APPROXIMATE DESIGN METHOD FOR SINGLE STAGE

PULSE TUBE REFRIGERATORS

J. M. Pfotenhauer1, Z.H. Gan2, and R. Radebaugh3

1
University of Wisconsin – Madison
Madison, WI 53706
2
Cryogenics.Lab.
Zhejiang University
Hangzhou, 310027 P.R. China
3
NIST – Boulder
Boulder, CO 80303

ABSTRACT

An approximate design method is presented for the design of a single stage Stirling
type pulse tube refrigerator. The design method begins from a defined cooling power,
operating temperature, average and dynamic pressure, and frequency. Using a
combination of phasor analysis, approximate correlations derived from extensive use of
REGEN3.2, a few ‘rules of thumb,’ and available models for inertance tubes, a process is
presented to define appropriate geometries for the regenerator, pulse tube and inertance
tube components. In addition, specifications for the acoustic power and phase between
the pressure and flow required from the compressor are defined. The process enables an
appreciation of the primary physical parameters operating within the pulse tube
refrigerator, but relies on approximate values for the combined loss mechanisms. The
defined geometries can provide both a useful starting point, and a sanity check, for more
sophisticated design methodologies.

KEY WORDS: pulse tube refrigerators, design

INTRODUCTION
ATTACHMENT I
Two 50-minute
CREDIT LINEclass sessions
(BELOW) TOofBEthe Cryogenics
INSERTED ONcourse at the University
THE FIRST PAGE OF of Wisconsin
EACH
– Madison
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EXCEPT to the topic ofON
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159, 225 - 234,During this284
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- 1382, 1383 who1467
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1474,
1491 - 1498, 1499 - 1506, 1507 - 1514, and 1629 - 1639

CP985, Advances in Cryogenic Engineering: Transactions of the

Cryogenic Engineering Conference—CEC, Vol. 53, edited by J. G. Weisend II
© 2008 American Institute of Physics 978-0-7354-0504-2/08/$23.00

1437
unfamiliar with the topic, to the design process of the pulse tube refrigerator and the
physical parameters that define, constrain and optimize its geometry. Various authors
provide well-developed numerical models for designing pulse tube refrigerators that
simultaneously solve the equations of mass, momentum, and energy conservation. [1-3]
However, while such models are recommended for those interested in an accurate design or
commercial product, they are impractical as a means to introduce a physically intuitive
justification for pulse tube design. The material presented in this report summarizes the
lectures presented to the first year graduate students in the Cryogenics course and provides
a step-by-step procedure for an approximate design of the pulse tube refrigerator. This
approach relies on design charts for the regenerator and inertance tube that have been
developed independently through the use of REGEN3.2, and inertance tube models [4-8]. It
utilizes optimized phase relations between the sinusoidal mass flow and pressure waves in
a manner similar to that presented by Hoffman & Pan[9] and Radebaugh[10], and makes
use of an empirical ‘rule-of-thumb’ to determine the pulse tube volume. Most significantly,
the approach provides a method to define the geometry of the three primary components,
the regenerator, pulse tube and inertance tube. The sequence of topics presented here
follows that given in the classroom: 1) defining the desired and required operation
parameters, 2) estimating the necessary acoustic power at the warm and cold ends of the
regenerator, 3) determining the dimensions of the regenerator and the mass flow and phase
at its cold end, 4) fixing the pulse tube volume and dimensions, and 5) determining the
length and diameter of the inertance tube.

DESIGN PROCESS

Desired and Required Parameters

From the perspective of a user, the primary parameters of interest for a cryocooler are
the net cooling capacity, Qc the desired operating temperature, Tc, and the warm – or heat
rejection – temperature, Tw. Beyond these, for a Stirling-type pulse tube refrigerator, it is
necessary to define the average pressure, Po, the dynamic pressure amplitude, Pd, and the
cycle frequency, ƒ.
The choice of average pressure couples to the overall size of the system and the length
scale of the regenerator matrix. If the pressure is low, a large volume will be required for
effective heat transfer in the regenerator. On the other hand, high pressures will dictate
optimum performance with small length scales in the regenerator matrix, and miniature
size for the overall system. Practical fabrication limits for the regenerator matrix will in
part dictate the possible length scales and the associated maximum average operating
pressure. The time constant associated with the heat exchange process in the regenerator
also dictates an inverse relationship between the characteristic length scale of the matrix
and the cycle frequency. For the example developed here, a 400-mesh screen, with a
porosity of 0.6858, is chosen for the matrix and the associated desired and required
parameters are listed in TABLE 1. The pressure at any time during the cycle is assumed
to be uniform through the refrigerator (approximately true) and given by

TABLE 1. Example values for desired and required design parameters

Tc (K) 80 Qc (W) 25 Po (MPa) 2.5

Tw (K) 300 ƒ (Hz) 60 Pd (kPa) 326

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 P (t ) = Po + Pd sin (ω t ); ω = 2π f . (1)

The pressure ratio Pr, a parameter utilized by REGEN3.2 is related to Po and Pd by

Po + Pd
Pr = . (2)
Po − Pd

That is, Pr is the ratio of the maximum pressure to the minimum pressure over one cycle. In
this case, Pr=1.3.

Acoustic Power

The oscillating flow generated by the compressor provides acoustic power to the pulse
tube refrigerator components. The magnitude of the acoustic power is related to the
pressure and mass flow oscillations according to the equation:

1 RT
Wac = Pd m cos θ (3)
2 Po

where R is the gas-specific ideal gas constant, T is the time averaged temperature and θ is
the phase angle between the pressure and mass flow oscillations. It is significant to note
that the acoustic power in the regenerator varies nearly linearly with the temperature, so
that the acoustic power at the cold end, Wac,c , is approximately related to the acoustic
power at the warm end by:
Tc
Wac ,c Wac , w (4)
Tw

Because of the thermal and flow losses occurring in the regenerator and pulse tube, and
because the acoustic power is reduced with temperature through the regenerator, the net
refrigeration capacity available at the cold end of the pulse tube and regenerator is only a
fraction of the acoustic power generated in the compressor. The ratio of the net cooling
power to the acoustic power generated in the compressor defines the coefficient of
performance for the refrigerator:

Qc
COP = . (5)
Wac , w

Thus, knowledge of the COP and the desired cooling power defines the magnitude of the
required acoustic power from the compressor. Of course, it is of interest to minimize the
required compressor power, and therefore one would like to know how to maximize the
COP.

Mass Flow and Phase Angle at the Cold End of the Regenerator

As Radebaugh[10] points out, the dominant losses in a pulse tube refrigerator originate
in the regenerator and are proportional to the average magnitude of the mass flow in that
component. FIGURE 1 displays the phasor diagram relating the mass flow, pressure, and

1439
 • PdVreg
mw
θ r,w RTreg
,
θ r,c Pd
m•
c

FIGURE 1. Phasor diagram displaying magnitude and phase of mass flow in the regenerator. The phase
of the pressure oscillation is defined as 0°. The mass flow at the warm end of the regenerator leads the
pressure by θr,w while the mass flow at the cold end lags the pressure by θr,c.

mass storage terms in a regenerator. The vectoral addition reflects the equation for mass
conservation in the regenerator:
PVreg
mw = mc + (6)
RTreg

where the second term on the right hand side of equation (6) represents mass storage in the
dead volume of the regenerator, Vreg, at a temperature Treg, given by the reciprocal of the
average of 1/T in the regenerator. Because of the sinusoidal nature of P(t), its time
derivative, P , and thus the second term on the right hand side of equation (6), is
orthogonal to P(t). Note from equation (3) that the term m cosθ , that is the projection of
the mass flow vector onto the pressure axis, is constant throughout the regenerator. Thus
adjusting the angles θr,w and θr,c away from the condition

θ r,w = θ r,c (7)

results in a larger average mass flow rate in the regenerator than if equation (7) is satisfied.
Although this condition is approximate, it is a key requirement for minimizing the
regenerator losses and therefore maximizing the COP of the pulse tube refrigerator.
Whatever phase shifting mechanisms are available in the pulse tube refrigerator should
therefore be used to produce the condition given by equation (7).
From FIGURE 1 it may be noticed that with the condition defined by equation (7)

1 ω PdVreg
mc sin θ r ,c = . (8)
2 RTreg

Furthermore, by combining equations (3) and (4) we have

2Wac ,c Po
mc cos θ r ,c = . (9)
Pd RTc

Combining equations (8) and (9) eliminates the mass flow term, leaving

⎛ ω Pd2Vreg Tc ⎞
θ r .c = arctan ⎜ ⎟⎟ . (10)
⎜ 4Wac ,c PoTreg
⎝ ⎠

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Here we have also used the time derivative of equation (1) to determine the amplitude
relationship:
P = ω Pd (11)

Before equation (10) can be used to quantitatively determine θr,c values must be found for
Wac,c and Vreg. Knowing the COP is the key to evaluating Wac,c . Specifically, from
equations (4) and (5), Wac, c is given by
Tc Qc
Wac ,c = (12)
Tw COP

Various methods can be pursued to characterize regenerator performance and thereby

determine its geometry. Recent parametric studies using REGEN3.2[5,6] provide
convenient charts for this purpose. In these one finds that although the COP is influenced
by many variables, optimizing over all of these reveals in the end that the maximum value
of COP is most strongly influenced by Tc. For 80 K, assuming that 20% of the acoustic
power flow in the pulse tube is consumed by losses there, and including conduction loss
through the regenerator wall, one finds COP = 0.117. Combining this result with
equations (4) and (5) yields a value of Wac, c = 57.1 W. Furthermore an optimization
process through the use of REGEN3.2 reveals that the oscillation frequency and end
temperatures determine an optimum length of the regenerator. Also, as shown in
FIGURE 2, for a fixed choice of the parameters listed in TABLE 1, a maximum COP can
be identified as a function of mass flux through the regenerator. For example, with the
conditions chosen in TABLE 1, REGEN3.2 finds that the COP is maximized for a
regenerator length of 0.052 m and an inverse mass flux (Ag/ mc ) of 0.052 m2⋅s/kg

FIGURE 2. Results from parametric investigation with REGEN3.2. Solid circles: L=45 mm, Po=2.5
MPa, Pr=1.3, θr,c=-30°; open circle w/ solid line: L=52 mm, Po=2.5 MPa, Pr=1.3, θr,c=-30°; open circle w/
dashed line: L=52 mm, Po=2.0 MPa, Pr=1.3, θr,c=-30°; open diamond: L=52 mm, Po=2.5 MPa, Pr=1.3, θr,c=-
10°; open square with dot: L=52 mm, Po=2.0 MPa, Pr=1.39, θr,c=0°; open square: L=52 mm, Po=2.5 MPa,
Pr=1.3, θr,c=0°; open square with x: L=52 mm, Po=3.0 MPa, Pr=1.24, θr,c=0°.

1441
respectively. Here Ag = Vreg/Lreg is the cross sectional area of gas flow; equal to the total
cross sectional area times the porosity.
As long as the optimized mass flux is held constant, the cooling capacity of the
regenerator can be scaled directly with the regenerator area. This fact can also be
appreciated by inspection of the linear relationship between the amplitude of the mass flow
at the cold end of the regenerator and the cooling capacity. The combination of equations
(4), (5) and (9) provides the relationship

2 Qc Po 1
mc = . (13)
Tw COP Pd R cos θ c

Combining equation (13) with the optimum inverse mass flux provides an expression for
the gas flow area:

⎛ A ⎞ 2 Qc Po 1 V
Ag = ⎜ g ⎟ = reg . (14)
⎝ mc ⎠opt Tw COP Pd R cos θ c Lreg

An iterative solution to equations (10) and (14) yields the values of Ag and θr,c. For the
given example, Ag = 3.54 x 10-4 m2 (with associated regenerator diameter of 25.6 mm) and
θr,c = -39°. Additionally, the amplitude of the mass flow at the cold end is 6.81 g/s.
Note that the compressor must provide the same values of mass flow and phase (with
opposite sign) at the warm end of the regenerator. Having defined the optimum geometry
for the regenerator, the design process moves next to the pulse tube.

Pulse Tube Volume and Dimensions

The gas flow oscillation from the cold end of the regenerator into the pulse tube
defines a cold end swept volume, Vc,pt the maximum value of which is given by

2Vc 2mc RTc

Vc , pt = = . (15)
ω ω Po

Based on an empirical ‘rule of thumb’[10], the total volume of the pulse tube should be
three to five times larger than Vc,pt. If the pulse tube is designed for low temperature
operation (4 K - 20 K) the value of five times Vc,pt is appropriate, while for operation
around 100 K, three times Vc,pt is the better choice. In either case, if the pulse tube is too
small, excessive losses are caused by penetration of the cold oscillation to the warm end.
Alternately, if the volume is too large, excessive power is required from the compressor to
develop the desired dynamic pressure amplitude. Continuing with the example
calculation, a value of 3.5 for operation at 80 K is selected and results in a pulse tube
volume of 8400 mm3.
A limit on the pulse tube aspect ratio may be identified by considering the conditions
necessary to avoid turbulence in the oscillating boundary layer at the pulse tube walls. As
shown by Akhavan etal.[11] the critical Reynolds number for oscillating flow is given by

ρ ucritδ 2v
Recrit = = 280; δ = (16)
µ ω

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where ρ, u, and µ are the density, amplitude of the cross-sectional mean velocity, and
dynamic viscosity respectively, while δ is the boundary layer thickness dependent on ν, the
kinematic viscosity and ω, the angular frequency. The maximum limit of the cross-
sectional mean velocity defined by equation (16) imposes a minimum limit to the cross
sectional area of the pulse tube for a given mass flow rate. From equation (15) it can be
seen that a maximum velocity and the associated minimum area are related by

mRT
ucrit Amin = V = . (17)
Po

From equations (16) and (17) then, the limit on the cross-sectional area is:

mδ
Amin = . (18)
Recrit µ

The limit of cross-sectional area must be considered at both the warm and cold ends. The
larger minimum area will then define the minimum cross sectional area for the pulse tube.
In most cases, the cold end conditions will define the limit. However, to calculate
equation (18) for the warm end, a value of m pt ,w must be found. From the equation for
conservation of energy in the pulse tube[4] the vectoral diagram displayed in FIGURE 3
results. Here γ is the specific heat ratio, cp / cv. An expression for the magnitude of the
mass flow at the warm end of the pulse tube is then obtained geometrically from FIGURE
3:

1/ 2
⎧ 2 2
⎫
T ⎪⎛ 2Wac ,c Po ⎞ ⎡⎛ ω PdVreg ⎞ ⎛ ω PdV pt ⎞⎤ ⎪
= c ⎟⎟ + ⎢⎜⎜ + ⎟⎥
⎟⎟ ⎜ γ RT
m pt , w ⎨⎜⎜ ⎬ . (19)
Th ⎪⎩⎝ Pd RTc ⎠ ⎣⎢⎝ 2 RTreg ⎠ ⎝ c ⎠ ⎦⎥ ⎪⎭

For the example calculation, Ac,min = 1.57x10-4m2 and Aw,min = 7.49x10-5m2. Using Ac,min,
the diameter and length of the pulse tube become dpt = 14.1 mm and Lpt = 53.6 mm.
Finally, utilizing the geometric relations associated with θpt displayed in FIGURE 3,

⎛T ⎞ 2Wac ,c Po
m pt , w ⎜ w ⎟ cos θ pt = mc cos θ r ,c =
⎝ Tc ⎠ Pd RTc
(20)
⎛T ⎞ ωP V ωP V
m pt , w ⎜ w ⎟ sin θ pt = d reg + d pt
T
⎝ c⎠ 2 RTreg γ RTc

m• θ r,c Pd
c PdVreg
2RTreg
•

θ pt
mp

P&dVpt
t,w
(T
Tw

γ RTc
c
)

FIGURE 3. Phase diagram displaying the relationship between the mass flow vectors in the pulse tube as
defined by the conservation of energy in the pulse tube.

1443
an expression for θpt is obtained:

⎡ ω Pd2 (Vreg γ Tc + 2V ptTreg ) ⎤

θ pt = arctan ⎢ ⎥ (21)
⎢⎣ 4γ TregWac ,c Po ⎥⎦

For the example parameters defined above, θpt = 57°.

Inertance tube dimensions

The diameter and length of the inertance tube are determined by the required phase
angle, θpt, where it interfaces with the warm end of the pulse tube, and the acoustic power
flow at the same location. Various inertance tube models are available[7,8] and show that
for smaller values of acoustic power (less than 1 watt), the inertance tube does not provide
any appreciable phase shift.. For the example calculation carried out here, the model by
Schunk etal.[7] finds that for Po = 2.5 MPa, Pr = 1.3, Wac = 57.1 watts and θ = 57°, the
required length and diameter for the inertance tube are 2.92 m and 4.67 mm respectively.

SUMMARY

A method for approximating the design of a pulse tube refrigerator has been presented.
For user defined parameters of cold end temperature and cooling power, the method
requires definition of the average and dynamic pressure and cycle frequency. Utilizing
established design charts for the regenerator and inertance tube, and phasor diagrams, the
approach provides a method to define the diameter and length for the pulse tube,
regenerator, and inertance tube components as well as the required performance of the
compressor including acoustic power, mass flow, and pressure-flow phase relationship.

REFERENCES
1. J. Liang, A. Ravex, and P. Rolland, Cryogenics vol. 36 (2), pp. 87-106, (1996).
2. C. Wang, P. Y. Wu, and Z. Q. Chen, Cryogenics vol. 33 (5), pp. 526-530, (1993).
3. M.Y. Xu, Y. L. He, and Z. Q. Chen, Cryogenics vol. 39, pp. 751-757, (1999).
4. R. Radebaugh and A. O’Gallagher, “Regenerator operation at very high frequencies for
microcryocoolers,” in Advances in Cryogenic Engineering, vol. 51, pp. 1919-1928, (2006).
5. S. Vanapalli, M. Lewis, Z.H. Gan and R.Radebaugh, 120 Hz pulse tube cryocooler for fast cooldown to
50 K, Applied Physics Letters, 90(7): 072504 (2007),
6. J. Shi, J.M. Pfotenhauer, and G.F. Nellis, “Dimensionless Study and Optimized Design of the
Regenerator,” in Cryocoolers 14, S. Miller, ed., pp. 419-427 (2007).
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Tubes,” Journal of Fluids Engineering, vol. 127 (5), pp.1029-1037 (2005).
8. R. Radebaugh, M. Lewis, E. Luo, J.M. Pfotenhauer, G.F. Nellis, and L.A. Schunk “Inertance Tube
Optimization for Pulse Tube Refrigerators,” in Advances in Cryogenic Engineering, vol. 51A, pp. 59-67,
(2006).
9. A. Hoffman and H. Pan, Cryogenics vol. 39, pp. 529-537, (1999).
10. R. Radebaugh, Foundations of Cryocoolers Short Course Notes, Cryogenic Society of America, Oak
Park, IL, (June 13, 2006).
11. R. Akhavan, R. D. Kamm, and A. H. Shapiro, J. Fluid Mech. vol. 225, pp. 395-422, (1991).

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