Random Vibration, Exported Vibration and Passive Isolation Testing of the Ricor K508N Cryocooler
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Mok, Mason↗
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Vacuum-Induced Cryocooling in Cryogen Saturated Materials
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Adam M. Swanger↗
Cryocooler conduction-cooled SRF cavities for compact particle accelerators
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43 PARTICLE ACCELERATORS↗
Variable-Tension-Cord Suspension/Vibration-Isolation System
A system for mechanical suspension and vibration isolation of a machine or instrument is based on the use of Kevlar (or equivalent aromatic polyamide) cord held in variable tension between the machine or instrument and a surrounding frame. The basic concept of such a tensioned-cord suspension system (including one in which the cords are made of aromatic polyamide fibers) is not new by itself; what is new here is the additional provision for adjusting the tension during operation to optimize vibration- isolation properties. In the original application for which this system was conceived, the objective is to suspend a reciprocating cryocooler aboard a space shuttle and to prevent both (1) transmission of launch vibrations to the cryocooler and (2) transmission of vibrations from the cryocooler to samples in a chamber cooled by the cryocooler. The basic mechanical principle of this system can also be expected to be applicable to a variety of other systems in which there are requirements for cord suspension and vibration isolation. The reciprocating cryocooler of the original application is a generally axisymmetric object, and the surrounding frame is a generally axisymmetric object with windows (see figure). Two cords are threaded into a spoke-like pattern between attachment rings on the cryocooler, holes in the cage, and cord-tension- adjusting assemblies. Initially, the cord tensions are adjusted to at least the level necessary to suspend the cryocooler against gravitation. Accelerometers for measuring vibrations are mounted (1) on the cold tip of the cryocooler and (2) adjacent to the cage, on a structure that supports the cage. During operation, a technician observes the accelerometer outputs on an oscilloscope while manually adjusting the cord tensions in an effort to minimize the amount of vibration transmitted to and/or from the cryocooler. A contemplated future version of the system would include a microprocessor-based control subsystem that would include cord-tension actuators. This control subsystem would continually adjust the cord tension in response to accelerometer feedback to optimize vibration-isolation properties as required for various operating conditions. The control system could also adjust cord tensions (including setting the two cords to different tensions) to suppress resonances. Other future enhancements could include optimizing the cord material, thickness, and braid; optimizing the spoke patterns; and adding longitudinal cords for applications in which longitudinal stiffness and vibration suppression are required.
Villemarette, Mark L.↗
Summary Report of Mission Acceleration Measurements for STS-95: Launched October 19, 1998
John H. Glenn's historic return to space was a primary focus of the STS-95 mission. The Hubble Space Telescope (HST) orbital Systems Test (HOST), an STS-95 payload, was an in-flight demonstration of HST components to be installed during the next HST servicing mission. One of the components under evaluation was the cryocooler for the Near Infrared Camera and Multi-Object Spectrometer (NICMOS). Based on concerns about vibrations from the operation of the NICMOS cryocooler affecting the overall HST line-of-sight requirements, the Space Acceleration Measurement System for Free-Flyers (SAMS-FF) was employed to measure the vibratory environment of the STS-95 mission, including any effects introduced by the NICMOS cryocooler. The STS-95 mission represents the first STS mission supported by SAMS-FF. Utilizing a Control and Data Acquisition Unit (CDU) and two triaxial sensor heads (TSH) mounted on the HOST support structure in Discovery's cargo bay, the SAMS-FF and the HOST project were able to make vibratory measurements both on-board the vibration-isolated NICMOS cryocooler and off-board the cryocooler mounting plate. By comparing the SAMS-FF measured vibrations on-board and off-board the NICMOS cryocooler, HST engineers could assess the cryocooler g-jitter effects on the HST line-of-sight requirements. The acceleration records from both SAMS-FF accelerometers were analyzed and significant features of the microgravity environment are detailed in this report.
McPherson, Kevin↗
An Overview of NASA Efforts on Zero Boiloff Storage of Cryogenic Propellants
Future mission planning within NASA has increasingly motivated consideration of cryogenic propellant storage durations on the order of years as opposed to a few weeks or months. Furthermore, the advancement of cryocooler and passive insulation technologies in recent years has substantially improved the prospects for zero boiloff storage of cryogenics. Accordingly, a cooperative effort by NASA's Ames Research Center (ARC), Glenn Research Center (GRC), and Marshall Space Flight Center (MSFC) has been implemented to develop and demonstrate "zero boiloff" concepts for in-space storage of cryogenic propellants, particularly liquid hydrogen and oxygen. ARC is leading the development of flight-type cryocoolers, GRC the subsystem development and small scale testing, and MSFC the large scale and integrated system level testing. Thermal and fluid modeling involves a combined effort by the three Centers. Recent accomplishments include: 1) development of "zero boiloff" analytical modeling techniques for sizing the storage tankage, passive insulation, cryocooler, power source mass, and radiators; 2) an early subscale demonstration with liquid hydrogen 3) procurement of a flight-type 10 watt, 95 K pulse tube cryocooler for liquid oxygen storage and 4) assembly of a large-scale test article for an early demonstration of the integrated operation of passive insulation, destratification/pressure control, and cryocooler (commercial unit) subsystems to achieve zero boiloff storage of liquid hydrogen. Near term plans include the large-scale integrated system demonstration testing this summer, subsystem testing of the flight-type pulse-tube cryocooler with liquid nitrogen (oxygen simulant), and continued development of a flight-type liquid hydrogen pulse tube cryocooler.
Hastings, Leon J.↗
Summary Report of Mission Acceleration Measurements for STS-95
John H. Glenn's historic return to space was a primary focus of the STS-95 mission. The Hubble Space Telescope (HST) Orbital Systems Test (HOST). an STS-95 payload, was an in-flight demonstration of HST components to be installed during the next HST servicing mission. One of the components under evaluation was the cryocooler for the Near Infrared Camera and Multi-Object Spectrometer (NICMOS). Based on concerns about vibrations from the operation of the NICMOS cryocooler affecting the overall HST line-of-sight requirements, the Space Acceleration Measurement System for Free-Flyers (SAMS-FF) was employed to measure the vibratory environment of the STS-95 mission, including any effects introduced by the NICMOS cryocooler. The STS-95 mission represents the first STS mission supported by SAMS-FF. Utilizing a Control and Data Acquisition Unit (CDU) and two triaxial sensor heads (TSH) mounted on the HOST support structure in Discovery's cargo bay, the SAMS-FF and the HOST project were able to make vibratory measurements both on-board the vibration-isolated NICMOS cryocooler and off-board the cryocooler mounting plate. By comparing the SAMS-FF measured vibrations on-board and off-board the NICMOS cryocooler, HST engineers could assess the cryocooler g-jitter effects on the HST line-of-sight requirements. The acceleration records from both SAMS-FF accelerometers were analyzed and significant features of the microgravity environment are detailed in this report.
McPherson, Kevin↗
In-Flight Performance of the TES Loop Heat Pipe Rejection System: Seven Years in Space
The Tropospheric Emission Spectrometer (TES) instrument heat rejection system has been operating in space for nearly 8 years since launched on NASA's EOS Aura Spacecraft. The instrument is an infrared imaging fourier transform spectrometer with spectral coverage of 3.2 to 15.4 microns. The loop heat pipe (LHP) based heat rejection system manages all of the instrument components waste heat including the two mechanical cryocoolers and their drive electronics. Five propylene LHPs collect and transport the instrument waste heat to the near room temperature nadir viewing radiators. During the early months of the mission, ice contamination of the cryogenic surfaces including the focal planes led to increased cryocooler loads and the need for periodic decontamination cycles. Focal plane decontamination cycles require power cycling both cryocoolers which also requires the two cryocooler LHPs to turn off and on during each cycle. To date, the cryocooler LHPs have undergone 24 start-ups in orbit successfully. This paper reports on the TES cryocooler loop heat pipe based heat rejection system performance. After a brief overview of the instrument thermal design, the paper presents detailed data on the highly successful space operation of the loop heat pipes since instrument turn-on in 2004. The data shows that the steady-state and transient operation of the LHPs has not changed since 2004 and shows consistent and predictable performance. The LHP based heat rejection system has provided a nearly constant heat rejection heat sink for all of its equipment which has led to exceptional overall instrument performance with world class science.
allowable flight temperature↗
Zero Boil-Off System Testing
Cryogenic propellants such as liquid hydrogen (LH2) and liquid oxygen (LO2) are a part of NASA's future space exploration due to their high specific impulse for rocket motors of upper stages suitable for transporting 10s to 100s of metric tons of payload mass to destinations outside of low earth orbit and for their return. However, the low storage temperatures of LH2 and LO2 cause substantial boil-off losses for missions with durations greater than several months. These losses can be eliminated by incorporating high performance cryocooler technology to intercept heat load to the propellant tanks and modulating the cryocooler to control tank pressure. The active thermal control technology being developed by NASA is the reverse turbo-Brayton cycle cryocooler and its integration to the propellant tank through a distributed cooling tubing network coupled to the tank wall. This configuration was recently tested at NASA Glenn Research Center, in a vacuum chamber and cryoshroud that simulated the essential thermal aspects of low Earth orbit, its vacuum and temperature. Testing consisted of three passive tests with the active cryocooler system off, and 7 active tests, with the cryocooler powered up. The test matrix included zero boil-off tests performed at 90 full and 25 full, and several demonstrations at excess cooling capacity and reduced cooling capacity. From this, the tank pressure response with varied cryocooler power inputs was determined. This test series established that the active cooling system integrated with the propellant tank eliminated boil-off and robustly controlled tank pressure.
Plachta, David W.↗
Liquid Nitrogen Zero Boiloff Testing
Cryogenic propellants such as liquid hydrogen (LH2) and liquid oxygen (LO2) are a part of NASAs future space exploration due to their high specific impulse for rocket motors of upper stages suitable for transporting 10s to 100s of metric tons of payload mass to destinations outside of low earth orbit and for their return. However, the low storage temperatures of LH2 and LO2 cause substantial boil-off losses for missions with durations greater than several months. These losses can be eliminated by incorporating high performance cryocooler technology to intercept heat load to the propellant tanks and modulating the cryocooler to control tank pressure. The active thermal control technology being developed by NASA is the reverse turbo-Brayton cycle cryocooler and its integration to the propellant tank through a distributed cooling tubing network coupled to the tank wall. This configuration was recently tested at NASA Glenn Research Center, in a vacuum chamber and cryo-shroud that simulated the essential thermal aspects of low Earth orbit, its vacuum and temperature. Testing consisted of three passive tests with the active cryo-cooler system off, and 7 active tests, with the cryocooler powered up. The test matrix included zero boil-off tests performed at 90 full and 25 full, and several demonstrations at excess cooling capacity and reduced cooling capacity. From this, the tank pressure response with varied cryocooler power inputs was determined. This test series established that the active cooling system integrated with the propellant tank eliminated boil-off and robustly controlled tank pressure.
Cryogenic fluid management↗
Cryogenic aspects of a 20 MW class low-temperature superconducting generator for the renewables industry
In this paper we give a progress update on the cryogenic design for cooling a 20 MW class, partially superconducting generator with stationary field coils for offshore wind renewables industry [1-2]. This is a continuation of an earlier program on a 10 MW system dating back ten years. Whereas this new power rating increase leads to a radial diameter expansion of the superconducting field coils from 4 to > 9.5 m, it maintains the axial length. We show the design based on this scaled up with enlarged diameter. The field coil size increase asks for higher cooling power that leads to a bigger cold box size to accommodate the cryocoolers. In the design, as many as 8 cryocoolers can be accessed and serviced from the nacelle that houses the main cryogenic components. A typical thermal load balance sheet with all components is given and compared against the available cryocooler cooling power at different operating conditions. Due to the cryocoolers’ local point of contact cooling within the nacelle, the temperature gradient of the thermal shield that fully encloses the cold mass with its embedded field coils needs to be balanced out to minimize the heat burden on the field coils. This requires additional analytical efforts and implementation of further design features. The extended nacelle houses the cold box with its cryogenic infrastructure. The interface for the envisaged cryogenic pushbutton closed-loop circulating system remains invisible, requires no handling of cryogenic liquids and is hermetically closed. The field coil diameter increase also leads to a greater initial helium gas storage volume. In addition, it requires higher initial room temperature fill pressure within the toroidal helium vapor storage tanks and in cooling tubes connecting to the cryocoolers. The toroidal helium gas tanks are thermally coupled with the thermal shield so that helium convection inside the storage tank can improve heat transfer and reduce the temperature gradient of the thermal shield. Besides those heat transfer challenges, additional mechanical strain within this large structure is exerted on the torque tubes during initial cooldown and when energizing field coils. Some of those design challenges are quite unexpected, leading to novel workarounds in order to maintain the chosen cooling strategy. Finally, we assess those design limitations in view of further cryogenic scalability with emphasis on manufacturability and assembly.
cryogenics↗
The X-ray Microcalorimeter Spectrometer (XMS): A Reference Cryogenic Instrument Design for Constellation-X
Constellation-X, a mission now belonging to the Beyond Einstein initiative, is being planned to inherit the x-ray sky from Chandra, XMM-Newton and Astro-E. The first two of four observatories in the constellation will be launched together in 2013 and followed a year later by the launch of the remaining two. The four will independently orbit the Sun-Earth Lagrange point L2. An instrument compliment resides in the Focal Plane Module (FPM) of each observatory 10 m from the Optics Module and consists of three Hard X-ray Telescope (HXT) detectors, a Reflection Grating Spectrometer (RGS) focal plane CCD camera and an X-ray Microcalorimeter Spectrometer (XMS). Instrument awards are scheduled for early 2006. The reference detector for XMS is a 32 x 32 array of microcalorimetric superconducting Transition Edge Sensors (TES). Each pixel casts a variable resistance in a SQUID based multiplexed readout circuit which is coupled to series SQUID arrays for amplification and finally read out by external electronics. A multi-stage continuous ADR will provide the stable 50 mK desired for the TES array and a stable 1 K for the series SQUID arrays while also lifting thermal parasitic and inefficiency loads to a 6 K cryocooler interface. The 6 K cryocooler is expected to emerge from the joint-project Advanced Cryocooler Technology Development Program (ACTDP) in which Constellation-X is an active participant. Project Pre-Formulation activities are marked by extensive technology development necessitating early, but realistic, thermal and cooling load requirements for ADR and ACTDP-cryocooler design points. Such requirements are driven by the encompassing XMS cryostat and ultimately by the thermal environment imposed by the FPM. It is further desired that the XMS instrument be able to operate on its side in the laboratory, with a warm vacuum shell, during an extensive calibration regime. It is that reference system design of the XMS instrument (microcalorimeter, ADR, cryocooler and cryostat) which is the subject of this paper.
Whitehouse, Paul L.↗
Results of an Advanced Development Zero Boil-Off Cryogenic Propellant Storage Test
A zero boil-off (ZBO) cryogenic propellant storage concept was recently tested in a thermally relevant low-earth orbit environment, an important development in the effort to apply this concept to flight projects. Previous efforts documented the benefits of ZBO for launch vehicle upper stages in a low-earth orbit (LEO). Central to that analysis is a ZBO Cryogenic Analysis Tool that estimates the performance of each component and the ZBO system. This test is essential to the validation of that tool, and was the first flight representative configuration tested in a thermally representative environment. The test article was comprised of a spherical 1.4 m diameter insulated propellant tank, with a submerged mixer, a cryogenic heat pipe, flight design cryocooler, and a radiator. All were enclosed in a thermal shroud and inserted into and tested in a vacuum chamber that simulated an LEO thermal environment. Thermal and pressure control tests were performed at sub-critical LN2 temperatures and approximately 2 atmospheres pressure. The cold side of the ZBO system performed well. In particular, the heat pipe performed better than expected, which suggests that the cryocooler could be located further from the tank than anticipated, i.e. on a spacecraft bus, while maintaining the desired efficiency. Also, the mixer added less heat than expected. The tank heating rate through the insulation was higher than expected; also the temperatures on the cryocooler hot side were higher than planned. This precluded the cryocooler from eliminating the boil-off. The results show the cryocooler was successful at removing 6.8 W of heat at approximately 75 K and 150 W of input power, with a heat rejection temperature of 311 K. The data generated on the ZBO components is essential for the upgrade of the ZBO Cryogenic Analysis Tool to more accurately apply the concept to future missions.
Plachta, David↗
Guarded Hot Cylinder Apparatus for Characterization of Thermal Insulation Systems and Materials at Liquid Hydrogen Temperatures
As interest in liquid hydrogen (LH2) continues to grow within the energy and mobility sectors, so does the demand for testing capabilities at deep cryogenics temperatures. However, cost-, complexity-, and safety-related challenges associated with handling LH2 effectively limit the landscape of possible options. As an alternative, LH2 temperatures can be accessed via a helium-based cryogenic refrigerator, or “cryocooler”. Recently, NASA and its partners CB&I and Shell began the development of a cryocooler-based calorimeter to characterize the thermal performance of insulations and other materials down to 20 K. Deemed the Guarded Hot Cylinder (GHC), the apparatus utilizes a small vacuum chamber in conjunction with a GM cryocooler and trim heater to control the cold boundary temperature. A sealed, cylindrical copper cup bolts to the cryocooler and houses the material specimen, with an internal, cylindrical test heater assembly to maintain the warm boundary. The steady-state heat load, traveling radially through the specimen, is measured via the electrical input power to the test heater and then used to evaluate the material’s absolute thermal performance. Initial checkout and validation of the GHC using a common bulk-fill insulation material showed close agreement with published data from standardized LN2 boiloff calorimetry testing. The instrument is now considered a lab standard, with the goal of incorporating it into the ASTM C1774 standard in the future, and it is in continuous use, examining insulation materials for next-generation LH2 applications.
Swanger, Adam (ORCID:000000021487592X)↗
A small helium liquifier which provides continuous cooling based on cycled isentropic expansion
This simple cryocooler provides a small reservoir of liquid helium at a stable temperature of 4.2K. It uses a novel adaptation of the Simon expansion cryocooler to provide continuous cooling. Operation is in a four stage cycle: (1) A closed vessel of helium under high pressure is cooled to 12K using a conventional Gifford-McMahon closed-cycle cryocooler. (2) The pressure is released adiabatically providing cooling to 4.2K. (3) Liquid helium is collected in a second, well insulated, vessel. (4) The first vessel is repressurized. The cycle time is 15-30 minutes. In this manner, a pool of liquid helium is continuously maintained in the second vessel, with a temperature stability of 0.03 degrees. The continuous cooling power available is 3mW. This design provides simplicity and reliability through the absence of any orifices or moving parts at cryogenic temperatures except for the conventional Gifford-McMahon cryocooler.
Winter, C.↗
Gas adsorption/absorption heat switch, phase 1
The service life and/or reliability of far-infrared sensors on surveillance satellites is presently limited by the cryocooler. The life and/or reliability, however, can be extended by using redundant cryocoolers. To reduce parasitic heat leak, each stage of the inactive redundant cryocooler must be thermally isolated from the optical system, while each stage of the active cryocooler must be thermally connected to the system. The thermal break or the thermal contact can be controlled by heat switches. Among different physical mechanisms for heat switching, mechanically activated heat switches tend to have low reliability and, furthermore, require a large contact force. Magnetoresistive heat switches are, except at very low temperatures, of very low efficiency. Heat switches operated by the heat pipe principle usually require a long response time. A sealed gas gap heat switch operated by an adsorption pump has no mechanical motion and should provide the reliability and long lifetime required in long-term space missions. Another potential application of a heat switch is the thermal isolation of the optical plane during decontamination.
Chan, C. K.↗
Design Models for the Development of Helium-Carbon Sorption Crycoolers
We have developed models for predicting the performance of helium-based Joule-Thomson continuous-flow cryocoolers using charcoal-pumped sorption compressors. The models take as inputs the number of compressors, desired heat-lift, cold tip temperature, and available precooling temperature and provide design parameters as outputs. Future laboratory development will be used to verify and improve the models. We will present a preliminary design for a two-stage vibration-free cryocooler that is being proposed as part of a mid-infrared camera on NASA's Next Generation Space Telescope. Model predictions show that a 10 mW helium-carbon cryocooler with a base temperature of 5.5 K will reject less than 650 mW at 18 K. The total input power to the helium-carbon stage is 650 mW. These models, which run in MathCad and Microsoft Excel, can be coupled to similar models for hydrogen sorption coolers to give designs for 2-stage vibration-free cryocoolers that provide cooling from approx. 50 K to 4 K.
Lindensmith, C. A.↗
Hot Views on Cold Crystals: The Application of Thermal Imaging in Cryocrystallography
We have used thermal imaging techniques to visualize the cryocooling processes of macromolecular crystals. Cryocooling is a common technique used for structural data collection to reduce radiation damage in intense X-ray beams and decrease the thermal motion of the atoms. From the thermal images it was clear that during cryocooling a cold wave progresses through a crystal starting at the face closest to the origin of the cold stream and ending at the point furthest away. As an extension to this work, we used thermal imaging to study small crystals, held in a cryo-loop, in the presence of vitrified mother liquor. The different infrared transmission and reflectance properties of the crystal in comparison to the mother liquor surrounding it are thought to be the parameter that produces the contrast that makes the crystal visible. An application of this technology may be the determination of the exact location of small crystals in a cryo-loop for automated structural genomics studies. Data from initial tests in support of application development was recorded for lysozyme crystals and for bFGF/dna complex crystals, which were cryocooled and imaged in large loops, both with visible light and with infrared radiation. The crystals were clearly distinguished from the vitrified solution in the infrared spectrum, while in the case of the bFGF/dna complex the illumination had to be carefully manipulated to make the crystal visible in the visible spectrum. These results suggest that the thermal imaging may be more sensitive than visual imaging for automated location of small crystals. However, further work on small crystals robotically mounted at SSRL did not clearly visualize those crystals. The depth of field of the camera proved to be limiting and a different cooling geometry was used, compared to the previous, successful experiments. Analysis to exploit multiple images to improve depth of field and experimental work to understand cooling geometry effects is ongoing. These results will be presented along with advantages and disadvantages of the technique and a discussion of how it might be applied.
Snell, Eddie↗