Design and fabrication of a long-life Stirling cycle cooler for space application. Phase 3: Prototype model

A second-generation, Stirling-cycle cryocooler (cryogenic refrigerator) for space applications, with a cooling capacity of 5 watts at 65 K, was recently completed. The refrigerator, called the Prototype Model, was designed with a goal of 5 year life with no degradation in cooling performance. The free displacer and free piston of the refrigerator are driven directly by moving-magnet linear motors with the moving elements supported by active magnetic bearings. The use of clearance seals and the absence of outgassing material in the working volume of the refrigerator enable long-life operation with no deterioration in performance. Fiber-optic sensors detect the radial position of the shafts and provide a control signal for the magnetic bearings. The frequency, phase, stroke, and offset of the compressor and expander are controlled by signals from precision linear position sensors (LVDTs). The vibration generated by the compressor and expander is cancelled by an active counter balance which also uses a moving-magnet linear motor and magnetic bearings. The driving signal for the counter balance is derived from the compressor and expander position sensors which have wide bandwidth for suppression of harmonic vibrations. The efficiency of the three active members, which operate in a resonant mode, is enhanced by a magnetic spring in the expander and by gas springs in the compressor and counterbalance. The cooling was achieved with a total motor input power of 139 watts. The magnetic-bearing stiffness was significantly increased from the first-generation cooler to accommodate shuttle launch vibrations.