboexpander at the flow

compressor

efficiency

E-_J == U

temperatures dictated was used as the basis heat exchanger varied by a fixed efficiency

by the individual cycle optimizations. for the recuperator, without changes with flow rates and pressures. for all cases. The mass of the inverter

The slotted plate heat exchanger in size. I.e., the performance of the performance was characterized power levels. heat on was scaled with electric

The inverter

For
i

exchanger

the Advanced cycle, two changes were considered. First, a light weight replaced the slotted plate design as the recuperator. The effect of this modification

the predictions is to reduce system mass for equivalent was to allow for the use of an advanced turbine design could be either a turboexpander with the brake about 100 K. Either of these devices would produce efficiency, thereby reducing the cycle input power. 2.5 Component This section components place effort. Model during Phase Descriptions summarizes I to upgrade further important physical from that

performance levels. The second change with lower internal heat leak. The turbine with the generator a net gain in turbine at the equivalent result,

at 230 K or a turboalternator

and functional details status their

features about prior

for each

of the main that took of this

in the cycle.

Section

3 discusses the hardware modifications

additional

developments to the beginning in the

Section 6 describes Hardware.

will be implemented

Engineering

21

'reare
TN-508
= m :

Power

Conversion

The converted
m

compressor from

is driven DC

by a three phase voltage

induction

motor.

Power three

to the motor AC power

must with

be a

unregulated

at the bus to controlled

phase

nearly sinusoidal waveform. Figure 2.8 is a schematic illustrating the electric power flow to the system. The power conversion package consists of a voltage pre-regulator and a transformercoupled inverter. The pre-regulator has been functionally portion defined, must convert but about the hardware implementation input power has not yet been established. The pre-regulator 200 W of DC has been

==

(28 V +/- 7 V) to 28 V +/- 0.2 V. The inverter

of the package

Spacecraft Power 28 + 7 Volt-DC

_=2 W

28 +-7 Volt-DC
= =

Pre-Regulator (DC-DC Convener) Vo-+ 2% 3-Phase Transformer-Coupled Inverter 15 Volt-RMS P RMS (Per Phase)

Figure designed, frequency, harmonic fabricated three content phase with

2.8.

Schematic

Diagram

of Input the inverter

Power

Conversion DC power are to high variable low in the

and

demonstrated. A key feature simple

It converts of the three electronics.

regulated is the current from

AC.

achievement levels the inverter

of very

relatively

Because phase current

motor, the quality in reducing overall Figure transformer energized voltage motor. from signals.

in approximating electrical losses. the basic in series

sinusoidal

is important

2.9 shows

circuit

features

of the inverter. windings phase transistor

The switches

inverter

consists

of six chopped to the

coils connected The

in a ring.

The primary a three

in the coils are sequentially that supply signals AC output

the DC supply secondary pattern

by six pairs windings

of MOSFET provide on the primary

Y - connected

The timing

for the switches

side is set by logic

that trigger

22

'reare
the IR2110 by cascaded
= ,

TN-508
bridge D-type drivers that switch the MOSFET$ that are triggered on and off. by clock The signals logic from signals are generated chip. flip flop elements a timing

Inverter
v

Power

Section
Vo

(oc BUS)
IRF540

7 IRF540_L

Q6

Vo

il U
Vo2 Vo
i

Vo
Vb2

QI

Vo

Vo

Q4

Q4
i

7
J

Figure 2.9. Simplified

Circuit Diagram

of Inverter

periods.

Each of the primary voltage (Vp) waveforms is a square wave with a period of 12 clock The inverter output is constructed from these waveforms and therefore has the same

period. The inverter output frequency is thus one-twelfth the clock frequency. It is set through a potentiometer adjustment of the timing chip. Figure 2.10 illustrates typical wave forms generated by the inverter.
For fixed transformer output operation winding voltage of the ratios, there are basically are the during only two controllable DC input voltage has been and testing variables the clock by

that

influence

the The

waveform.

These

frequency.
i

motor/compressor

controlled

23

reare
manually
= =

TN-508 frequency and During and supply circuitry ratio between voltage. could In in a space voltage this way, characteristics the circuitry near and cooldown for the slip would timing

adjusting voltage.

motor/compressor and supply be modified efficiency. requirements

the inverter operation a fixed

be evaluated

as functions environment, and frequency

of frequency,

of the system

to maintain

supply

an optimum

The start sequence for the cycle.

would

also be programmed

to meet power

.................... 7 ............................................................... '................... .................................... 7 ...................................... :.................. : 1 Voltage

.................... :..,...-7".p.,,+,_ .......................................................... i........ .,,_:. _ ............... :................................................... ._q-.,_

10V/div

!
i............... i

,
_ ..................... ? ............... ","5

_
..................................... _ .....................................

"
_ ..................................... i_,i

i
.....................

':

,J_.

_,

)i.

_.,_'
w !

........................................ T............................... _.._ ................................................................_-*,._a r_-: ................................... , i

!"",..., ._f

::

i'-_,:,r" :

.................... ! ................... ;,_< ................ -k-................ ;...................................... _ ................ i.,............... ]..................... i..................... ./'i 'h i: Ii !_., _ r'i i

..................... : ........ if ...................................... '.',.=.--..................... :i: ......... :.,,.'::-! .............. ! .......... ...................... :./..i4, Current i ,' _i :i:/ _, ..'

10A/div :"._ :/ _ i............ (_ .................. :IT ................. "..................... , .................. _ ................. _? ................. ","-'.,'_'.'.' i ! ! ' ,',. r_ ! i ',,-- ./";" ........... :.,......_ ..................... _ .................... i..................... L...:'......TL__: .................... _ .................... _................... _ ........... J......_ ...................... 0,00000 s 250.000 us 500,000 us 50,0 us/div

Figure

2.10.

Inverter

Output

Waveforms

regulator testing. efficiency 200W 0.95.

The performance of the power conversion system is characterized as the efficiency of the and the efficiency of the inverter. The efficiency of the inverter has been measured in At optimum was 0.95. We've input. conditions We expect assumed corresponding a comparable that the regulation as the inverter conversion of the motor the power controller to an input level portion portion, system power of 390W, the peak measured Model at of performance on the Engineering conditioning efficiency

of the power

can be built will also be 0.90. to a

with at least The The heat due cold mounting

as high an efficiency overall efficiency from to losses plate.

i.e., the regulator

is the product

of the two components, transmitted

will be conductively

Motor/Compressor The motor/compressor converts input three phase AC power form of a continuous flow of gas at a suitable pressure ratio. The compressor is a single The part stage centrifugal machine with to useful fluid power in the

an impeller

approximately

15.24 mm (0.6") diameter. diameter that is an integral

impeller is attached of the three phase,

to a solid rotor shaft of 6.35 mm (0.25") brushless induction motor. The motor is

24

reare
TN-508 compact, possible journal external and overall bearings. surfaces the size and design speed of the The by a spiral machine shaft groove are intended to achieve acting the highest gas efficiency for the assembly. is supported gas thrust on tilt pad, bearing self acting

Axial loads are carried of the impeller.

on opposing

The useful time

performance enthalpy AC power

of the machine power. to the

is characterized The useful motor. The

as an overall is given

efficiency, input assembly

the power

ratio

of

fluid power integrated

to input electric input

fluid power major

by the product

of flow is the of

rate and isentropic electrical leakage addition generation.

w

rise of the fluid as it is compressed.

The electric losses in the

consist

losses in the motor, windage and drag losses losses around the impeller and aerodynamic to the heat of compression Since the machine losses efficiency, is impractical. of overall cycle is small, and constructed to estimate performance,

in the bearings, losses in the losses as an integral of the machine contribution

and at the clearance seals, impeller and diffuser. In to additional measurement components. analysis that heat of assembly,

of the gas, each of these The performance

contributes

the individual yield From overall

is determined of internal supporting efficiency

by tests that

and calculations

relative

the standpoint

it is the overall

that is important.

it

From the standpoint of design optimization provides guidance in design and optimization

of the machine, of the machine.

it is the

In the through heat rejection.

brassboard However,

test

hardware, design

the basis

motor/compressor for the system Model

is cooled incorporated will include

by

water

circulating for cycle of the

the housing.

The original the design

a fluid loop means

of the Engineering

for conducting

a major portion of the heat from the assembly conductively to a cold base plate. A portion heat due to compression will be rejected to a similar cold plate through an aftercooler. Recuperative Heat Exchanger

The counterflow
_I

heat exchanger

provides

for efficient

precooling

of the high pressure

gas

flowing from the compressor to the turbine inlet. Important features of the design combine low pressure losses, high transverse heat transfer between the gas paths and low axial heat transfer from the warm end of the assembly to the cold end. A further important characteristic is that no
w

organics

are present The heat have

in the assembly consists rows

eliminating

the potential thin wall rings

for contaminants stainless by steel an

from outgassing. tubes in which The disks 300 and

exchanger disks two

of two annular annular of copper slots

pairs rings

of copper each

and matching annular

are axially machined

positioned.

accurately

automated

electric

discharge machining process. Warm gas passing through the slots in the disks give up heat that is conductively transferred to the outer matching ring through the wall of the stainless tube. The overall pressure configuration losses. is designed specifically for very high thermal effectiveness with low

In the brassboard tube walls. Axial

test article,

the disks

and rings

are separate

components, during

soldered

to the

positioning

is done by means

of "dimpling"

the tube walls

the assembly Model, thin wall

process, and visually aligning each disk/ring pair as they are inserted. In the Engineering the disk/ring pairs are replaced by solid disks. The disks are separated by stainless

25

'reare

TN-508

spacers that provide structural support and a pressure boundary between the two counterflowing gas streams. The assembly is vacuum brazed with headers for the tube connections at each end. The performance of the heat exchanger is defined in terms of a thermal effectiveness, the

ratio of heat transferred between the two streams to the maximum amount possible, and pressure losses in each of the high and low pressure streams. Axial conduction and radiation from external surfaces are included in the definition of thermal effectiveness. Turboexpander Useful refrigeration turboexpander. This heat losses for the cycle is produced by expansion of the gas as it flows through refrigeration is used to cool the load and absorb heat from other end. shaft. The shaft work that is produced gas through from the expansion circuit is The brake circulates a dissipative

the

parasitic

at the cold

absorbed by a brake on the same where the work is rejected as heat. There adiabatic performance brake the circuit turbine are two important and turbine. equal that the The

characteristics heat leak. heat leak The were

that

affect

the

performance reflects

of the the

turbine, aerodynamic

the

efficiency of the would

adiabatic

efficiency

is determined

by the operating The net

temperatures refrigeration

of the in the from

and the turbine.

If the turbine of a pure

100 % efficient, expansion.

the refrigeration

produced

isentropic

machine would be reduced by the heat leak from the brake to the turbine. In the present machine, the adiabatic efficiency at design point is about 0.78. The effect of heat leak is to reduce the net efficiency of the turbine to about 50%.

overall

The parasitic heat leak within the turboexpander assembly is a substantial portion of the loss at the cold end. Figure 2.11 shows the heat leak in watts as a function of cold and

warm end temperatures for two turboexpander designs. The first (Fig. 2.11 a) gives the heat leak for the baseline machine that was tested during Phase I. Figure 2.1 l b gives the heat leak for the Engineering Model Design. The difference between the two machines is in the wall thickness of the support tube between the warm and cold ends of the machine. Model, For the tested turbine, is reduced this to thickness was 0.254 0.152 mm (0.006"). mm (0.010"). In the Engineering the wall thickness

Using about

A reduction in warm end temperature Figure 2.1 lb as a guide, if the brake by about Such it is capable concerns pads. losses 0.7 W. 20 W. a change should

can have temperature

a substantial is reduced

effect on cycle performance. from 300k to 240k, the heat in input power to the cycle Since of The to implement. or radiator consideration For this design, small, in order bearing the brake in reducing the journal the been to reduce has

leak is reduced is a circulator, total heat brake bearings shaft clearance successfully

This corresponds be relatively of 8 W. operation

to a reduction straightforward The most cold plate

of pumping is of the order the reliable type,

fluid to a separate

for rejection.

to be rejected

important

temperature surface and

of the bearings. is supported tests,

are of the self acting and tilting leakage run at speeds

in which

the shaft rotor.

on a film of gas between this type

Clearances at the turbine

in this type bearing In separate

are very

to 10,000

revs per second

at temperatures

as low as 180 K.

26

'reare
TN-508

,w

e_

,,,.,v

f'4

lla
H

(M) _l_e"l leel..I

1,I

[-, e4
,mm

e,,i

(M)),lea'l

leeH

27

'reare
3. CRITICAL A major level suitable categories: COMPONENT DEVELOPMENT focused Model. on developing These efforts the components are broadly

TN-508

part of Phase for use

I activities

in the cycle divided into

to a two

in the Engineering

l)

analyses and

and tests to support

the thermodynamic

performance

goals

of the cycle,

2)
m

developments components.

to

demonstrate

critical

mechanical

features

to

be

used

in

[]
w

The first category component level, cycle at cryogenic

includes tests on each of the four components. Some but most of the tests were carried out with components temperatures. The developments include aerodynamic

were performed at the assembled in a closed improvements to the

compressor and turboexpander, and determination of the optimum voltage-frequency relationship for the motor and inverter. The mechanical developments included work on the bearing systems for the compressor section contains section and three fabrication section methods for the compressor the development and the heat used exchanger This the tests. parts. The first describes describes about activities associated to perform with each

component. The third 3.1

The second provides

test facilities instruments

and procedures

information

and data acquisition.

Component

Testing

Inverter

The
w

inverter

used

for all tests

to date

was

developed

through

a NASA/GSFC

funded

project under development, compressor. Phase tests.

the SB1R program. Figure 3.1 is a photograph of the inverter. During its initial a breadboard assembly was built and tested with an early version of the There were no additional It was used development routinely tests modifications to drive 1000 required to this device during a broad point all closed over during bearing range of the the motor/compressor hours of use during levels

I of this program. During Phase between is 200W levels

development
= m =

and aerodynamic Its performance voltage were used

development with the motor frequency

It was also used during characterized Although

loop system

I it accumulated

approximately was well has been and slip speed.

conditions. relationships for the system These power

tests to optimize input the in excess to date

the design

power 10W the

or less, the inverter to help speed

operated

to power

of 400W.

the cooldown

of the system

and to achieve

m N

cooling power during the tests in December The only modification replacement of the potentiometer used to set frequency. Motor/Compressor

required

has been

Developments system and developments were

for the motor/compressor in aerodynamic conducted in bench

assembly performance

include of

improvements the compressor. for closed

to the loop

bearing Bearing

improvements

top tests without

the requirements

28

reare
TN-508

ld
=

|t
w

.7.-

Figure td operation.
m

3.1.

Three

Phase

Inverter

Test Article of new system impellers tests and diffusers. These with tests the entire

Aerodynamic tests were of compressor in operation.

improvements conducted

involved to support

the fabrication the aerodynamic loop and

|'!

Performance consisted cryocooler

developments. level

tests in an isolated

closed

The original radial support

motor/compressor

assembly

incorporated magnet

pressurized thrust

gas bearings to carry

to provide axial loads.

for the shaft

and a passive

permanent

bearing

This assembly had been useful in providing robust support of the motor prior to the start of this effort. The bearing space, acting bearing reliability because tilt pad was there gas also is no external bearings replaced source the of pressurized pressurized self additional groove replaced by a spiral

for the shaft during the developments system had to be modified for use in the journal The in order capacity. bearings. magnetic to improve Figure Self thrust the 3.2 is and bearings. carrying

gas to activate journal gas bearing thrust

acting

of start stop operation

and to provide

a photograph showing an impeller and shaft. The which

M

a tilt pad journal bearing, Figure 3.3 is a photograph developments and tilt angle consisted

the spiral groove thrust face for the impeller, of the compressor assembly. of spin until tests with tilt pad stability bearings

bearing

of a series varied

in

the clearances

of the pads were

the desired

and start up Final to

behavior was obtained. The initial settings adjustments are performed using trial and observe between

can be predicted error approaches

approximately with suitable

by analysis. instrumentation

and monitor shaft stability. The final settings for the tilt pad bearings are a compromise high capacity (very close clearances) and low drag (relatively large clearances). Tests to integrate to meet the spiral that groove the thrust bearing provided were the straightforward. paragraphs). necessary thrust The bearings spin No

were

designed

the new impeller

geometry bearings

(see following

Mechanical capacity.

tests were adjustments

performed to verify are required.

29

'reare
TN-508

k=_

L_

! Figure 3.2. Compressor (right) Impeller and Shaft Thrust (top), Face (]eft)

t.J

Tilt Pad Bearing

and Spiral

Groove

U
U

La

L_

Figure

3.3.

The Brassboard

Compressor

Assembly

3O

Feare
.,

TN-508

Improvements redesigning
W

to compressor hole

the

aerodynamic impeller, and The

performance developing drilled hole However, impeller

of a

the

compressor The simple was was

were initial poor,

made

by and to the the been

the desired input the

diffuser. the efficiency

assembly resulting a solid electric has

incorporated produced in excessive improve piece balancing

a drilled

impeller. and

impeller

to fabricate was designed from wire, simplifying 3.4 shows

pressure power. alloy.

flow characteristics. impeller of the new a need the

A replacement A key feature This eliminates and

with contoured

flow channels assembly, A plunged

efficiency.

is that it is machined a two piece integrity.

of titanium

for brazing structural the required

of the component machining original to show process impellers. the internal

increasing

discharge new and removed

is used to produce A portion flow passages.

flow channels. design

Figure

U
-_ d
W

[J

of the shroud

on the new

on the right

U
L_

i
i

B
l

U
14

U U
Figure 3.4. Original Drilled Hole Impeller several (1) and Bladed diffuser Impeller (r) were at several evaluated speeds,

N
I i !

In addition through testing

to the impeller

development, Tests consisted

configurations the compressor

with the impeller.

of operating

pressure ratios and flow and in air. Temperatures,

rates for each geometry configuration. flow rates, pressures and input power produced, from which

Tests were performed in neon to the inverter were recorded. A geometries will be selected

series of performance curves were for use in the Engineering Model.

u

final design

Heat []
P

Exchanger Development of the counterflow accurate heat and exchanger establishing focused new on verifying that predictive so that the

modeling

of performance

was

fabrication

methods

B
N
31

reclre
TN-508 assembly could be brazed. The first objective The was met by testing objective at cryogenic was met through temperatures design and during tests of the entire cryocooler subcomponent braze experiments.
w

system.

second

The
w

test article annular (0.14") the were it was This

used

in the brassboard using of slots There that the was that

assembly Figure Each

consisted

of copper

plates 0.13 annular

and

stainless pair This The vibration could rely be on

tubes wide

that are soldered the two had and x 3.5 mm

together rows long.

soft solder. in each. assembly

3.5 is a photograph slot is approximately 1000 slots in each was strong Model fairly

of a disk/ring row.

showing approach

mm (0.005")

are approximately process not sufficiently all contaminants Engineering

advantage difficult

straightforward. launch the that flux) would from

disadvantages loads,
N

that the assembly to assure a redesign

to withstand hardware

(primarily

removed.

prompted

for the

vacuum brazing. Thus, would have the required

!

contaminants could be baked out at high temperature, and the assembly strength. The new design incorporates stainless steel spacers between the stainless steel tubes and disk/ring pairs.

copper

plates

replacing

= W

L_ W

II
lml

I
l

U
W

Figure

3.5.

Disk/Ring

Pair For Brassboard

Heat

Exchanger

_m m

32
m

@reare
TN-508 Several Generally, series of braze conducted trials were performed cleaning on plate and spacer subassemblies. braze materials, the trials were to assess and preparation methods,

temperatures and the effects of changes in geometry on the integrity of the brazed joints. Braze integrity was assessed by tear tests and helium leakage testing. These efforts were successful in finalizing a suitable Tests cryocooler the
w

configuration

and fabrication model

methodology. exchanger were performed assembly information recorded with of the full in rate, to of

f_ ::3

to verify loop

the predictive at various the with

of the heat and

system

operating

conditions.

The heat exchanger compressor. provided Test data all the were

was installed flow necessary for a range

brassboard

turboexpander

Measurements

temperatures

and pressures

at the inlet and exit ports of the device.

accurately characterize flows and temperatures Turboexpander

the performance down to 35 K.

Tests

were

performed

with two turboexpanders.

The

brassboard

turboexpander

had been

designed for roughly 8 W capacity at 65 K (thus accommodate heat exchanger ineffectiveness).

u

providing about This machine

5 W to the load and 3 W to was tested with two brake

diameters and over a range of brake temperatures. capacity of about 5 W was tested at lower flow rates turboexpanders were data in the tested at temperatures cycle. Fluid from lines performance conducted were closed obtained loop for temperatures

A second, smaller turboexpander with a to assess the cycle at different loads. Both 300 K down 70 warm K and and to about 35 K.. cold end 35 K All of each Detailed tests were of the between at the

about

turboexpanders were readily adaptable is a photo showing the turboexpander

to the flanged tube connections in the facility. Figure 3.6 housings and the two turbine shafts. The machine on the mm diameter rotor.

left has a 2.38 mm diameter turbine rotor, the one on the right is the 3.18 The fittings on the housings are for warm and cold end tube connections.
w

modeling

These of

tests were primarily aimed at obtaining more to be used the turbines and to provide corroborative data about The data were then used to upgrade

to verify aerodynamic heat leak within the models for the

turboexpander assemblies. turbines and for the cycle. Closed Loop Brassboard

the performance

System

Tests

system

In addition to meeting the objectives tests provided practical operating

stated above at the component experience with the system.

level, the closed loop The system includes

instrumentation and controls and controls so that pressures, performed assessing behavior the relative of the system. impact

that allow for detailed characterization of each of the components flow rate and temperatures could be varied widely. The tests were goals of documenting in individual describes individual component component performance performance and controls. and of variations on the overall

with the complementary

The next section

the facility,

instrumentation

33

@reare

TN-508

|i

Figure

3.6.

Turboexpander

Housings

and Two Turbine

Shafts

3.2

Facility Three

Description series of tests were performed with the brassboard facility. The first series,

r...a

performed compressor, (0.22") conducted series took

June heat

9-12, 1992, provided data on the exchanger and the 3.18 mm (0.125") brake over a range 1992. of temperatures performance The 3.18 mm 1992, provided

steady state operation diameter turboexpander and data inlet pressures. was The again for the 2.38

of the inverter, with a 5.59 mm second The tested, series, third with a and were or state

diameter place

in September

mm turbine.

in December

turboexpander

reduced diameter brake wheel and at higher configuration was the same for all of implemented was
m

system loads. The facility's primary components the tests. However, several modifications series of tests. The of the most important with of these liquid the cooldown system nitrogen

between

the first and second for assisting capacity

changes

to include

a provision affected

helium,

due to the decreased

of the 2.38

mm turbine

compared

to the 3.18 mm turbine. at steady

These changes conditions.

N

only the cooldown

rate, not the performance

of the cooler

Test Facility
L_

Figure These
i

3.7 is a schematic include gas in the the power management, system

showing control and

the

primary the

systems compressor, and data to these

in the brassboard turboexpander, acquisition

test

facility. The system

systems exchanger, fluid

system, In addition

counterflow

heat

instrumentation

subsystems. a vacuum

working

is neon.

components,

34
u

'reare
TN-508
i

maintained
w

the

integrity Figure

of the vacuum

vessel

in which

the heat

exchanger

and

turboexpander systems.

were installed.

3.8 is a more detailed

flow diagram

of the facility

and support

Gas

Management

j o res,or [._____.__. 1 1
Power
I

!-

"--_4-

....

"L

!'

'
!

Conditioning

, i
I
neon gas .... instrumentation "-- - - electric power
m

Exchanger "" "I Data ,, 1 I# "ea'I 1-I I ['" Acquisition

,
I
l ........ Figure 3.7.

iturbine

l-

i
_Vacuum Vessel

Generalized

Test Facility

Schematic

H
i

Power

Conditioning

i t & i

The electricity

power

conditioning could

consists

of the equipment

necessary

to convert

110 volt 60 Hz supply converted

to a form which

be used to drive

the compressor.

A DC power

t 1 E_ J

_=-=__

wall electricity to regulated DC power to drive the inverter. A Sorensen model DCR 40-25B2, rated to 25 amps, 40 volts was used for most tests. A Hewlett-Packard model 6269B rated at 50 amps, choice 40 volts was substituted for a short interval to allow of power supply has no effect on results of the tests. for repairs to the Sorenson. The

The other inverter converts As configured Gas Management

component the direct

in the power current testing,

conditioning phase the frequency

system which

is the rotating

field

inverter.

The

to a three

signal

is used to drive

the compressor.

for the brassboard

and voltage

were set independently.

= = r_

The gas management system decontamination of the gas, isolation pressure control during testing and

allows for purge and fill of the cryocooler of sections of the facility for replacement the bypassing of flow during flow cooldown loops

and test loop, of components, subsystem for all

or during

testing. In general this system incorporated valves and extra operations except steady state testing at design point.

that are required

35

@eare
I >

TN-508

J_i

ra_

L. = .m

=--'-4 GO1

.J Ld

2>

O O m z=

36

'reare
The accumulator pressure. accumulator. pressure constant also neon
m

w- 08
system tank is initially is included the system system flow supplied with neon from a gas cylinder. outlet used The A three gallon into the to the low relatively system leakage exposed of to in the circuit pressure pressure The cooldown circuit. during to provide gas from control a volume for use in regulating is bled back the system

When side

is high, gas from is low, pressure

the compressor the accumulator system was

is pumped

When of the make

to maintain management

system

pressure

and warm

up of the system. for a small portion

provided

up gas to the system The leakage in the vacuum made vessel

to compensate in the warm was sealed

but continuous levels. control

out of the system. The tubing Provisions

occurred

of the flow circuit

ambient.

to high vacuum circuit

were have

with a compressor flow rate. flow rates. the bypass

bypass

to permit point, and

of flow mm turbine

to the and

turbine
m

independent

of the compressor matching requires through fluid Ultra-high contaminants.

At the design

the 3.18

the compressor mm turbine,

For off design by means

operation, flow. of a manually

for tests with valve. were used

the 2.38

the turbine

less than the full compressor circuit

A portion operated of neon

of the compressor

flow can be diverted The brassboard system

m

working testing.

in the purity

system Research

is neon. grade neon

Two was

grades used

during in the refill

neon was used for the initial

stages

of purge final

and refill purge and

to remove

for the

stages, remove flowing

and for the tests. A commercial cryogenically condensable contaminants from the neon through the cryogenic adsorber that will is cooled condense Contaminants exchanger charcoal,

cooled charcoal bed adsorber was used to after initial purge and refill cycles. Gas to approximately this 77 K (liquid do nitrogen so in the at or above temperature

temperature). adsorption heat bed of activated onto the surfaces for the circuit. first

and are removed where contaminants charcoal prior of cooldown

from the gas stream. The gas also flows through a not condensed in the heat exchanger are adsorbed The gas was circulated The adsorber was through then the adsorber from the to testing. isolated

of the granular

particles.

few hours

The The precooler stainless the tube

:

facility tubes

includes together upstream which

a precooler along their

to assist length.

in speeding During

the rate of cooldown heat exchanger made of the precooler, flows

of the system. by brazing a fraction then returned two of to

consists outlet

of a vacuum flow is directed is open

jacketed through

counterflow

steel

operation

the compressor
w

one of the tubes Liquid nitrogen The

of the precooler, or helium is isolated

main

flow just

of the turbine.

through from

the other the system

in the precooler the desired System The

to atmosphere. is achieved.

precooler

when
w

system

temperature

Vacuum

contained components within

portions of the cryocooler within a vacuum vessel are also wrapped vessel

and facility that are subject to reduce convective heat insulation temperatures. to reduce The

to cryogenic leak from radiation main

temperatures are ambient. These from the surfaces are involved

in multilayer

the vacuum

that are at ambient

components

37

'reare
the heat exchanger, the turboexpander facility, vessel showing and load. Figure 3.9 shows a physical within (36") in and such view end of the cryocooler The cylinder within. passthroughs Buna-N vacuum gage. Vacuum
i

T - os
of the cold vessel. steel the arrangement (12 inch) sealed with were ports of components 91 cm support for power box, O-rings the vacuum long flanges. as for the stainless

vacuum Tubing rated

is a 30.5 cm were

diameter Buna-N used

with

a flanged for

top plate 10 -8 torr used to seal

that provided or below the other

structural

for the components instrumentation

mounted Electrical leads. ionization

passthroughs were

O-rings

on the cold

inside consists was pump was

the

vessel

was

maintained pump, pump, HS-2,

at

10 -5 torr pump, 2012A,

or better

during

testing. valve.

The The

vacuum roughing The

system pump

of a roughing a Varian

a diffusion model with

and a high vacuum with a capacity of 285 liters

an Alcatel

direct-drive model pump

of 11 ft3/min. valve

diffusion

a capacity

of air per second box was

from a pressure was collar Cold

of 5x10 -4 torr or less. the diffusion pump

An Airco-Temescal effectively. the pumps

2 inch sliding A 2.5 inch (6.35

gate high vacuum in the cold cm) vacuum

used to isolate

from the cold box when

the pressure

too high for the diffusion

to operate

port on the

of the cold box was used to connect Load Load Heater on the cryocooler

to the cold box.

"--2 E

at the cold end was controlled

and simulated

with a model

PFO-6

Hotwatt heater, over a heating potential Heat

rated for 400 watts of heating at an input element which is enclosed in stainless of the gas.

voltage steel.

of 120 volts. The neon passes The enclosure eliminates the

==

for contamination System

[]
i

Rejection Heat

H
w

is rejected

from the cryocooler

at the following

warm

locations

of the system:

Inverter Motor/compressor Compressor Turboexpander The inverter housing, brake. was kept at nominal motor/compressor gas from the ambient housing compressor The tube was temperature was cooled cooled by a muffin by water in a commercial in the brake was fan mounted through shell and steel. removed above passages tube from the in heat the

gas, and

t==a

circuit the

board.

The The

flowing

housing. using

exchanger

using

water

on the shell side. shell and 290 K, flowed

heat generated

B N
m u

gas

commercial

heat exchanger

constructed

of 316 stainless

House

water,

at approximately

on the shell side, with the neon

flow on the tube side.

38
w

reare
r L =

TN-508

Nil TOP
. 7

L=

---HEAT
1=====UI
= =

EXCHANGER

- --TURBOEXPANDER
w

DIFFUSION 6 MICRON

PUMP --1
/ /

FILTER---"

- -------COLD - --'----HEATER
/

TRAP

--

---VACUUM

VESSEL

/
f B

INSTRUMENT (TYP)

TEE J

Figure

3.9.

Brassboard Insulation

Test Facility has been

Cold End Omitted)

(Multilayer
B

Tubing,
m

Connections The tubing, Inside either or indium

and Valving connections and vessel, joints valving primarily or with components leakage. used flanged vessel in the static test facility fall into two general

categories. were made O-rings

the vacuum with seals. The and there a welded

316 stainless

steel tubing connections passages

was used. sealed from new

Connections with a Buna-N for vessel materials

All tubing cryocooler

in the vacuum

was assembled

the brassboard were leak tested,

tests.

and flow

within

the vacuum

was no detectable

39
i

TN-508 Tubing exposed to ambient conditions outside the vacuum vessel consisted primarily of

copper tubing. Connections as Swagelok . Ball valves,

were typically needle valves,

made with metal to metal compression fittings, such and regulators used for control of the facility outside for high vacuum service. which were considered to

the vacuum vessel were generally The plumbing outside the vacuum have Filters a negligible impact

commercial quality, not intended vessel contained some small leaks, of the system.

on the operation

Two system.
m

filters Each

are

installed upstream

in the test

loop

to trap steel

particulates mesh elements

that

might

remain

in the

One

is located

of the inlet to the turbine stainless

and one is upstream

of the inlet to the cylindrical

compressor. assembly. Cycle Cold

consists

of 6 micron

in a welded

Trap experimental pressure by the counterflow upstream stream to the low pressure heat exchanger was exiting was inlet. diverted from installed A small through the turbine. in the described at the portion this cold cold This facility end trap. design was of the 7 %) of The was more

A small system the flow cooling relatively effectively to freeze was

out contaminants

of the turbine turbine stream

( about

in the high provided ineffective controlled

in removing by bypassing

contaminants. flow through

Contamination the cryogenic adsorber

above.

Test Procedures

Each stabilization, Next, cleaned isolated the using from

test steady

series state was

consisted tests, started

of

several gas

phases: The circulation.

system was The after

cleaning, first gas the flushed

cooldown, with facility cooled clean

thermal neon. then was by was solely

and shutdown. to begin The

system began

compressor

in the was

the cryogenic the flow circuit. For tests In general,

adsorber. During

cooldown

cryogenic

adsorber

tests performed

in June

the system

the turboexpander. cooldown process. reached. external Because thermal thermal the facility

in September and December the precooler was used to speed the cooldown continued until a target temperature at the cold end was was allowed refrigeration of the heat to stabilize. to cool all exchanger, performance state During cooldown, components inside this component of the heat constant were tests were was the the the turbine vacuum slowest was Once and and the vessel. to reach important, until was the steady

Then the system precooler provided of the thermal equilibrium. was allowed equilibrium mass

In tests where to operate was reached.

detailed Then

exchanger

for 6 - 12 hours the steady the turbine temperature.

at a nearly

cold end temperature performed. the system

state test matrix allowed to warm 3.3 Instruments Two detailed types

was completed, slowly to room and Data of instruments of the cooler

and compressor

stopped,

Acquisition were used in the facility: precision instruments and instruments to measure to support

performance

and of the individual

components,

40

'reare
the operation of instruments of the facility. with important Figure 3.8 shows the location of each. of the instruments. Most performance Table characteristics measurements the basic recorded automatically of the data acquisition with a 386 personal computer. system and associated supporting Figure 3.10 shows equipment.

TN-508 3.1 is a list were

configuration

Software data. current one hour of screen Each the parameters

based were

on ASYST was was scanned once frequency to provide

used a minute were

to coordinate and its value manually recording Turbine

the reading

and

recording inverter

of the of for set DC input

instrument

was then recorded. speed, Data every files were half hour,

A majority recorded a reduced

recorded In addition

by the computer. to the automated

and compressor entered. of data

and voltage, intervals. parameters

and inverter were printed

a hard copy record.

Temperatures
i

Two thermometers
= ,

types of instruments were used for temperature (PRT's) were used to record all performance also used for the heat exchanger were used for the remainder for measurements K range. temperature The Their PRT leakage temperatures of the temperature at the turbine high accuracy elements

measurements. measurements measurements. they

Platinum resistance inside the cold box. Omega Type

They

were

just outside

the cold box.

T thermocouples

PRT's were other heat

m

used end

because Figure 3.11

are more how holes

sensitive the PRT's board

than for the were with

sensors exchanger

in the 65-70 warm tube

also accounts

for their selection shows mounting

measurements.

installed thread board. board wire

within The

sections. The electrical path

are attached are threaded

to a G-10 through

and shellac. primary to the end, is used has

leads for each PRT sides,

in the mounting of the mounting where A very of the the sensors fine gauge board to the mounting

for heat

to the sensors and back is along path from

is through down the base along the electrical

the center leads. edge

along

the end to the outer this effect. The

to the point

are attached. sensor board.

The secondary to minimize been eliminated

path for heat leakage direct the by removing

of the mounting

connection

the outer

Pressures

Performance addition, of valves. system the volume The was performed output pressure These which pressure measurements before

measurements gages valves were allowed

of pressure included information. isolation the piping gas circulated calibrated units. in

were the Each

made

using as

pressure for

transducers. critical the cleaning pressure

In

facility, transducer

backup

and for operational testing,

and gage was installed during instrument,

with a set of the minimizing

of the pressure leading through over

instruments to the pressure

or flow through

did not have clean transducers value

it prior to testing. desired ranges. A least to convert squares fit

were

their

on the calibration

data in order

to generate

a linear

equation

the voltage

to the desired

in engineering

H
i

41
n

_reare

TN-508

L L w

=__ w

@
om

_m

II

42

'reare
Table ID PI P2 P3 P4 P5 P9 PI0 PII Pg6 dPI0 dP! 1 dPl2 dPl3
L

TN-508

3.1

Instruments

in the Brassboard TYPE PRESSURES Rosemount

Omega

Test Facility [ RANGE 0-15 psig 0-25 psig 0-25 psig 0-25 psig 0-15 psig 0-25 psig 0-25 psig 0-25 psig 0-30 psi 0-10 in H20 0-30 in H20 0-30 in H20 _+30 in H20 0-100 in H20 1-10 in H20 30'-625 K 30-625 K 30-625 K 14-325 K 14-325 K 75-475 K 75-475 75-475 K K ACCURACY 0.0375 0.0375 0.0375 0.0375 0.0375 0.0375 0.0375 0.0375 0.025 psi psi psi psi psi psi psi psi

LOCATION Compressor Inlet Compressor Exit Flowmeter Inlet Turbine Inlet Turbine Exit Nozzle Exit Bypass Flowmeter Impeller Exit Brake Exit Bypass Flowmeter HX Low P Side HX High P Side Turbine Turbine Labyrinth Seal Brake Flowmeter Inlet

Omega Omega Rosemount

Omega

Omega Omega Helicoid Gould Gould Gould Rosemount Rosemount Gould TEMPERATURES

in H20

0.075 in H20 0.075 in H20 0.15 in H20 0.25 in H20 0.025 in H20 1.0C 1.0C 1.0C 0.07C 0.07C 0. I0C 0.1 lC 0.11 C 1.0C 0.10C 1.0C 1.0C 3.0C 3.0C 1.0C 1.0C 3.0C

dPl4 dP 15

Compressor

TI T2 T3 T4 T5 T6 T7 T8 T9 TI0 Tll T12 TI3 TI4 TI5 Tl6 T17

Compressor Compressor

Inlet* Exit Inlet

Type T TC Type T TC Type T TC LS PT-I ll (2) ** LS PT-111 (2) LS PT-111 LS PT-111 (2) LS PT-I 11 (2) Type T TC LS PT-111 Type T TC Type T TC Type T TC Type T TC Type T TC Type T TC Type T TC

Compressor Flowmeter Turbine Inlet Turbine Exit HXLoPSide Inlet HX Lo P Side Exit HX Hi P side Inlet Cooling Water HX Hi P Side Exit Turbine Brake Return Turbine Brake Cold Trap Turbine Turbine Housing Brake Housing Inlet

30-625 K 14-325 K 30-625 K 30-625 30-625 30-625 30-625 30-625 30-625 K K K K K K

Bypass Flowmeter Bootstrap

NOTES: Compressor June tests. at the inlet to the impeller during September Inlet Temperature located in tube upstream of housing for

Inlet Temperature measured and December Tests. LS PT-111 #111. refers to Lakeshore

platinum

resistance

thermometers,

part

43

reclre
Mass Flow Rate

TN-508

Flow

rate in the test loop was measured

using Flow-dyne

venturi

type flow

meters

at two

locations: the compressor outlet each meter's inlet and the pressure During
w

and the turbine bypass loop. The pressure and temperature at drop across each meter were used to determine the flow rate. for the 3.18 the cooldown mm turbine, phase no flow through the bypass loop adsorber through was is a

parameter

testing During

permitted.

During

this period, a fraction

the measured

flow rate at the compressor of the tests, is bypassed when flow around

outlet

is the same

as the

flow rate to the turbine. not in the flow loop,

the cryogenic the turbine,

of the compressor

throttling valve and back to the compressor inlet. For this reason, it is necessary the compressor output flow and the bypass flow, as the flow to the turbine between the two.
u

to measure both is the difference

PRT

G-IO
U

MOUNTING

BOARD

.....

ill

]ca

TuBEri
I

.L J_
.1

Figure

3.11.

Mounting

Detail

for Platinum

Resistance

Thermometers

44
u

'reare
z._

Turbine

and Compressor The rotational shaft shaft

Rotational

Speed and compressor ground were between in the measured the probe measured using capacitance probe in As An

speeds there passes

of the turbine is a small the probe,

probes. the wall the flat

i

On each on the

flat surface there

on the shaft.

A capacitance

of the housing

is used to measure

the capacitance is an increase the speed where

and the shaft. capacitance.

amplified signal is sent to an oscilloscope, "spikes" in the voltage signal.

m

is determined

by the time

between

Inverter

Power The inverter power is determined by measuring voltage the DC power supply's was output measured the voltage The voltage power, with a drop was

calculated
f 3

as the product 3478A volts, resistor,

of the measured Multimeter. also using and the current

and current. was determined

The voltage Multimeter.

Hewlett-Packard across a precision to 0.01 Heater heater measured

The current

by measuring

a Hewlett-Packard was measured

3478A

to 0.01 amps.

F_
m

Cold

Load The

Power power The was calculated using as the product precision of the heater power drop supply across voltage and signal

current. resistor,

The voltage

was reduced current

resistors

and read directly the voltage

as an analog

by the computer.
J

was determined the current.

by measuring

a precision

and then calculating

Vacuum
m

The pressure is equipped

i

level in the vacuum therrnocouple gage

vessel tubes

is measured measurement. Unit's display

with a Varian rough vacuums

Multigauge

System.
and

It a are

with

to measure

(> lxl0 -3 torr) of the vacuum

Bayard-Alpert recorded

Ionization

tube for high vacuum Multigauge

Measurements

manually

from the Varian Control were and input The would

onto the data sheets.

F_ m

3.4

Contamination Specific

procedures to assembly provided model. if present,

implemented during the

to

control program intended

contamination E91. The for for contamination long

in

the

brassboard gained from in the where

INi

cryocooler Phase engineering contamination,

prior

the testing model is

experience term

I also

to define engineering

requirements

control testing facility.

be more troublesome

than in the brassboard

H
m

cleaned

Fluid lines and fittings (elbows, tee and cross junctions, flexible tubing and flanges) were using paper wipes and isopropyl alcohol (IPA) and blown dry using nitrogen gas. The aftercooler, brake heat exchanger and flow meters were cleaned by rinsing with IPA to remove employing parts during

compressor
m

and dried with nitrogen. Valves in the flow loop were disassembled and cleaned grease and other contaminants from internal surfaces. A two-step process was used IPA were in an ultrasonic cleaned bath, followed prior by deionized to minimize water rinse and air drying. immediately to use the possibility for recontamination

In general,

45
m

'reare
storage residual and handling. used The in the heat vapor exchanger reflow was soldering rinsed thoroughly This using cleaning IPA solvent process. step was several times was circulated Completed separate prior

TN-508 to dissolve the

repeated

until the effluent from the heat exchanger was visibly clean. Heated nitrogen gas through the heat exchanger to dry it and to remove any loose particulate material. such as the turboexpander facility. and compressor and were particles filters were stored tested were previously packaging in the installed in They were removed from these test setups Particulate to eliminate in clean

subassemblies facilities.

to installation

in the brassboard

(6 micron)

inlet lines of the compressor Prior

I t = m 1 -

and the turboexpander

from the flow. neon gas and the gas to remove to dilute system. grade facility neon most the This and and the cleaning that the had of

to the start of testing, a cryogenic trap.

the flow loop was filled This involved evacuation purity (UHP) to about which cycles,

with high purity to about neon to about the

was

run through air.

50 millitorr

of the air and then backfilling residual through fill/vent three gas was procedure pressure reached which behavior The system gauges was pressure and pressure process

with ultra-high transducer for a total grade

15 psig the

was then reduced fittings of eight neon. Flow

i psig by venting air from with five times

gas to atmosphere

purged

repeated

UHP

times with certified

research

was started

in the brassboard

cleaned using a liquid nitrogen cooled charcoal was implemented following the first cooldown drop about across the turbine rotor increased pressure when could 240 K and the differential This experience at low temperature after the cryogenic were extracted I. Samples from were vapor,

adsorber. This additional test. It had been observed the turbine exhaust following a brief This

temperature warm-up

= I

be restored presence the flow

only a few degrees. was freezing disappeared Gas testing samples

indicated

the possible

of contamination

in the gas, anomalous

and restricting cleaning

in the turbine.

step was introduced. loop several solvents. After times during the course was of the found it

the flow

program about

in Phase including

sent to an outside

laboratory

for analysis freeze

of possible out problem bottles

contaminants to contain

air, water

IPA, and other about indicated were returned 42 K.

One set of samples a potential further sampling at the time the standards and new could

180 ppm by volume at temperatures that the gas though

of nitrogen. below contaminated

This represented by the

for the turboexpander was were grade. determined filled, The even

and analysis, the gas for research be directly

had been

supplier

the certifications gas cylinders

that the gas met to the supplier

contaminated

gas was obtained

with verified certificates attributed to this nitrogen

a

of analysis. No affect contamination. gained in contamination in the could design outgas and

on turboexpander

performance

N The will solder Cleaning processes tubing feasible. contaminants Gas have flux Fabrication experience a direct methods, compounds control operation have the for the Phase of the gas been I brassboard to eliminate long-term test model facility cooler. braze and testing. benefit engineering altered during

particularly which

for the heat exchanger, into fittings and other eliminate the use be polished procedures

process

techniques for lines, were defined which used in the filling cooler and fittings

components were developed and new cleaning of CFC-based and alcohol-based solvents. All the tight potential for surface-absorbed bakeout will be on gas to so that vacuum access

will

to minimize and vacuum were which

will be metal-sealed

and cleaning

also developed will allow

that will be implemented to the process

the EM cooler and sampling ports will be installed determine contamination levels at any time.

46

'reare
4. TEST This components turboexpander was to obtain over a range employing at lower RESULTS section at the detailed presents system 1992 the results level. The and without :_nd loads. turbine. capacities. turbine. speeds. Turbine to obtain was system performance over a range system data of the three first series supplemental The second These The These third series was of tests performed with The objective with

TN-508

brassboard diameter

performed precooling.

a 3.18

mm

in June

of this series components 1992 to speed data used

performance

measurements A special

on the system series was precooling

and the individual performed additional was carried was out

of temperatures a 2.38 mm diameter to steady and

in September performance brake

heat exchanger

the rate of cooldown flow rates and

state conditions.

tests provided test series

cooling turbine

in December at lower

1992 with the 3.18 mm diameter temperatures 4.1 June at higher

tests yielded

data with the turbine

1992 Tests

- 3.18 mm Diameter

The objectives 40 K, and to obtain rates and characterized components l) for temperatures.

of this first test series were accurate performance of these data Each objectives

at 65 K, and flow well was

for the components met.

of pressures, behavior

Overall

cold end temperatures

from 300 K to 37 K.

The performance

of the individual

was also well documented: relationships between compressor speed, pressures, temperatures, flow rate and input

power 2)

were established, thermodynamic providing thermodynamic speeds performance corroboration performance and pressures. was operated present successfully selected which data for about from this 60 hours test without incident. of raw data Finally, (in data a of the heat exchanger models, and was defined for a range of at design temperatures was

measured, 3) the

for predictive of the

turboexpander

temperatures, Furthermore, The engineering are then few selected The complete from

the system following units)

pages

series. vs. time.

Plots Plots

are first presented in combinations are tabulated power,

in the format for detailed load, heavy

of parameter discussion

of reduced

presented

are meaningful

to performance and analysis. exit

assessment.

data points electric input

cooling 4.1. The

and turbine

temperature is about

are

shown

for the the

60 hour test in Figure

solid line is the temperature temperature

of the gas at the exit 260 K, reflecting until Input the turbine power (the Cooling at the

the turbine

(at the inlet to the load).

The initial

fact that the data acquisition system did not actively begin recording exit had been lowered to this temperature during initial gas cleaning heavy dashed line) is the product of DC voltage and DC current capacity, or load, is the light solid line. This value is the difference

information operations. between

supplied

to the inverter. the enthalpy

47

'reare
TN-508 6OO

500
m

-_'

400
dr

,oo
zoo
100 load tem )erature 0
=3

o
Q..

-_-

0 0 10 2_0 30 time (hours) 40 50 60

Figure turbine parasitic

4.1. exit

Brassboard and

Cooldown

and Steady end

Test Matrix recuperator.

- 3.18 mm Turbine This load

- June

1992.

at the inlet

to the cold of tubing

of the

therefore

includes heat

heat loads

to the section

between

these components

as well as the electric

load to the heater. The parasitic heat load was about 0.6 W for this test series, mostly because of 0.5 W of conductive heat leak through the power leads to the electric heater. The data omissions in the figure reflect periods during which data were not recorded. The initial at about increased the system. beginning (the rated supplied). exchanger. 37 K. to 7750, This cooldown Just prior then 8000 is reflected phase took about 24 hours. to raise in power The turbine the pressure to the prudent exit temperature the compressor for the power leveled speed off was

to the leveling revs/second

of turbine in order

exit temperature,

ratio and flow rate through 8 hour period input to the system

as an increase

system

in the 20th hour.

This was felt to be the maximum

power for the motor and inverter are approximately half The high power was continued to complete the cooldown The intent was to reach measure thermal of the equilibrium thermal an accurate effectiveness

the 400 W that was being of the cold end of the heat in of this component at low

at the cold end of the heat exchanger

order to obtain temperature.

plotted pressure

Figure 4.2 illustrates the thermal stability at the cold end. Two temperature differences are in the figure showing the behavior at the warm end of the recuperator and the cold end as of time. streams The solid curve is the temperature difference between difference the high and low at the warm end, the dashed line is the corresponding at the cold end.

a function

48

'reare

TN-508

: ., ;''E

i'-o', c
,.i

! :

----oF hx warm end AT :old end AT .....

.................. _ ................... :................... _ .................................. --.o-.-hx

4
U
o

...:...., ........ _................... _................................ _.,..._ ................... ,................... , ................... _................ --{

', ,'

" "iq

I--

<3

i 'o,-! ......... ...... .--

................. i................... i................... i................... i................... i................... i................... i................

J
40

-2 5 10 15 20 time (hours) Figure 4.2. Temperature Differences Between the High and Low Pressure During System Gas Streams at 25 30 35

the Warm

and Cold Ends of the Recuperator time of t = 28 hours, stability in the loop. the

Cooldown. remain between was nearly the end 4.3

At an approximate constant, indicating reflect reflect through thermal two "curves" the differences and radiation

two temperature to that time, After

differences the differences stability

Prior

the cooling parasitic

rate of the heat exchanger. heat leak in the recuperator insulation surrounding

thermal

achieved, Figure

due to conduction

from the warm

the multilayer

the cold end components.

illustrates this approach to stability in terms of the thermal effectiveness of the heat exchanger. Thermal effectiveness was calculated for each set of measurements from real gas properties using the expression that the thermal = 28 hr. speed about given in Appendix clear I - Definitions was of Performance levels reaching to operate thermal without Parameters. greater changes equilibrium, The figure shows t for effectiveness and of the heat exchanger that the system was allowed out at just than 0.99 at about

As it became

the compressor in conditions

was reduced 12 hours. A series

the system

of "steady primarily data under

state"

tests were then performed. at t = 43 hr. obtained during

These

tests were conducted of the tests was loads were (such

over

a 17 good for

hour

period

beginning data

approximately points relatively to a desired were

The purpose over a range the That 17 hour

to obtain recorded

performance speeds. each speed)

for the turboexpander steady conditions.

of temperatures, period. Data parameter

and turbine as turbine

Eighteen was changed

test point

is, a system (such values.

condition.

Key parameters steady

as turbine

and heat exchanger

temperatures)

were then monitored

until they reached

49

reare
TN-508

E >

0.95

_,
B rLJ X

0.9

0.85
..E

0.8 0
I

10

15
time

20
(hours)

25

30

35

40

Figure

4.3.

Thermal

Effectiveness

of the Heat Exchanger

during

Cooldown

This

In general, temperatures at the inlet and exit of the is because of the low thermal mass of the turboexpander reflect exchanger for each the performance made test. Many of this machine. of the "steady state" it too time consuming to wait

turbine stabilized relatively quickly. assembly. Steady state test results hand, the large thermal end mass of of for the cold of this

accurately the heat component

On the other results yield

for equilibrium

optimistic

characterization

the thermal effectiveness steady state performance recorded thermal results.

of the heat exchanger. However, of the heat exchanger - Test 15 hours exchanger recorded

two critical tests accurately reflect the J1 and Test J12. Test J1 data were temperature. The on the measured 63 should 5.1) and

after approximately inertia of the heat Test 12 data were

of steady operation at the same low end after this period of time had no effect had been (listed the effects of thermal mass

after the cold end of the cycle measured performance 5. for discussion. in Table 4. l, which

at approximately in Table

K for 3 hours.

For this test condition,

of the heat exchanger

be negligible. A comparison between the predicted behavior was excellent. See Section Steady state test results are summarized

gives

measured

parameters

at only The

several locations in the cycle. However, because of the thermal mass a few of these test conditions can be used to accurately characterize data are more useful in documenting the performance of the individual The temperature, first six columns rate, and list the pressures voltage at the compressor,

of the heat exchanger, system performance. components. the inlet

compressor From

the flow

the electric

and current calculated

to drive (column

the compressor.

these data, overall

power

train efficiency

can be directly

7) for each test point.

5O

reare
Overall electric heat load values, input efficiency the value power input train power efficiency point. To is the ratio Under of work for an isentropic compression thermal (see Appendix varied I). Column steady 8 lists the calculated conditions, that erroneous effectiveness exchanger should temperature power. for each have for the full range effectiveness between pressure 15 and 16. system ratio,

T - o8
to the actual of the (at a these and net of tests encountered, 0.993 from speed, differs rotational

from 0.991 will give

(at a load temperature the tabulated relations

near 40 K), to about

of 65 K). Columns

the extent

the corresponding and calculated

tests

refrigeration

9 - 14 list turbine heat leak.

inlet temperature, in columns

Gas temperature are given

at the exit from

the load heater,

and system

load (including

the 0.62 W parasitic)

Data for the performance of the compressor and motor during these tests are limited to the 18 test conditions listed in the table. Overall, the power train efficiency varied from about 0.27 to 0.30 gave conditions. modifications during these train Later tests. efficiencies design. for these The tests was to establish purpose was to verify design the performance the point. relationship the 4.4 are Figure Separate tests using as 0.31 show other for combinations the same train of impellers motor under efficiency and diffusers test by power as high comparable is improved

tests on the compressor

that the power

to the motor earlier,

As noted of the between diameter summarizes efficiencies plotted turbine efficiency

one of the key objectives over a range of conditions. coefficient during leak

turboexpander of the brake turbine (corrected

and speed wheel performance

for the turbine. best efficiency the steady

This information at the turbine

is used to establish and aerodynamic the heat

that will yield

state tests. in Appendix with

Net efficiencies I) for each speed during that once

for heat

as described

of the test points is well 0.77

as a function is properly shows

of the speed accounted

coefficient

u/c 0. The plot shows in efficiency efficiency obtained

leak to the defined. at u/c 0

for, the trend

coefficient

The plot also = 0.63. The design 0.52. cycle point.

that as the maximum

tests was about

conditions

for test

point produced

J7, seen was 0.51,

in Table

4. l, correspond

closely

to the

system of 65 K. of

Net refrigeration in Section

by the system

was 5.9 W at a load temperature aerodynamic to improve will be used

At this condition, Discussions efficiency

u/c 0 for the turbine 5 explain by modifications

with a corresponding

efficiency

how this information

the overall

to the turbine.

51

'reare
TN-508

H w

e_
u !

_-_n Ilm

=m m

[,-,

52

'reare
80%
u o o

TN-508

I
t3 i_

70%
o d
1311

o o 4Oo

0 ,O._a " o. ........................................................

;............................

tO

60%

i ............................. + .......... o

net

efficiency

(J 4.--

aerodynamic efficiency of the turbine

50%

40%

"11 ........... _1 ........... ! ..............................................................

+
30% 0.4 L 0.45 0.5 u/c
o

+
I

0.55

0.6

0.65

Figure

4.4.

Turbine

Efficiencies

During

Steady

State

Tests

(3.18

mm Turbine).

4.2

September

1992 Tests

- 2.38 mm Diameter

Turbine with a reduced capacity turbine to system at lower flow rates. The that had been at 65 flow K in neon. rates designed for use in it gave The with tests the by and However,

provide helium were (about using liquid

Tests were performed further information consisted 5 K. performance aimed of the at about specifically Thus

during two separate cooldowns about the performance of the turbine compatible system rotor it was not optimized data 3.18 for operation

turboexpander reasonable performance

of a 2.38 mm diameter and was mechanically at acquiring with the

with the rest of the system. for comparison lower turbine was liquid Because of the

at lower

system with

mm turbine. directly through

capacity

5 W compared a portion helium.

10+ W from the 3.18 mm turbine), flow

the cooldown using

accelerated nitrogen

of the compressor

a precooler

The compressor. bypassed

flow

capacity a throttle

of

the

small

turbine

was

less flow

than

the

design end inlet. one

flow Only

rate about

for

the was

As a result, through

a portion valve

of the compressor directly

at the warm

of the cycle

and returned

to the compressor with a smaller

one -

half the compressor of operation for lower equivalent equivalent capacity. input input

flow was sent through to replacing 4.5 shows Figure

the heat exchanger the system

and the turboexpander. specifically load load,

This mode designed and

is equivalent power power

the compressor

refrigeration

temperature

for portions of the cooldown and steady state tests (after t = 28 hr.). The is the product of the total electric input power and the ratio of the turbine

53

'reare
w

TN-508
that would result from a smaller compressor

flow rate to the total flow rate. This is the power with the same power train efficiency.

300

3.5

250
m I : Ii i

-,__.i--.-_.

iX
_
_ :

.......effective cyc e power ._,......_....._.. _.............. ., 2.5

_ i_
= :

ii.............

_! ................ ;i ................... H

ttt14u
', :: i
:

3,
@

6"
W C7.

[U':_i' ..............

............... i................ ,.'................ _..........

@

.... :..... !. _i , ,.L Ioaa)emperature '_." i

-................. _ ..........................

i !

II h"

system load
_............... 1.5

__=

Ill

5O i :

0 0 5 10 15 20 time (hoclrs) 25 30 35 40

[] Figure
= =

4.5.

Cooldown

and Steady

State

Tests - three

with the 2.38 mm Turbine. during the first cooldown 28. The steady state on Sept. results 22 are

Four and
m H m

steady

state point

test points during

were recorded cooldown

one

additional

a second

on Sept.

listed in Table 4 2. through the turbine exchanger

The columns correspond to those has been added. The calculated during these tests because

for the June tests except that the flow rate thermal effectiveness values for the heat of the thermal lag of the heat exchanger.

are not meaningful 1992 Tests conducted to obtain shaft

IIIIIB

4.3

December Tests were speed, and turboexpander

- 3.18 mm Diameter

Turbine of the turboexpander at The brake wheel on the to increase the rotational as low as

iiw

higher original

in December to evaluate the performance data over a broader range of conditions. was reduced to 4.83 mm (0.190") diameter

speed. The temperature of the brake circuit was controlled during 220 K, and system performance was evaluated at loads approaching The that had system precooler
imi

tests to temperatures 10 W at 65 K. of the liquid nitrogen tests. The

cooldown used isolated

of the system during from tests parameters 80 K). steadied

was the

accelerated smaller about the cooldown after

by means turbine. and the 7.5 hours

precooler important nitrogen exit

been was

with during

Figure steady

4.6

summarizes

performance

state

the system

of operation

(as the turbine

temperature cooldown.

approached The system

The turbine provided all additional out at a load temperature of about

refrigeration to complete the 36 K at the exit from the load

54
u

reare
TN-508 heater parasitic after heat about load 2.5 hours of operation at 36 K. At this time there was about load was 35.6 0.68 W of an at the cold end of the system. The source the turbine of this parasitic has not been K with determined. input power The temperature at the exit from to the inverter of 381 V. at this condition

500 ! input
m

15 power

400 v

,,,,
.................................... ................ ....... ............... ........

12
ra')

N
m

.02
I:1. e_

300

................
3
0

m J

E
"-'

200
EZ

i........................................
l ...... _[ ................................... _....... load temPerature

El.

o
r_ m

100

............ 3

0 0 10 20 time (hours) 30 40

r_

Igl m_
J

Figure

4.6

Cooldown

and Steady

State

Tests

w/3.18

mm Turbine

(Reduced to about

Brake). 65 K for a

series

The load heater was turned on to warm the cold of steady state tests. The tests had three objectives: to evaluate to evaluate to obtain the turbine the system at higher speed, at increased loads, brake

end of the system

and

data with a reduced

temperature.

-:.-2 m

system.

A total of 13 steady state test points were selected to demonstrate the flexibility of the Results are listed in Table 4.2. The first point was recorded at the end of the cooldown, of 36 K. The next 6 tests were recorded for a range of turbine speeds at two to approximately 65 K by varying the heater recorded at elevated system pressure, with the four tests were conducted at reduced system

at a load temperature

ir.....l

pressure ratios. The load temperature was held input power. The following two conditions were heater load of about 10 W at 65 K. pressure and varying brake temperature. Several with test J7. data points ratio show how The final

these

tests

met

the objectives.

First,

compare than

test D2.1 is close to

Conditions

for both tests are similar. at the turbine is about

For both tests, 1.6, and the load

the load temperature is larger

65 K, the pressure

the 5 W design

value. The DC input power to the cycle for test J7 is 324.6 W. For test D2. I, the power is 345.4 W. The ratio of the input power to the net cooling is 55 W/W for test J7 and 51 W/W for test

55

reare
D2.1. Most of this difference achieved in test D2.1. This calculated significantly perceived inlet compressor December is because of the improved resulted from the reduction turbine efficiency at the higher in the brake wheel diameter.

TN-508 speed The was The of the and is

power train efficiency for the two tests implies that the power train efficiency higher for the December and September series. In fact this was not the case. improvement housing tests, is a result was used of using for different measurement tests, temperature. was some locations For used. for these test series. For the June compressor temperature the gas temperature the This upstream September temperature

for the compressor

temperature

inlet because

the gas temperature than the upstream

at the inlet to the impeller

somewhat higher the housing.

heat is transmitted

to the gas from

Tests basically
= m

D3.1

and the

D3.2 parasitic

illustrate heat For these

how leak

the cycle

efficiency

improves has available

with

increased

load net

of

because

through

the turbine

a reduced

impact

on the in excess

efficiency 10 W. specific condition

of this component. The DC electric power of about was achieved

tests, the total cooling

was slightly

=:

_-

input power was 424 - 425 W for the two tests. This corresponds to a 42 W/W at the load temperature of 67 - 68 K. As noted earlier, this test simply by increasing to 9600 the system rev/sec, pressure. two Note tests, also that the speed yielding a net of the turbine for these

turbine was allowed to increase efficiency of about 0.61.

m

The heat leak

m

data

recorded

for tests D4.1 constant heat

- D4.4 input leak

were

used to assess ratio to the system. turboexpander decreasing brake the

the accuracy and flow The the brake load

of estimates kept temperature This was temperature reduced

of was and to

in the turboexpander. resuIting reducing in the the net in a nearly the load and load conductive

For these

tests, the pressure power in the as

rate was

nearly

constant, lowered, changes increasing

assembly. temperature

produced

temperature, However, the turbine a decrease heat leak.

generally

refrigeration.

approximately 220 K (test D4.4), the brake circuit. This produce

Fro

speed decreased because in turbine aerodynamic If an increase in overall the brake wheel (higher) speed.

of the increased efficiency that cycle diameter efficiency must

density in offset the is to be be adjusted

improvement

from

the reduced

i..1

realized by operating accordingly to allow

the brake at lower temperature, the turbine to operate at optimum

56

@eare
u

TN-508

,--I

c-i

I .... i-

m
g

,.g

e.i

,-_

,-_

,-4

ei

ei

[=,

o
O i

"0
r

.P., ,4 _ _ _ _ oo_ ,o_'o. _ _, _. ,,',. "_

_0 ,.,,j
m

c,l 0 _, _ O_ _,

d "0 C _ IJ o

.4
w

zs

e4

e_

ei

e_

r-i

e.i

ei

ei

ei

eg

--

.-;

--

m u

i
I
57

'reare
5. DISCUSSION There are several OF TEST important RESULTS conclusions derived from the tests:

TN-508

Inverter inverter efficiency

- The and

inverter slip

functioned ratio were

as designed established.

during

all tests.

Relationships relationship

between can be section

A frequency/voltage

"hard-wired" into the next generation device. dealing with testing, they were a small subset
n

These results are not presented in the prior of tests performed during system tests.

Compressor . Operating maintained at relatively fixed

m

conditions values for

for the compressor (speed and flow rate) were the system level tests. From time to time, the Separate combinations was installed tests of in

compressor conducted diffuser efficiency.

J

speed was changed in a closed loop were Generally, Subsequent

by adjusting the frequency to the inverter. used to evaluate the performance of various these tests resulted system tests, in incremental an improved improvements motor stator

and impeller.

in compressor

to the cryogenic

the compressor. from the changed Figure curves 5.1 shows result from

Comparative tests were performed to judge the change in efficiency resulting motor. The same diffuser and impeller combination were used with both tests. the results. Power train efficiency motor motor stator. design assembly is shown The used during for two curves cryogenic power machines. give system The tests. upper at The train of the tests with the changed lower performance in power

comparable conclusion

conditions to be drawn

with the compressor is that the improved 15 %. This corresponds

will produce in input

an increase

efficiency of roughly same magnitude. Heat predictions shows desired effectiveness target. that the Exchanger from and The

to a decrease

to the cycle

[:|

- Test model results losses.

results agree The

for

the

heat Table with were

exchanger 5.1 shows the model that at the done

were

used

to evaluate The met for both

the table the by

a thermal experimental pressure

of this device. closely test results

the comparison. predictions, the cold heat end, exchanger ensuring

thermal

confirm

test points

for this comparison steady

so because

they were

preceded

substantial periods of time at nearly stability in the heat exchanger.

m

temperatures

thermal

Turboexpander efficiency
N

- Test the value

results

for

the

turboexpander to meet

showed its expected

that

the

measured There

net

is below

needed

for the system

targets.

are two

contributing factors. First, the aerodynamic efficiency of the turbine was initially lower than the target of 0.76 at design pressure ratio and flow rate. This occurred because the brake wheel was too large, causing the turbine to operate at a less than optimum speed. The tests in December the data was the with a reduced brake wheel demonstrated that this modification turbine speed and efficiency. The second effect results from were used to verify the heat leak calculation for the turboexpander. was successful in increasing conductive heat leak. Test This calculation the conductive path method through

=: z

then used to predict the heat penalty for a design in which turboexpander assembly was modified to reduce heat leak.
u

--Z

58

reare
Power Train Efficiency vs Flow Coefficient
0.35

TN-508

I
6750 _s

eompresso D2 diffuser I!10

_=_m

o---- --------_o6500 6000 _ --_o

d"
W

0.30

'0

6500 I .... 6000 .... ...'.

) i -..... ;
"',.

F_ 12 pole stalor 4/6/93

H i O L = ",

0.25

I !

l
F_ i

i
I

0.20
==-W

0.15

0.16

0.17

0.18 d> =

0.19 Ih P=A,um

0.2

0.21

Flow Coeffident.

Figure
U

5.1.

Comparison

between

Brassboard

Compressor was used and turbine before series relating

(12 pole stator) in Brassboard speed

and Modified System Tests. The figure to the in

Compressor Figure
M i

(24 pole stator). 5.2 illustrates axis is u/c0, fluid

The 12 pole design of heat leak turbine, coefficient, upper The corrections reflects

the effects the speed

on efficiency. in brake rotor

shows The from Figure From a speed

test data horizontal

for the 3.18 mm diameter velocity. of points This The

and after the change the turbine of points

diameter. efficiencies plotted correction. be set at

tip speed

theoretical 2.11.

"spouting" The lower

are the calculated on the relationships without for the turbine to the maximum

test data corrected, the upper series

for heat leak. series 0.65.

were based point

the measured

net efficiency,

of data, one concludes near would

that the design correspond Since

should

coefficient

roughly

aerodynamic

efficiency

that can be achieved

for this machine.

c o is related

only to the inlet temperature

and pressure ratio, it is the tip speed that must be adjusted to achieve the desired value for u/c o. This was done during testing by reducing the diameter of the brake wheel to allow the turbine to operate at higher speed, one that corresponds to u/c o of nearly 0.63 at design conditions.

59

'reare
Table 5.1. Comparisons between Heat Exchanger Tests Results and Model Predictions. Test Jl Flow Rate Stream Inlet Inlet Inlet Inlet 1.61 g/s 295.5 38.2 .209 MPa 136 MPa 0.9918 0.9914 (dP/P) Stream (meas.) (meas.) 0.014 0.015 0.012 0.012 0.012 0.012 0.010 0.010 K Test J12 1.25 g/s 297.4 65.9 .214MPa .141MPa 0.9934 0.9925 K

TN-508

Temperatures Warm Pressures Warm

= =

Cold Steam Stream

Cold Stream Thermal H

m

Effectiveness Data Model

Pressure H
N

Losses Warm (model)

Cold Stream N
i

(model)

H
D
g m

Tinct tinct

6/92

A o

qcorrected Tlcorrected

6/92

12/92 I ....

12/92 i ''o '

80%

....

! ........

I ....

g E,
W

70% .
>,,

N
i

u
u

60%

e'-

....................... _ ......................... f......................... i......................... r ...................... i....................... !

I

L_ lunB

50%

....................... l......................... r ........"i_ ..........._.................................................. i

o_l

I
] I

40%

A4I i
, t

iA _

,t

l
i
: ..............................

'I '
i I

i .......................

'
u [ ] I [ I [ ! n I n i i i I i

30% 0.4

t __L-L._L--

0.45

0.5

0.55 u/d
0

0.6

0.65

0.7

Figure
i

5.2.

Effects

of Heat Leak

and Turbine

Speed

on Efficiency

60
i

'reare
A second were model made incorporating the effect including testing. trend, during important thermal fact can be derived the heat leak through integrals conductivity from the this figure. turboexpander the brake affected All corrections using of construction. by the turboexpander ratio. used These parameters show heat efficiencies to calculate by calculating a consistent This for the materials

TN-508
for heat leak model thermal

is most sensitive However, conditions, widely and consistent accurate. System

to the temperature inlet this

difference

between is strongly

and the cold end of the turbine. operating varied a clear leak is

of heat leak on efficiency temperature, is a strong To the extent

flow rate, indication

and pressure that the model

that the aerodynamic

(corrected)

Performance The test results

and Implications were used

for the Engineering design Model. changes

Model for the components has been Table system. and to assess using

to establish assumed

the expected the system the results

performance

of the Engineering losses

This assessment

performed

model incorporating of this assessment.

for the prototype

5.2 summarizes

Test J7 was used as a baseline listed was in the Table. 5.88 watts was 0.29. Electric input 0.5 watts including

for the assessment. to the inverter heat leak of parasitic

Important was 324 W. through

parameters Net cooling leads. heater

from The was

this test are the cycle train The power 305 K.

power

from

efficiency

The inlet temperature

to the compressor

(at the impeller)

turboexpander aerodynamic efficiency and net efficiencies were 0.707 and 0.494, respectively, where the lower value reflects the 3.3 W heat leak from the brake (at 310 K). The turbine speed
w

was

8000

rev/s was applied

for this 0.994

test corresponding by the definition model, the turboexpander

to a u/c 0 of 0.525. used in reducing effectiveness test

The data

heat

exchanger 13. The pressure losses

thermal Using the losses in the

effectiveness definition
!

(Appendix includes

in the system between were

the thermal

was 0.993. (which

through

the tubing

and the compressor

heat exchanger)
u

3.6 kPa on the high pressure of values in the table

side and 2.3 kPa on the low pressure show what the system model calculates

side. for the

The same
w

second

column

test conditions. such system

Test values

in normal

type are input to the model. is that the model power and compressor train

The values

in bold type rate, inlet

are predicted. values, pressure other

The significance as aerodynamic parameters

of this column efficiency

uses several and fairly

of the test parameter flow accurately predicts

for the turbine,

efficiency,

and temperature

to the compressor, including of numbers Model engineering

speed

the load and input power. uses the same at design model Specifically, system model have train to calculate those has the expected measured been efficiency cycle during to are in has been

L w

The third column performance to be system tests expected based in the

of the Engineering on the brassboard. on the results to 0.58 as a result

conditions. the power

For this calculation, replaced efficiency

the efficiencies increased

components in Figure

0.33

of the tests shown of operating

5.2, and the net turbine and reduced input values The

increased expected
u

at higher by the model.

speed

heat leak.

No changes are given

in the performance type, bold values

of the heat exchanger.

to the model

normal

are predicted

61
n

@reare
TN-508
m

Table

5.2.

Comparison and System

Between Predictions Test J7

Test Results

Model (Caic.) 325W 0.29

(J7)

Eng.

Model

Input
= =

Power Efficiency Inlet Temp. Inlet Press. Exit Press. Effectiveness

(Meas.) 324 W 0.29 305 K 35.0 kPa 123.8 kPa 1.36 g/s 0.993 66.05 K

(Calc.) 200W 0.33 290 K 8.1 kPa 71.9 kPa

Power Train Compressor Compressor Compressor Flow Rate Heat Exch. Turbine Turbine Turbine Turbine Turbine Turbine

305 K 35.0 kPa 120.5 kPa 1.36 g/s 0.993 66.5 K 117.5 kPa 37.3 kPa 8000 0.51 0.707 5.83W

1.07 g/s 0.993 66.7 K 70.3 kPa 8.8 kPa 9600 0.58 0.76 5.0W 65 K

Inlet Temperature Inlet Pressure Exit Pressure Speed Efficiency Aero Efficiency

120.2 kPa 37.3 kPa 8000rps 0.494 0.707

Net Cooling
L_ u

5.88W 64.88 K

Load Temperature

64.88

[] m
!

6.

ENGINEERING

MODEL

The present Prototype Model

Engineering involve

Model Cooler. be

is designed The main details and using

to incorporate differences the the presence same

all major between

design

features The

that will be and the Engineering in the disassembly,

in the Prototype hardware but will

the Engineering that fasteners would

Model be present

construction are

of instrumentation. materials

fabricated

Prototype,
=

components

assembled

using

threaded

to permit

adjustment, and replacement or repair of seals, some of which are located present in the Engineering Model

of internal components if necessary. This requires the use in the cryogenic regions. Secondly, instrumentation is be absent in the Prototype. The instrumentation

that would

=_ m

provides additional data used for verification and diagnostics during testing at the component level. The presence of additional instruments also involves additional flanged and sealed connections. As a result, the Engineering Model hardware is somewhat heavier and more complex than an all-welded, hermetic Prototype. Model and the Prototype The following paragraphs the changes Design that have been of the Engineering include the geometric describe each of the made to the brassboard System is also Model

H
m

details
w

Similarities between the Engineering and materials of key components. Model components, identifying A description of the Preliminary

Engineering configurations. presented.

62

@eare
w

TN-508

6.1 Inverter

The Components

The wired the circuits

inverter

has been are

modified designed

to upgrade and integrated to be either to the mounting

from S-class

discrete or

electronics The have

components selected

and for

to printed Model The

circuitboards housing

components. is designed plate.

components comparable the heat housing Figure

Engineering

components generated in the a is 171 mm 6.1 shows

available inverter (6.75")

as S class. is transmitted diameter

for the inverter long and has

so that The

by conduction

inverter

x 102 mm (4.0")

a mass

of 2.3 kg (5 lb.).

physical layout of the inverter and housing. There are no changes performance characteristics of the inverter. Table 6.1 lists the design Appendix counterparts.
w

to the operating or point characteristics. and their S-class

II

lists

the

circuit

components

for

the

Engineering

Model

FERRITE

CORES

PHASE

OUT

m /

_ --

178

m m

\
\
\

I _
"-COOLING FINS

DC POWER CONTROL SIGNALS

IN

"_--

179

mr-r] --_--

Figure

6.1.

Engineering

Model

Inverter.

63

reare
m

TN-508

Table
n

6.1. Inverter

Characteristics. 400W 300W 28 V IIA 15.4 V - rms 6.2 A - rms

Maximum Rated Input Input Output Output Input

Input Power Power

DC Voltage Current Voltage Current Frequency (Design (3 Phase) Range Point) Temperature (per Phase)

Output Operating
u

3 - 10 kHz 240 K - 350 K 0.95 171 mmdia, x 102 mm (6.75" x 4.0")

Efficiency Size

_=

Mass

2.3 kg (5 Ib)

Compressor
m

The intended

Engineering design to allow The rotating unchanged

Model to reduce

version the overall

of the mass

compressor and efficiency of conduction and basic design. Metal

incorporates of the motor, The

minor and housing

modifications a major design change has also has into

LA

to improve

aerodynamic

performance

in the housing been modified compressor.

=

of the assembly. assembly

for heat rejection assembly, from

by means

to a cold plate of internal been seals have

at the end of the components incorporated

gas bearings

been

relatively

the brassboard

the design to reduce the possibility of outgassing of contaminants from organic o-rings (such as those used on the brassboard assembly). This has resulted in some weight penalty because the w flange flanges. would
H

bolting

forces

for

metal additional

seals

are

substantial, savings would

requiring

additional because

material the bolted

near

the

In the prototype, be replaced Figure

weight

be realized

flanges

by braze or weld joints. the compressor because assembly. The interface material for the compressor necessary housing to transfer the motor is the The stator to and

6.2 shows

tellurium
w

copper.

It is selected and bearings

of its high thermal a temperature

conductivity, at the large

heat from housing

the motor was designed flanged The

to the cold plate

end of the assembly. paragraph

to accommodate connections seals used

difference As noted metal

of 25 C between in the introductory

and the cold plate

w

interface

with a heat load of 400 W. are provided in the to allow are compressor

this section, components.

for assembly o-rings.

and disassembly Two shaft

of internal sensors

connectors are provided both of these sensors capacitance features probes for the Engineering

to allow for shaft position and speed monitoring during testing. One or would be eliminated in the Prototype assembly. The sensors are type used in the brassboard assembly. Table 6.2 summarizes key Model.

of the

64

reare
--SENSOR / CONNECTOR

TN-508

COMPRESSOR \

OUTLET

1
m m

I
76.2rnm LEAD CONNECTOR (3)

COMPRES_-O
m

END VIEW

INLET

Figure

6.2a.

Outline

Drawing

of Engineering

Model

Compressor

ill

IMPELLER _

STATOR

SECTION A-A
hJ

Figure
I

6.2b.

Cross

Section

Assembly

of Engineering

Model

Compressor

65

'reare
TN-508
m

Table Inlet Pressure

6.2.

Engineering Model Rated Conditions

Compressor 1.1 atm. 283 K 1.58 1.05 g/s 190 W 6550 rev/s

Inlet Temperature Pressure Ratio Flow Rate Power Speed Features Impeller Impeller Number Exit Diameter Inlet Diameter of Blades Tip

Input

Rotational

15.2 mm (0.6") 5.3 mm (0.21") 18 0.5 mm (0.02") 6.35 mm (0.25") 14.5 mm (0.57")

= =

Channel Height at Blade Motor Rotor Diameter Stator Length

Heat

Exchanger

The cleanliness.

heat This

exchanger component

has

been has the

redesigned largest

to increase internal volume

its strength in the

and system

improve and the

system largest

exposed surface area of material. freon reflow technique requiring

The brassboard flux. Because

assembly was soldered using a low temperature of the soldered assembly, it was not possible to

provide a high temperature vacuum this volume would be unacceptable the low temperature solder joints

bake of the assembly. The residual contaminants trapped in for long term testing at cryogenic temperatures. Furthermore, were not adequate to withstand vibration loads ultimately assembly providing has been modified

expected in the system. The Engineering Model version is a vacuum brazed improved cleanliness and acceptable levels of strength. The internal geometry slightly to meet these objectives. Figure are positioned and each stainless steel 6.3 shows axially four "c-rings". important annular Braze details outer series of the heat exchanger tube. The disks The disks between are assembly. separated the disks

Three tough

hundred pitch 300 spacers.

disks copper, series The

within

a single

are electrolytic and

contains

of slots.

by formed the

preforms

are used

disk/spacer assemblies are brazed in a vacuum furnace in subassemblies consisting of up to 50 disks. These subassembly stacks are then brazed together prior to insertion in the outer stainless steel tube. The final fabrication step is the welding of the headers to the ends of the tube. The have heat details of the internal geometry been determined using the same exchanger. assembly. The performance Table 6.4 summarizes (slots, number of disks, spacer thickness and length, etc.) thermal performance model that was used in the brassboard for this design is comparable features. the important heat exchanger

specification

to that of the brassboard

66

'reare
,

TN-508

,--- PLATES
/

== w

f
" WARM END OUT OUT

L m

Figure

6.3.

Engineering

Model

Heat

Exchanger.

Table
u u

6.3.

Heat Exchanger Rated Conditions

Features 1.05 g/s 1.74 arm. 284 K 1.2 kPa 1.4 arm. 65 K 1.1 kPa 0.993

How

Rate (High Pressure Side) Side) Side) (L.P. Side) Side)

Inlet Pressure Pressure

l

Inlet Temperature Loss (H.P. Inlet Pressure

(H.P.

(!rOW Pressure

Inlet Temperature Pressure Loss Thermal

Effectiveness Features

Core Diameter Core Length Number of Plates Core Mass

M

8.9 cm (3.5") 51 cm (20") 300 5. 3 kg (13.5 Ib) lb)

Header Assembly

Mass Mass

0.5 kg (1.1 lb) 5.8 kg (14.6

67

[] U

'reare
Turboexpander Three turboexpander. at higher machine and warm change improving by metal turboexpander Table 6.4. 6.2
m

TN-508
minor First, changes the brake were wheel conditions. Secondly, heat the has been conducted potential incorporated diameter This reduced from for will into has been the Engineering to allow aerodynamic the Model version efficiency of the

reduced

the turbine

to operate of the the cold This turbine, replaced The in

speed at design will

at design point. the

improve

the wall thickness the

of the cylindrical mm (0.010") end of the organic resulting features warm

shell connecting machine seals from have to the been outgassing.

ends of the machine reduce the overall seals assembly efficiency

from 0.25

0.15 mm (0.006").

of the turboexpander. in Figure 6.4.

Finally, Important

to reduce

contamination

is shown

of the design

are listed

The Engineering The components

Model

Cryocooler into a cryocooler and electric heater frame. actuated The leads. loop for performance design to simulate The vacuum isolation tabletop the valve load and endurance The will be will be located system the vacuum all vacuum will be

will be assembled an outline a filter

testing.
w

Figure a vacuum under and

6.5 shows vessel,

drawing

of the preliminary

of this assembly. pumping

heat inside

exchanger,

turboexpander, mounted the mounting for tubing,

on top of a steel with a pressure of the basewell.

located
m

surface, power

between contains and

pump attached rejected from through

the port

in the bottom

basewell

passthroughs
m

and instrumentation

The compressor

inverter

to a vertical mounting plate that provides support from the inverter through vertical fins to naturally conducts plate and to a cold plate through this cold system an aftercooler will be mounted for the

for the heat rejection convected air behind compressor. electronics

system. Heat is the panel. Heat is circulated data

the compressor

on the back of the panel. on an adjacent

Refrigerant

A computerized

acquisition
r_

and panel gages

rack (not shown).

_4

68
w

reare
I 1 2.6mm i

TN-508

SHAFT

SENSOR

CONNECTORS llg

_ _ BRAKE OUTLET

_/_
i

311imm

\ _ EXIT TURBINE

!
BRAKE
W

INLET

._1

\
CYLINDRICAL SHELL

TURBINE

INLET

/1-

GAS BEARINGS

_/
-I

/_

__//
w

_TURBINE

ROTOR

BRAKE WHEEL

Figure

6.4.

Engineering

Model

Turboexpander

69

'reare
Table Flow 6.4. Engineering Rated Model Turboexpander Condition 1.05 g/s 66.7 K 1.70 arm. 290 K 1.55 0.60 Features Turbine Nozzle Nozzle Rotor Height Width Angle. Angle Diameter 3.18 mm (0.125") 0.61 mm (0.023") 0.22 mm (0.009") 0 (radial) 30 o 9400 rev/s

TN-508

Rate

Inlet Temperature Inlet Pressure Brake Temperature Ex P ansion Ratio .... Net Efficiency

Inlet Blade Exit Blade

m

Rotational Speed Brake Diameter

4.8 mm (0.19" '

g =

COMPRESSOR --

INVERTER

2 \ 1

_/_fi_"

VACUUM VESSEL

MOUNTING

III1 IT

I
.J
m

_ _

VALVE ADAPTER

_//J/JJ/J_////JS/Yf/,/_, _/_' _ROUGHING PUMP

Figure

6.5.

Preliminary

Design

of Engineering

Model

Cryocooler

70
w

'reare
REFERENCES McCormick, J.A.; Valenzuela, Creare TM-1499; July 1991. 02. Swift, Sept., Swift, Space W.L.; 1988. A Reliable J.A.; Three-Phase bwerter for Small High Speed

TN-508

Motors;

Long-Life

Closed-Cycle

Cryocooler

for Space;

Creare

TN-453;

=2 W

0,3.

W.L.; Valenzuela, J.A.; Sixsmith, H.; All-Metal, Cryocoolers; Creare TM-1450; Nov., 1990. For Long-Life Attachment Single B, Contract Thermal Model Stage Reverse

Compact

Heat Exchanger

for

04.

Specifications Applications.

Brayton

Cycle

Cooler

For Space

# NAS5-31281.

September

11, 1989. Stage Reverse-Brayton Creare TM-1465;

05.

Dolan,

F. X.; Preliminary Cooler

Performance

For The Single

Cycle Cryogenic Feb. 1991 Ent, R.S.; Cycle

Description

and Sample

Calculations;

t) 6.
U

Performance R.D.;

Code for SSRB;

Creare

TM-1590; Inc.,

Feb., 1992. Cooler

1990.

7.

Arp, V. and McCarty,

Gas Pak (Ver. 3.1); Cryodata Stage Reverse

68.
m

Swift, W.L.; Performance of a Single Create TM 1569; Aug., 1992. Goeking, K.W.; Contamination

Brayton

at 35 K;

99.
U

Control for

SSRB

I; Creare

TM

1494; Apr.,

1991.

Lw

71
z m

reare
APPENDIX DEFINITIONS Compressor AHs
11/= U 2

TN-508 I

OF PERFORMANCE

PARAMETERS

AH_ = CpTc,(PRcP U = _:NcDc

- 1)

U
= w

CI = 4rhc/pn: P, = VII 1

O2ye

k-I

fncCpTcl (PRcT
rip T

- 1)

P,
head coefficient flow coefficient enthalpy (m/s) heat (J/kg-K) inlet temperature pressure heats speed (m) (m/s) (kg/m 3) (m) (rev/sec) rotational diameter ratio (K) change (J/kg)

_F
w

Compressor Compressor Isentropic Tip speed Specific Compressor Compressor Ratio Compressor Compressor Compressor Compressor Compressor Compressor Inverter Inverter Invert Power

O AHs

U Cp

Wci
PR c
w

k
Nc

of specific

Dc CI Ih C

inlet velocity fluid density impeller (W) (V) (amps)

mass flow rate (kg/s) inlet diameter

P
DEyE

e,
w

power voltage current

VI Il qer

train efficiency

72
w

'reare
TN-508 Heat Exchanger

MINI(H1u

H2), (H4H2MIN),(H4_Ax

n3)]
-- H3)] (Data Reduction)

EHX-- MIN[(H1H4H1Heat

enx enx H1

H3 H3 (Cycle exchanger

Analysis) effectiveness inlet enthalpy exit enthalpy inlet enthalpy exit enthalpy (J/kg) (J/kg) (J/kg) (J/kg) (J/kg) (J/kg)

HX high pressure HX high pressure HX low pressure HX low pressure

= m

H2 H3

H4

H2MIN Minimum
l

H2 (=f(PI,T3)) H4 (=f(P3,T1))

H4MAX Maximum
m

Turbine
w

U =/1;NTD

Co = _/2(HT,e

Hvo,s)
-- HTO)

P/_T

rnT(nT!

PSHAFT
W

PNETqT,NET

Hn - HTO rlT'NET-- HTI -- HTO_

r_

where

Hmo,s = f(Pro ,T_ ) (Ignores

heat leak)

I'IT,A

HTt -- Hvo + _mT H-n - HTO,S

73

@reQre
where Qnx

T - os
is the combined conduction and radiation in SSRB heat leak from Calculation the warm end to the cold end gas stream (calculated 92-07-01).

of the turboexpander

Tip speed Turbine Turbine

(m/s) rotational diameter (m/s) power (W) (W) speed (m) (rev/sec)

NT
D T

Co
QLK E_
r_

Ideal velocity Heat leak (W) Net turbine Turbine Turbine Turbine Turbine Isentropic Turbine Turbine Turbine Turbine

PNET PSHAFT fll T Hn

shaft power

mass flow rate (kg/s) inlet enthalpy exit enthalpy turbine (J/kg) (J/kg)
(J/kg)

HTO HTO,S r_T,NET

exit enthalpy

net efficiency aerodynamic exit pressure efficiency (Pa) (K) (K) (corrected for heat leak)

rlT,A Pro
T. n
E

inlet temperature

T2
r_ I

HX high pressure

exit temperature

L_

74

@reare
APPENDIX INVERTER II LIST PARTS

TN-508

r I
w

>>>>

.d._._._
E c C

._
E

(2

EEEE

EEEE

4__ C C c C

C C C C

C
i

0000

<

< ZZZZ

>-

>-

0000 ZZZZ

0 Z

= i

>-

>-

0000 ZZZZ

0 Z

L_ H

3
w

x
D

[13

[13

<

<

>
,'v w ,.w

:13

-n

m w

L)

L)

k)

DDD_

75
w

@reare

TN-508

I IA_

> cNl_ c_ Nrc,,

(N

E_
C,

')
"E

dc
D 0 C

B_ UU..
u./ _.2

-oi

i-e

mo :o
o c)

LJ (....)U
w

888

_I.__ _ o]c
0

U_
I

8
<

i(,.)
I

iz

1- Io oo ZZZ

71 7 ,

>-i
i

o Z

o z

o o ZZZ

i.1;

i
......

o Z

o Z

%11 N

_I
"_tl

al
_J _-.-i

'_

rv

_r._ i

It- r-I

1:3.

76