Development and testing of an independent two-stage valved linear compressor for space applications

doi:10.11949/0438-1157.20241296

Abstract

Abstract:

In cosmic exploration, a dependable low-temperature environment is indispensable for space detectors. The valved linear compressor (VLC) functions as the core component in the Joule-Thomson (JT) throttling cryocooler, with its structure and performance having a direct bearing on the cryocooler's cooling efficacy and efficiency. To attain lightweight and efficient VLCs for space applications, the motion characteristics of the double-acting piston structure are analyzed, building on the research foundation of our group. The gas load is then determined using the describing function method. By optimizing the motor structure and gas valve, an independent two-stage VLC prototype is developed, accompanied by variable parameter studies across different charging pressures and piston strokes. Experimental findings reveal that as the charging pressure rises from 0.1 MPa to 0.3 MPa, the mass flow rate increases by 337%, while the pressure ratio decreases by just 19.7%. Both motor efficiency and isentropic efficiency peak at 0.15 MPa. As the piston stroke expands from 2 mm to 10 mm, the mass flow rate multiplies by 10.6, and the pressure ratio increases by 9.6 times. Motor efficiency peaks at 4 mm, whereas isentropic efficiency demonstrates a linear increase with stroke length. Testing confirms that this compressor's maximum output performance is 16 mg/s at a pressure ratio of 19.7, sufficient to match the output capacity of two single-stage compressors. The creation of this prototype establishes a foundation for meeting the lightweight and efficient demands of future space throttling cryocoolers.

Key words: compressor, non-linear load, gas valve, optimization, output capacity, experimental validation, lightweight and efficient

摘要：

在宇宙探索中，可靠的低温环境对空间探测器至关重要。有阀线性压缩机是Joule-Thomson（JT）节流制冷机的驱动部件，其结构及性能直接影响制冷机制冷性能及效率。基于课题组研究基础，本文优化压缩机电机及气阀，研制了一款单机两级有阀线性压缩机原理样机并开展相关研究测试。实验结果表明，随着充气压力从0.1 MPa增加至0.3 MPa时，质量流量增长337%，压比仅降低19.7%，电机效率与等熵效率在0.15 MPa时达到最大；随着活塞行程从2 mm增加至10 mm时，质量流量增长了10.6倍，压比增长了9.6倍，电机效率在4 mm时达到最大，而等熵效率与行程呈线性增长趋势。该压缩机最大输出性能为16 mg/s（19.7压比），能覆盖两台单级压缩机的输出能力。该原理样机的研制，为后续空间节流制冷机的轻量高效需求奠定了基础。

关键词: 压缩机, 非线性负载, 气阀, 优化, 输出能力, 实验验证, 轻量高效

CLC Number:

TB 652

Xinquan SHA, Ran HU, Lei DING, Zhenhua JIANG, Yinong WU. Development and testing of an independent two-stage valved linear compressor for space applications[J]. CIESC Journal, 2025, 76(S1): 114-122.

沙鑫权, 胡然, 丁磊, 蒋珍华, 吴亦农. 空间用单机两级有阀线性压缩机研制及测试[J]. 化工学报, 2025, 76(S1): 114-122.

Figures/Tables 17

Fig.1 Schematic structure diagram of two-stage valved linear compressor

Table 1 Parameters of single two-stage linear compressor

参数	值
整机质量G/kg	9.5
活塞直径D₁/mm	32
活塞直径D₂/mm	16
运行频率f/Hz	30~60
比推力F_max	27

Fig.2 Theoretical cycle of two-stage valved linear compressor

Table 2 Working process of two-stage valved linear compressor

工作过程	低压级状态	高压级状态
1	压缩(1→2)	膨胀(1′→2′)
2	压缩(1→2)	吸气(2′→3′)
3	排气(2→3)	吸气(2′→3′)
4	膨胀(3→4)	压缩(3′→4′)
5	吸气(4→1)	压缩(3′→4′)
6	吸气(4→1)	排气(4′→1′)

Fig.3 Principle structure of flat valve

Fig.4 Pressure loss of valve hole of gas valve under different hole diameters

Table 3 Stiffness and maximum stress of flat valve

阀片	阀片刚度/(N/m)	最大应力/MPa
低压进气阀片	93.5	79.4
低压排气阀片	254	198.9
高压进气阀片	75	73.6
高压排气阀片	107	97.1

Fig.5 Stress of flat valve (taking low-pressure suction valve as an example)

Fig.6 Modal analysis (taking low-pressure suction valve as an example)

Table 4 First-order natural frequency of flat valve

阀片	一阶固有频率/Hz
低压吸气阀片	263
低压排气阀片	522
高压吸气阀片	280
高压排气阀片	357

Fig.7 Prototype and test bench of independent two-stage valved linear compressor

Table 5 Main performance parameters of sensors

0~30 mg/s

0~5 mg/s

±0.5% Rd plus ± 0.1% FS

Fig.8 Influence of inflation pressure on pressure ratio and mass flow rate

Fig.9 Influence of inflation pressure on efficiency

Fig.10 Influence of piston stroke on compressor mass flow rate and pressure ratio

Fig.11 Influence of piston stroke on compressor efficiency

Fig.12 Compressor performance curve

References 31

1	Xu L, Zou Y L, Jia Y Z. China's planning for deep space exploration and lunar exploration before 2030[J]. Chinese Journal of Space Science, 2018, 38(5): 591-592.
2	刘建峰, 沈飞. 制冷技术在空间红外光学系统中的应用及其发展趋势[J]. 红外, 2011, 32(1): 16-22.
	Liu J F, Shen F. Application of cooling technology in space infrared optical systems and its development trend[J]. Infrared, 2011, 32(1): 16-22.
3	Holmes W, Chui T, Johnson D, et al. Cooling systems for far-infrared telescopes and instruments[R]. Astro2010: The Astronomy and Astrophysics Decadal Survey, Technology Development Papers, 2010 (13): 13-22.
4	甘智华, 王博, 刘东立, 等. 空间液氦温区机械式制冷技术发展现状及趋势[J]. 浙江大学学报(工学版), 2012, 46(12): 2160-2177.
	Gan Z H, Wang B, Liu D L, et al. Status and development trends of space mechanical refrigeration system at liquid helium temperature[J]. Journal of Zhejiang University (Engineering Science), 2012, 46(12): 2160-2177.
5	Duband L. Space cryocooler developments[J]. Physics Procedia, 2015, 67: 1-10.
6	汪伟伟. 空间用有阀线性压缩机设计与实验研究[D]. 杭州: 浙江大学, 2014.
	Wang W W. Design and experimental study on a valved linear compressor for space application[D]. Hangzhou: Zhejiang University, 2014.
7	Orlowska A H, Bradshaw T W, Hieatt J. Development status of a 2.5 K—4 K closed-cycle cooler suitable for space use[M]//Cryocoolers 8. Boston, MA: Springer US, 1995: 517-524.
8	Jones B G, Ramsay D W. Qualification of a 4 K mechanical cooler for space applications[M]//Cryocoolers 8. Boston, MA: Springer US, 1995: 525-535.
9	Narasaki K, Tsunematsu S, Yajima S, et al. Development of cryogenic system for SMILES[C]//AIP Conference Proceedings. Anchorage, Alaska (USA): AIP, 2004: 1785-1796.
10	Sugita H, Sato Y, Nakagawa T, et al. Cryogenic system for the infrared space telescope SPICA[C]//Space Telescopes and Instrumentation 2008: Optical, Infrared, and Millimeter. Marseille, France: SPIE, 2008: 919-927.
11	Shinozak K, Sugita H, Sato Y, et al. Developments of 1—4 K class space mechanical coolers for new generation satellite missions in JAXA[C]//Cryocooler. Atlanta, USA: ICC Press, 2011: 1-8.
12	Sato Y, Shinozaki K, Sugita H, et al. Development of mechanical cryocoolers for the cooling system of the Soft X-ray Spectrometer onboard Astro-H[J]. Cryogenics, 2012, 52(4/6): 158-164.
13	Narasaki K, Tsunematsu S, Ootsuka K, et al. Development of 1 K-class mechanical cooler for SPICA[J]. Cryogenics, 2004, 44(6-8): 375-381.
14	Raab J, Tward E. Northrop Grumman Aerospace Systems cryocooler overview[J]. Cryogenics, 2010, 50(9): 572-581.
15	Quan J, Zhou Z J, Liu Y J, et al. A miniature liquid helium temperature JT cryocooler for space application[J]. Science China Technological Sciences, 2014, 57(11): 2236-2240.
16	You L X, Quan J, Wang Y, et al. Superconducting nanowire single photon detection system for space applications[J]. Optics Express, 2018, 26(3): 2965-2971.
17	马跃学, 王娟, 李建国, 等. 空间有阀无油线性压缩机实验优化[J]. 工程热物理学报, 2019, 40(8): 1729-1734.
	Ma Y X, Wang J, Li J G, et al. Experimental optimization of space oil-free J-T compressors[J]. Journal of Engineering Thermophysics, 2019, 40(8): 1729-1734.
18	Liu S S, Sha X Q, Ding L, et al. Investigation of the frequency and stroke characteristics of two-stage valved linear compressor in a 4 K JT cryocooler[J]. Applied Thermal Engineering, 2020, 176: 115432.
19	沙鑫权, 李瑛, 刘少帅, 等. 基于PV图的氦工质有阀线性压缩机实际循环[J]. 轻工机械, 2020, 38(1): 41-45.
	Sha X Q, Li Y, Liu S S, et al. Actual cycle of helium valved linear compressor based on PV diagram[J]. Light Industry Machinery, 2020, 38(1): 41-45.
20	Sha X Q, Ding L, Huang Q, et al. Performance testing of helium valved linear compressor system capable of providing compression ratio over 200[M]//Advanced Topics in Science and Technology in China. Singapore: Springer Nature Singapore, 2023: 664-671.
21	陈志超, 刘少帅, 蒋珍华, 等. 空间用液氦温区节流制冷机最小总功耗参数匹配策略研究[J]. 真空与低温, 2022, 28(3): 259-265.
	Chen Z C, Liu S S, Jiang Z H, et al. Research on the matching strategy of minimum power consumption for space application liquid helium temperature JT cryocooler[J]. Vacuum and Cryogenics, 2022, 28(3): 259-265.
22	褚晋简, 刘少帅, 王鹏, 等. 用于空间BIB探测器的0.3 W@4.2 K大冷量轻量化低温系统[J]. 红外与毫米波学报, 2023, 42(6): 885-895.
	Chu J J, Liu S S, Wang P, et al. A 0.3 W@4.2 K high-capacity lightweight cryogenic system for space BIB detection[J]. Journal of Infrared and Millimeter Waves, 2023, 42(6): 885-895.
23	Biao W, Ji G L, Wu Y N. Drive and control system for a Stirling cryocooler[M]//Cryocoolers 10. Boston, MA: Springer US, 2002: 791-793.
24	Liang K, Stone R, Hancock W, et al. Comparison between a crank-drive reciprocating compressor and a novel oil-free linear compressor[J]. International Journal of Refrigeration, 2014, 45: 25-34.
25	刘莉, 张华, 丁磊, 等. 有阀线性压缩机输出特性关键影响因素研究[J]. 制冷技术, 2019, 39(1): 34-38.
	Liu L, Zhang H, Ding L, et al. Study on key influencing factors of output characteristics of a valved linear compressor[J]. Chinese Journal of Refrigeration Technology, 2019, 39(1): 34-38.
26	赵长安. 控制系统设计手册-上册[M]. 北京: 国防工业出版社, 1991: 160.
	Zhao C A. Control System Design Manual-Volume I[M]. Beijing: National Defense Industry Press, 1991: 160.
27	李子成, 崔晓钰, 丁磊, 等. 有阀线性压缩机吸气阀片位移特性的可视化实验[J]. 制冷学报, 2023, 44(5): 19-24, 69.
	Li Z C, Cui X Y, Ding L, et al. Visualization experiment of displacement characteristics of suction valve in a valved linear compressor[J]. Journal of Refrigeration, 2023, 44(5): 19-24, 69.
28	林梅,孙嗣莹. 活塞式压缩机原理[M]. 北京: 机械工业出版社, 1987: 167.
	Lin M, Sun S Y. Principle of Piston Compressor[M]. Beijing: China Machine Press, 1987: 167.
29	Liang K, Stone R, Dadd M, et al. Piston position sensing and control in a linear compressor using a search coil[J]. International Journal of Refrigeration, 2016, 66: 32-40.
30	Ding L, Zhang H, Sha X Q, et al. Study on the establishing-process of piston offset in the helium valved linear compressor under different operating parameters[J]. International Journal of Refrigeration, 2022, 133: 80-89.
31	Huang Q, Ding L, Sha X Q, et al. Experimental investigation on piston offset and performance of helium valved linear compressor with an external gas bypass[J]. International Journal of Refrigeration, 2023, 145: 417-424.

[1]	Zhenglei HE, Dingding HU. Multi-objective optimization of papermaking wastewater based on multi-agent reinforcement learning [J]. CIESC Journal, 2025, 76(4): 1617-1634.
[2]	Chengcheng XU, Suola SHAO, Wenjian WEI, Xu ZHENG. Research on heating performance of direct-condensation thermal storage aluminum radiant heating panel under multiple working conditions [J]. CIESC Journal, 2025, 76(4): 1545-1558.
[3]	Xiangrui ZHAI, Wei ZHANG, Qianqian ZHANG, Jiuzhe QU, Xufei YANG, Yajun DENG, Bo YU. Active heat transfer enhancement technology for solid-liquid phase change energy storage based on external field disturbance [J]. CIESC Journal, 2025, 76(4): 1432-1446.
[4]	Pengfei ZHAO, Ruomei QI, Xinfeng GUO, Hu FANG, Lufei XU, Xiao LI, Jin LIN. Analysis of hydrogen-to-oxygen impurities in a 1000 m³/h alkaline water electrolysis system [J]. CIESC Journal, 2025, 76(4): 1765-1778.
[5]	Junliang HUO, Zhiguo TANG, Zongjun QIU, Yuhua FENG, Xu JIANG, Leyi WANG, Yu YANG, Fanfan QIAO, Yifan HE, Jianliang YU. Experimental research on risk of freezing and plugging during CO₂ pipeline venting under throttling effect [J]. CIESC Journal, 2025, 76(4): 1898-1908.
[6]	Xinying LI, Chang SU, Chao GUO, Jian PANG, Chao WANG, Chun LI. Application and optimization of CRISPR editing technology in Streptomyces [J]. CIESC Journal, 2025, 76(3): 922-932.
[7]	Jing ZHANG, Yue YUAN, Yanmei LIU, Zhiwen WANG, Tao CHEN. Advance on the preparation of itaconic acid by biological method [J]. CIESC Journal, 2025, 76(3): 909-921.
[8]	Duankanghui YANG, Wenjin ZHOU, Linlin LIU. Synthesis of hydrogen network considering group cascade layout of compressors [J]. CIESC Journal, 2025, 76(3): 1102-1110.
[9]	Yaqi HOU, Wei ZHANG, Hong ZHANG, Feiyu GAO, Jiahua HU. Optimization of LBM multiphase flow models based on machine learning and particle swarm algorithm [J]. CIESC Journal, 2025, 76(3): 1120-1132.
[10]	Liwen ZHAO, Guilian LIU. Performance enhancement and parameter optimization of complex catalytic reaction system based on system integration [J]. CIESC Journal, 2025, 76(3): 1111-1119.
[11]	Qin SUN, Guoqing ZHOU, Wanling ZHAI, Shan GAO, Qianqian LUO, Jian QU. Heat transfer characteristics of topology optimized channel flat-plate pulsating heat pipe under local multiple heat sources [J]. CIESC Journal, 2025, 76(3): 1006-1017.
[12]	Ke LI, Biping XIN, Jian WEN. Sequential quadratic programming optimization of continuous variable density multi-layer insulation coupled with vapor cooled shield in liquid hydrogen storage tank [J]. CIESC Journal, 2025, 76(3): 985-994.
[13]	Nannan XIE, He CHEN, Guanghua YE, Zhongming SHU, Songbao FU, Xinggui ZHOU. Interaction of multiple impellers for gas-liquid stirred tank and optimization of their combinations [J]. CIESC Journal, 2025, 76(2): 564-575.
[14]	Jinhao BAI, Xiaoping GUAN, Ning YANG. Analysis and optimization of flow characteristics in a filter-press water electrolyzer mastoid plate [J]. CIESC Journal, 2025, 76(2): 584-595.
[15]	Gonghan GUO, Huidian DING, Qiang LI, Shengkun JIA, Xing QIAN, Yang YUAN, Haisheng CHEN, Yiqing LUO. Dynamic Bayesian optimization method for batch distillation operation process [J]. CIESC Journal, 2025, 76(2): 755-768.