Cryocooler controller systems and methods

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Solution Overview

Problem

Conventional cryocooler controllers are inefficient, noisy, and generate significant waste heat, which negatively impacts the weight, cost, and performance of cryogenic refrigeration systems, particularly in compact applications such as infrared cameras where low noise and high sensitivity are required.

Innovation Solution

A compact and efficient cryocooler controller design featuring a motor driver controller that generates clean, noise-free drive signals using a buck-boost inverter stage with a minimal number of components, achieving efficiencies greater than 95% and reducing waste heat, allowing for higher cooling powers and lower operating temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional cryocooler controllers are used, then basic cooling control is achieved, but waste heat generation increases and efficiency decreases

Engineering Contradiction:

Improvewaste heatVSAvoidcontroller efficiency

Core Design Contradiction:

Loss of energyVSUse of energy by moving object

Solution Approach 1:

The patent extracts and removes the problematic conventional controller components that generate waste heat, replacing them with an optimized controller design that eliminates the harmful thermal byproducts while maintaining cooling control functionality

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the operational parameters of the controller to achieve greater than 95% efficiency, specifically optimizing the motor driver controller and inverter stage parameters to minimize energy loss and waste heat generation during cryocooler operation

Inventive Principle:

Principle #35Parameter changes

2Reliability

If conventional controllers are used, then cooling control is provided, but noise is generated that degrades sensor performance

Engineering Contradiction:

Improvesensor system performanceVSAvoidcontroller noise

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent converts the potentially harmful noise-generating operations of the controller into beneficial clean drive signals through optimized inverter stage design, where the switching operations that traditionally create noise are reconfigured to produce electromechanically clean outputs that enhance rather than degrade sensor performance

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Weight of moving object

If conventional controllers are used, then basic operation is maintained, but system weight increases

Engineering Contradiction:

Improvecontroller weightVSAvoidsystem performance

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent segments the controller into functional modules (motor driver controller, inverter stage, motor driver) that can be optimized independently, allowing reduction of overall controller weight while maintaining or improving system performance through targeted optimization of each segment

Inventive Principle:

Principle #1Segmentation

4Volume of moving object

If compact cryocooler design is implemented, then size is reduced, but cooling power may be compromised

Engineering Contradiction:

Improvecryocooler volumeVSAvoidcooling power

Core Design Contradiction:

Volume of moving objectVSPower

Solution Approach 1:

The patent changes key operational parameters including achieving greater than 95% controller efficiency and optimizing the buck-boost inverter stage to deliver high current capability in a compact form, thereby maintaining high cooling power output despite reduced system volume

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution enables higher performance and reliability in cooled sensor systems by minimizing noise and variability in infrared imagery, facilitating integration in compact applications like spaceflight and infrared cameras with improved cooling powers and stable operating temperatures.

Implementation Method 1

A motor driver controller generates electromechanically clean drive signals using a buck-boost inverter stage with a minimal number of components

Methodology Applied

Scientific EffectBuck-boost inverter:

Data Source

PatentUS11635244B2Cryocooler controller systems and methods

Publication Date: 2023.04.25 TELEDYNE FLIR COMMERICAL SYST INC

AI summary

Techniques are disclosed for systems and methods to control operation of a cryocooler/refrigeration system to provide cryogenic and/or general cooling of a device or sensor system. A cryocooler controller includes a motor driver controller configured to generate motor driver control signals based on operational parameters corresponding to operation of a cryocooler controlled by the controller, and a motor driver configured to generate corresponding drive signals to drive a motor of the cryocooler. The motor driver includes a first stage with a first pair of switches coupled serially between an input of the motor driver and a ground of the motor driver, a second pair of switches coupled serially between an output of the first stage and the ground of the motor driver, and an inductor coupled between the first and second pairs of switches, where operation of each switch is independently controlled by the motor driver control signals.