A liquid-cooled dummy load control method and a liquid-cooled dummy load control system

Abstract

The application relates to the technical field of liquid cooling test equipment, and discloses a liquid cooling dummy load control method and a liquid cooling dummy load control system. A total power set value determined according to the heat dissipation power of a server is acquired; according to the total power set value and a preset phase-to-phase balance distribution strategy, single-phase load module balance distribution is performed on a three-phase power supply system to calculate three-phase power distribution values; according to the three-phase power distribution values and the single-phase load module configuration of each phase of the three-phase power supply system, the configuration strategy of the single-phase load module in each phase is calculated, so that the sum of the powers of each phase is the corresponding power distribution value and does not exceed the single-phase load module quantity limit of each phase through the configuration strategy; and single-phase load module switch control is performed on each phase of the three-phase power supply system according to the configuration strategy. The application is favorable for simulating the heat dissipation of a server under a real three-phase electrical load working condition, thereby meeting the high-standard requirements of modern data center liquid cooling system tests.

Description

Technical Field

[0001] This invention relates to the field of liquid-cooled testing equipment technology, and in particular to a control method for a liquid-cooled dummy load and a control system for a liquid-cooled dummy load. Background Technology

[0002] With the rapid development of liquid cooling technology in data centers, the demand for performance testing of liquid-cooled air conditioners and systems is increasing. To ensure the quality and performance of data center delivery, many newly built data centers use liquid-cooled dummy load testing equipment to cool the data center servers before formal acceptance and commissioning. During the test, the liquid-cooled system is used to replace the servers in the liquid-cooled dummy load testing equipment, which can obtain the cooling effect of the liquid cooling system on the servers. This allows for performance evaluation and stability testing of the liquid cooling system to determine whether it can meet the heat dissipation requirements of the data center.

[0003] In existing technologies, liquid-cooled dummy load testing equipment typically uses high-resistivity electric heating elements (such as alloy resistance wires) to simulate the heat output of a server. The principle is based on Joule's law: heat = current² × resistance × time. By controlling the current and resistance of the electric heating element, the heat output can be controlled. Its core objective is to simulate the thermal load of a server, generating heat equivalent to that of the server itself, thereby primarily testing the actual heat dissipation capacity of the liquid cooling system.

[0004] This dummy load can be considered a purely thermal dummy load or a basic thermal load simulator. However, since it generates heat through a resistance wire heating element, it can only achieve a simple change in total power and cannot simulate the heating situation of a server under real three-phase electrical load conditions.

[0005] Therefore, existing liquid-cooled dummy load testing equipment cannot simulate the heat generation of servers under real three-phase electrical load conditions, thus failing to meet the high standards required for testing modern data center liquid-cooled systems. Summary of the Invention

[0006] The main objective of this invention is to provide a control method and control system for a liquid-cooled dummy load, aiming to solve the technical problem that existing liquid-cooled dummy load testing equipment cannot simulate the heat generation of servers under real three-phase electrical load conditions, thus failing to meet the high standards required for testing modern data center liquid-cooled systems.

[0007] To achieve the above objectives, the present invention provides a control method for a liquid-cooled dummy load, which is applied to a liquid-cooled dummy load testing device. The liquid-cooled dummy load testing device includes a three-phase power supply system, and each phase of the three-phase power supply system is configured with multiple single-phase load modules of different power levels. The method includes the following steps:

[0008] Obtain the total power setting value determined based on the server's heat dissipation and power consumption;

[0009] Based on the total power setting value and the preset phase-to-phase balance distribution strategy, single-phase load modules are balanced and distributed to the three-phase power supply system to calculate the three-phase power distribution value; wherein, the sum of the three-phase power distribution values ​​is the total power setting value, and the absolute value of the difference between any two phase power does not exceed the preset threshold.

[0010] Based on the three-phase power allocation value and the configuration of single-phase load modules in each phase of the three-phase power supply system, calculate the configuration strategy of the single-phase load modules in each phase, so as to make the sum of the power of each phase equal to the corresponding power allocation value and not exceed the limit of the number of single-phase load modules in each phase.

[0011] According to the configuration strategy, single-phase load module switching control is performed on each phase of the three-phase power supply system.

[0012] Optionally, the method for calculating the three-phase power distribution value includes the following steps:

[0013] Set the total power setting to an integer value;

[0014] Calculate the integer k and remainder r of the average power distribution in the three-phase power distribution:

[0015] k = floor(P / 3), r = P-3k;

[0016] Where P is the total power setting value;

[0017] Based on the value of the remainder r, allocate the three-phase power:

[0018] If r=0, then the power of each phase in the three-phase power is k;

[0019] If r=1, then the power of one phase is k+1, and the power of the other two phases is k;

[0020] If r=2, then the power of two phases is k+1, and the power of the other phase is k.

[0021] Optionally, the single-phase load modules configured in each phase of the three-phase power supply system include: three first single-phase load modules with a power of 4kW; three second single-phase load modules with a power of 2kW; and two third single-phase load modules with a power of 1kW; the maximum power of each phase is 20kW; and the sum of the maximum power of the three phases is 60kW.

[0022] Optionally, the method for calculating the configuration strategy of the single-phase load module in each phase includes the following steps:

[0023] For each phase power allocation value p, let x be the number of first single-phase load modules used, y be the number of second single-phase load modules used, and z be the number of third single-phase load modules used; where... , , ;

[0024] ;

[0025] Determine x, y, and z using the following steps:

[0026] Step (1): Determine the z value:

[0027] If p is odd, then let z = 1;

[0028] If p is even and p≤18, then let z=0;

[0029] If p=20, then let z=2;

[0030] Step (2): Calculate the remaining power q = p - z;

[0031] Step (3): Calculate x = min(3, floor(q / 4));

[0032] Step (4): Calculate y = (q - 4x) / 2.

[0033] Optionally, the liquid-cooled dummy load testing equipment further includes a current sensor and a voltage sensor respectively installed for each phase; the method further includes:

[0034] The actual power output of each phase is detected using current and voltage sensors.

[0035] The switching state of the single-phase load module in each phase is adjusted by comparing the actual power output of each phase with the three-phase power distribution value.

[0036] Optionally, the liquid-cooled dummy load testing equipment further includes a temperature sensor for monitoring the temperature of each single-phase load module; the method further includes:

[0037] Monitor the operating status and temperature of each single-phase load module;

[0038] Determine whether each phase outputs the corresponding power allocation value based on the working status of each single-phase load module;

[0039] Based on the temperature of each single-phase load module, determine whether to perform switching control on the single-phase load module with abnormal temperature.

[0040] Optionally, the liquid-cooled dummy load control method is used to continuously test a cluster of servers under test, the cluster including multiple servers; the step of obtaining the total power setpoint determined based on the server's heat dissipation and power consumption includes:

[0041] Establish a running status feedback link to communicate with each server under test in the server cluster to be monitored, and obtain the actual power consumption data of each server under test in real time.

[0042] Dynamic power consumption simulation curves are generated based on the actual power consumption data of each server under test.

[0043] Based on the dynamic power consumption simulation curve of each server under test, the total power sampling value that needs to be tested separately for each server under test is obtained.

[0044] Optionally, the step of performing single-phase load module switching control on each phase of the three-phase power supply system according to the configuration strategy includes:

[0045] Based on each total power sample value, the phase-to-phase balance distribution strategy, and the configuration strategy of the single-phase load module in each phase, a three-phase power distribution value corresponding to each total power sample value and a configuration strategy of the single-phase load module in each phase are generated. Based on the configuration strategy of the single-phase load module in each phase, the switching state combination of each single-phase load module in each phase is determined under each total power sample value.

[0046] Evaluate the switching action cost between combinations of switching states for each total power sample value;

[0047] With the goal of minimizing the cost of switching actions and satisfying the phase-to-phase balance distribution strategy and the configuration strategy constraints of the single-phase load module of each phase, the test sequence of the total power sampling value is optimized to generate the time-series total power sampling value after the test sequence is optimized. The time-series total power sampling value includes the total power setting value of each server under test arranged in time sequence.

[0048] Based on the time-series total power sampling value, perform adaptive optimization continuous testing on multiple servers under test.

[0049] Optionally, the step of performing adaptive optimization continuous testing on multiple servers under test based on the time-series total power sampling value includes:

[0050] Obtain the set key thermal parameters of the liquid cooling system, and establish a thermal steady-state basis based on the key thermal parameters;

[0051] After the three-phase power supply system switches to the current total power setpoint in the time-series total power sampling value, the changes in key thermal parameters are continuously monitored;

[0052] The actual test duration for the current total power setting value in the current test phase is determined by whether the key thermal parameters have reached thermal steady state.

[0053] To achieve the above objectives, the present invention also provides a liquid-cooled dummy load control system for executing the control method of the liquid-cooled dummy load; the system includes:

[0054] The input module is used to obtain the total power setting value determined based on the server's heat dissipation and power consumption.

[0055] The calculation module is used to perform single-phase load module balancing allocation to the three-phase power supply system according to the total power setting value and the preset phase-to-phase balancing allocation strategy, so as to calculate the three-phase power allocation value. The sum of the three-phase power allocation values ​​is the total power setting value, and the absolute value of the difference between the power of any two phases does not exceed a preset threshold. Based on the three-phase power allocation value and the configuration of single-phase load modules in each phase of the three-phase power supply system, the module calculates the configuration strategy of the single-phase load modules in each phase, so as to make the sum of the power of each phase equal to the corresponding power allocation value, and not exceed the limit of the number of single-phase load modules in each phase.

[0056] The control module is used to perform single-phase load module switching control on each phase of the three-phase power supply system according to the configuration strategy.

[0057] The technical solution of this invention helps to solve the technical problem that existing liquid-cooled dummy load testing equipment cannot simulate the heat generation of servers under real three-phase electrical load conditions, thus failing to meet the high standards required for testing modern data center liquid-cooled systems. Specifically, the liquid-cooled dummy load testing equipment includes a three-phase power supply system, with each phase of the three-phase power supply system configured with multiple single-phase load modules of different power levels; it acquires a total power setpoint determined based on the server's heat generation and power consumption, and then, according to a preset phase-to-phase balance distribution strategy, performs a balance distribution of single-phase load modules to the three-phase power supply system to calculate the three-phase power distribution value. Then, based on the three-phase power distribution value and the configuration of single-phase load modules in each phase of the three-phase power supply system, it calculates the configuration strategy for the single-phase load modules in each phase, and then performs single-phase load module switching control on each phase of the three-phase power supply system according to the configuration strategy. Therefore, the technical solution of the present invention can adaptively perform single-phase load module switching control on each phase of the three-phase power supply system according to the server's heat dissipation, so as to adaptively balance the server's heat dissipation to the three-phase power supply system, thereby simulating the server's heat dissipation under real three-phase electrical load conditions, and meeting the high standards, automatic control, and adaptive adjustment of server heat dissipation requirements of modern data center liquid cooling system testing. Attached Figure Description

[0058] Figure 1 This is a flowchart of the first embodiment of the liquid-cooled dummy load control method of the present invention;

[0059] Figure 2 This is a schematic diagram of the functional modules of the liquid-cooled dummy load control system in this invention;

[0060] Figure 3 This is a flowchart illustrating the calculation of three-phase power distribution values ​​in this invention;

[0061] Figure 4 This is a flowchart illustrating the configuration strategy for calculating the single-phase load module in each phase in this invention.

[0062] The objectives, features, and advantages of this invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0063] It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the invention.

[0064] In the following description, the use of suffixes such as "unit," "component," or "element" to denote elements is solely for the purpose of illustrative purposes and has no specific meaning in itself. Therefore, "unit," "component," or "element" may be used interchangeably.

[0065] Please see Figures 1 to 4 The first embodiment of the present invention provides a control method for a liquid-cooled dummy load, applied to a liquid-cooled dummy load testing device. The liquid-cooled dummy load testing device includes a three-phase power supply system, and each phase of the three-phase power supply system is configured with multiple single-phase load modules of different power levels. The method includes the following steps:

[0066] Step S10: Obtain the total power setting value determined based on the server's heat dissipation and power consumption.

[0067] Step S20: Based on the total power setting value and the preset phase-to-phase balance distribution strategy, perform single-phase load module balance distribution to the three-phase power supply system to calculate the three-phase power distribution value; wherein, the sum of the three-phase power distribution values ​​is the total power setting value, and the absolute value of the difference between any two phase power does not exceed a preset threshold.

[0068] Step S30: Based on the three-phase power allocation value and the configuration of single-phase load modules in each phase of the three-phase power supply system, calculate the configuration strategy of the single-phase load modules in each phase, so as to make the sum of the power of each phase equal to the corresponding power allocation value and not exceed the limit of the number of single-phase load modules in each phase through the configuration strategy.

[0069] Step S40: Perform single-phase load module switching control on each phase of the three-phase power supply system according to the configuration strategy.

[0070] This invention addresses the technical problem that existing liquid-cooled dummy load testing equipment cannot simulate the heat generation of servers under real three-phase electrical load conditions. If liquid-cooled dummy load testing equipment is used to simulate the three-phase heat generation of servers, manual configuration of the heat load is required, which leads to the following problems:

[0071] 1. When configuring three-phase heating power, three-phase imbalance is prone to occur, which can lead to large three-phase deviations, affecting power grid stability and equipment safety.

[0072] 2. Complex and error-prone operation: The liquid-cooled dummy load test equipment requires different sized power modules to be configured each time according to the actual heat output of the server required for the test. This results in the need to manually connect different sized power modules for each test, which is time-consuming, labor-intensive, and prone to errors.

[0073] 3. Low efficiency: Manually connecting power modules of different sizes is inefficient and cannot be automatically controlled, thus failing to respond quickly to dynamic testing requirements and resulting in long test preparation time.

[0074] 4. Lack of optimization: The optimal use of modules cannot be guaranteed, which may lead to frequent switching of modules and reduce the lifespan of the equipment.

[0075] 5. Inability to control precisely: It is difficult to achieve precise power control and real-time adjustment.

[0076] Therefore, if a liquid-cooled dummy load test device is simply used to simulate the three-phase heat output of a server, the aforementioned problem of three-phase imbalance under dummy load will exist, affecting power grid stability and equipment safety. Furthermore, each test requires manual readjustment of the power module connection method, which cannot quickly respond to dynamic test requirements and has a long preparation time, thus failing to meet the high standard requirements of modern data center liquid cooling system testing.

[0077] The technical solution of this invention not only helps to solve the technical problem that existing liquid-cooled dummy load test equipment cannot simulate the heat generation of servers under real three-phase electrical load conditions, thus failing to meet the high standards of modern data center liquid-cooled system testing, but also solves the technical defects in the simulation of the three-phase heat generation power of servers by the aforementioned liquid-cooled dummy load test equipment. Specifically, the liquid-cooled dummy load test equipment includes a three-phase power supply system, each phase of which is configured with multiple single-phase load modules of different power levels; it obtains the total power setpoint determined according to the server's heat generation power consumption, and then performs single-phase load module balanced distribution to the three-phase power supply system according to a preset inter-phase balance distribution strategy to calculate the three-phase power distribution value; then, based on the three-phase power distribution value and the configuration of single-phase load modules in each phase of the three-phase power supply system, it calculates the configuration strategy of the single-phase load modules in each phase, and then performs single-phase load module switching control on each phase of the three-phase power supply system according to the configuration strategy. Therefore, the technical solution of the present invention can adaptively perform balanced distribution to each phase of the three-phase power supply system according to the server's heat dissipation and power consumption, and calculate the configuration strategy of the single-phase load module in each phase. Then, according to the configuration strategy, the single-phase load module switching control is executed, so that the server's heat dissipation and power consumption are adaptively balanced to the three-phase power supply system, thereby simulating the server's heat dissipation under real three-phase electrical load conditions, and meeting the high standards, automatic control and adaptive adjustment requirements of modern data center liquid cooling system testing for server heat dissipation and power consumption.

[0078] In one specific embodiment, the preset threshold can be set to 1kW, that is, the absolute value of the difference between the power of any two phases is set to not exceed 1kW.

[0079] After determining the three-phase power distribution value under the total power setpoint and the configuration strategy of the single-phase load module in each phase, single-phase load module switching control is performed on each phase of the three-phase power supply system according to the configuration strategy, so that the single-phase load module switching control on each phase reaches the test duration according to the configuration strategy. The test duration can be a preset duration or a test duration matched to the test endpoint.

[0080] According to the first embodiment of the control method for liquid-cooled dummy load of the present invention, and the second embodiment of the control method for liquid-cooled dummy load of the present invention, the method for calculating the three-phase power distribution value in step S20 includes the following steps:

[0081] Step S21: Set the total power setting value to an integer;

[0082] Calculate the integer k and remainder r of the average power distribution in the three-phase power distribution:

[0083] k = floor(P / 3), r = P-3k;

[0084] Where P is the total power setting value;

[0085] Step S22: Allocate three-phase power according to the value of the remainder r:

[0086] If r=0, then the power of each phase in the three-phase power is k;

[0087] If r=1, then the power of one phase is k+1, and the power of the other two phases is k;

[0088] If r=2, then the power of two phases is k+1, and the power of the other phase is k.

[0089] Specifically, when allocating three-phase power based on the remainder, the system sets allocation logic for different situations to ensure that the power allocation value for each phase is definite and unique.

[0090] For example, if r=1, then the power of phase A is k+1, and the power of the other two phases is k (other lower priority replacement strategies can be set so that if a fault occurs when the power of phase A is k+1, it is replaced by the power of phase B being k+1, or if a further fault occurs, it is replaced by the power of phase C being k+1); if r=2, then the power of phases A and B is k+1, and the power of phase C is k (again, other lower priority replacement strategies can be set so that if a fault occurs when the power of phase A is k+1, it is replaced by the power of phases B and C being k+1). This ensures that the system configuration strategy is unique and facilitates the execution of single-phase load module switching control for each phase.

[0091] According to the second embodiment of the control method for liquid-cooled dummy load of the present invention, and the third embodiment of the control method for liquid-cooled dummy load of the present invention, the single-phase load module configured in each phase of the three-phase power supply system includes: three first single-phase load modules with a power of 4kW; three second single-phase load modules with a power of 2kW; two third single-phase load modules with a power of 1kW; the maximum power of each phase is 20kW; and the sum of the maximum power of the three phases is 60kW.

[0092] Data center servers typically consume power in the tens of kilowatts. In this embodiment, the sum of the maximum power of the three phases of the three-phase power supply system is set to 60kW, which can meet the liquid cooling testing needs of most servers. Of course, based on the design concept of this invention, the total power of the three-phase power supply system can be set to be larger, which is also included within the scope of protection of this invention.

[0093] Specifically, a three-phase power supply system includes phase A, phase B, and phase C. The total maximum power of the three-phase power supply system can be determined based on the sum of the maximum power of the three phases, which is 60kW. Therefore, the total power setting cannot exceed the maximum total power, and the total power setting must be an integer.

[0094] Of course, based on the premise that the specifications and quantity of single-phase load modules in each phase of a three-phase power supply system are equal, the specifications and quantity of single-phase load modules in each phase can also be set in other ways. As long as the requirements of three-phase power distribution can be met, they are all included within the protection scope of this invention.

[0095] According to the third embodiment of the liquid-cooled dummy load control method of the present invention, and the fourth embodiment of the liquid-cooled dummy load control method of the present invention, the method for calculating the configuration strategy of the single-phase load module in each phase in step S30 includes the following steps:

[0096] For each phase power allocation value p, let x be the number of first single-phase load modules used, y be the number of second single-phase load modules used, and z be the number of third single-phase load modules used; where... , , ;

[0097] ;

[0098] Determine x, y, and z using the following steps:

[0099] Step (1): Determine the z value:

[0100] If p is odd, then let z = 1;

[0101] If p is even and p≤18, then let z=0;

[0102] If p=20, then let z=2;

[0103] Step (2): Calculate the remaining power q = p - z;

[0104] Step (3): Calculate x = min(3, floor(q / 4));

[0105] Step (4): Calculate y = (q - 4x) / 2.

[0106] Based on the above calculation method, two advantages can be achieved:

[0107] First, when allocating the total power setting value to three-phase power, the number of each type of single-phase load module used in each phase is unique;

[0108] For example, when the total power setting is 18kW, the power allocation value for each phase is 6kW, i.e., p is 6. In this case, there are multiple single-phase load module configuration strategies for each phase:

[0109] (1) One 4kW single-phase load module and one 2kW single-phase load module;

[0110] (2) One 4kW single-phase load module and two 1kW single-phase load modules;

[0111] (3) Three 2kW single-phase load modules;

[0112] (4) Two 2kW single-phase load modules and two 1kW single-phase load modules;

[0113] Therefore, the above four configuration strategies will result in a non-unique configuration strategy for each phase. However, by adopting the configuration strategy in this embodiment, the following calculations are obtained: z=0; q=p-0=6; x= min(3, floor(q / 4))=1; y = (q - 4x) / 2= (6- 4) / 2=1;

[0114] Therefore, the configuration strategy for the single-phase load module is determined as follows:

[0115] One 4kW single-phase load module and one 2kW single-phase load module are provided to ensure a unique solution.

[0116] Second, prioritize the use of larger single-phase load modules to reduce the number of switching control operations of single-phase load modules in each phase, ensuring optimal module usage and avoiding frequent module switching that could reduce equipment lifespan.

[0117] The following are specific calculation examples for two different total power settings:

[0118] Calculation Example 1:

[0119] Total power setting P = 17kW;

[0120] (1) Three-phase power distribution calculation:

[0121] k = floor(17 / 3) = 5, r = 17 - 3×5 = 2;

[0122] Based on r=2, the two-phase power is determined to be 6kW and the one-phase power is 5kW;

[0123] Allocation results: = 6kW, = 6kW, = 5kW;

[0124] (2) Calculate the configuration strategy for the single-phase load module in each phase:

[0125] Phase A (6kW):

[0126] Since p=6 is an even number and ≤18, z=0 and q=6.

[0127] x = min(3, floor(6 / 4)) = 1;

[0128] y = (6-4×1) / 2 = 1;

[0129] Configuration: 1 x 4kW module + 1 x 2kW module;

[0130] Phase B (6kW): Same as Phase A;

[0131] Phase C (5kW):

[0132] Since p=5 is an odd number, z=1 and q=4.

[0133] x = min(3, floor(4 / 4)) = 1;

[0134] y = (4-4×1) / 2 = 0;

[0135] Configuration: 1 4kW module + 1 1kW module;

[0136] (3) Control execution:

[0137] According to the configuration strategy, control the switching status of the corresponding modules so that one 4kW module and one 2kW module are turned on in phase A and phase B respectively, and one 4kW module and one 1kW module are turned on in phase C.

[0138] Calculation Example 2:

[0139] Total power setting P = 46kW;

[0140] (1) Three-phase power distribution calculation:

[0141] k = floor(46 / 3) = 15, r = 46 - 3×15 =1;

[0142] Based on r=1, the power of one phase is determined to be 16kW, and the power of the other two phases is 15kW.

[0143] Allocation results: = 16kW, = 15kW, = 15kW;

[0144] (2) Calculate the configuration strategy for the single-phase load module in each phase:

[0145] Phase A (16kW):

[0146] Since p=16 is an even number and ≤18, z=0 and q=16.

[0147] x = min(3, floor(16 / 4)) = 3;

[0148] y = (16 - 4 × 3) / 2 = 2;

[0149] Configuration: 3 x 4kW modules + 2 x 2kW modules;

[0150] Phase B (15kW):

[0151] Since p=15 is an odd number, z=1 and q=14.

[0152] x = min(3, floor(14 / 4)) = 3;

[0153] y = (14 - 4 × 3) / 2 = 1;

[0154] Configuration: 3 x 4kW modules + 1 x 2kW module + 1 x 1kW module;

[0155] Phase C (15kW): Same as Phase B;

[0156] (3) Control execution:

[0157] Based on the above configuration, control the on / off state of the corresponding modules.

[0158] According to the first embodiment of the liquid-cooled dummy load control method of the present invention, and the fifth embodiment of the liquid-cooled dummy load control method of the present invention, the liquid-cooled dummy load testing equipment further includes a current sensor and a voltage sensor respectively configured for each phase; the method further includes:

[0159] Step S50: Detect the actual power output of each phase based on the current sensor and voltage sensor;

[0160] Step S60: Based on the comparison between the actual power output of each phase and the three-phase power distribution value, adjust the switching state of the single-phase load module of each phase.

[0161] In this embodiment, a feedback control element can be added based on the basic control method:

[0162] 1. The power sensor monitors the actual output power of the three phases in real time through current and voltage sensors.

[0163] 2. Compare the actual power with the set value and calculate the error.

[0164] 3. If the error exceeds the allowable range (e.g., ±0.5kW), recalculate the configuration strategy of the single-phase load module in each phase or fine-tune the working state of the single-phase load module.

[0165] 4. Dynamic adjustment through PID control algorithm ensures stable and accurate power output.

[0166] According to the first embodiment of the liquid-cooled dummy load control method of the present invention, and the sixth embodiment of the liquid-cooled dummy load control method of the present invention, the liquid-cooled dummy load testing equipment further includes a temperature sensor for monitoring the temperature of each single-phase load module; the method further includes:

[0167] Step S70: Monitor the operating status and temperature of each single-phase load module;

[0168] Step S80: Determine whether each phase outputs the corresponding power allocation value based on the working status of each single-phase load module.

[0169] Step S90: Based on the temperature of each single-phase load module, determine whether to perform switching control on the single-phase load module with abnormal temperature.

[0170] The operating state of each single-phase load module can be determined by detecting the state of the switching device used to control the single-phase load module switch. The switching device can be a relay.

[0171] In one specific embodiment, when the server under test is a single unit, step S10 may include:

[0172] Obtain the heat dissipation and power consumption fluctuation time curve of the server under test to determine the server's maximum heat dissipation and power consumption, average heat dissipation and power consumption fluctuation pattern;

[0173] Based on the maximum heat dissipation, average heat dissipation, and heat dissipation fluctuation patterns, a total power setpoint test sequence is formed. In this total power setpoint test sequence, several heat dissipation peaks from the maximum heat dissipation, average heat dissipation, and heat dissipation fluctuation patterns are sorted according to preset rules. Then, according to the total power setpoint test sequence, steps S20 and S30 are executed respectively to calculate the three-phase power allocation value corresponding to each total power setpoint and the configuration strategy of the single-phase load module in each phase. Thus, when executing step S40, single-phase load module switching control is performed on each phase of the three-phase power supply system according to the total power setpoint test sequence and the preset test duration of each total power setpoint.

[0174] Using the above method, continuous testing of several peak values ​​of heat dissipation power consumption, average heat dissipation power consumption, and heat dissipation power consumption fluctuation patterns can be automatically performed on a single server under test according to the configuration strategy, thereby achieving maximum automation and reducing the test efficiency reduction, error rate, and three-phase imbalance faults caused by manual intervention.

[0175] Furthermore, based on the test sequence of the total power setpoint, the preset test duration of each total power setpoint, and the configuration strategy of the single-phase load module in each phase determined according to the corresponding total power setpoint in each test period, a continuous control command for each single-phase load module in the continuous test scenario is mapped to form a continuous control command for each single-phase load module in the continuous test scenario. According to the continuous control command, the switching state of the single-phase load module in each phase is controlled in different test periods in the continuous test scenario, so that the three-phase power distribution is automatically realized according to the phase-to-phase balance distribution strategy in different test periods.

[0176] According to the first to sixth embodiments of the liquid-cooled dummy load control method of the present invention, and in the seventh embodiment of the liquid-cooled dummy load control method of the present invention, the liquid-cooled dummy load control method is used to continuously test a cluster of servers to be monitored, the cluster including multiple servers to be tested; step S10 includes:

[0177] Step S11: Establish a running status feedback link with each server under test in the server cluster to be monitored, and obtain the actual power consumption data of each server under test in real time.

[0178] Step S12: Generate a dynamic power consumption simulation curve based on the actual power consumption data of each server under test;

[0179] Step S13: Based on the dynamic power consumption simulation curve of each server under test, obtain the total power sampling value that needs to be tested separately for each server under test.

[0180] In the seventh embodiment of the liquid-cooled dummy load control method of the present invention, and in the eighth embodiment of the liquid-cooled dummy load control method of the present invention, step S40 includes:

[0181] Step S41: Based on each total power sample value, the phase-to-phase balance distribution strategy, and the configuration strategy of the single-phase load module in each phase, generate a three-phase power distribution value corresponding to each total power sample value and a configuration strategy of the single-phase load module in each phase. Based on the configuration strategy of the single-phase load module in each phase, determine the switching state combination of each single-phase load module in each phase under each total power sample value.

[0182] Step S42: Evaluate the switching action cost between switching state combinations under each total power sample value;

[0183] Step S43: With the goal of minimizing the cost of switching action and satisfying the phase-to-phase balance distribution strategy and the configuration strategy constraints of the single-phase load module of each phase, the test sequence of the total power sampling value is optimized and solved to generate the time-series total power sampling value after the test sequence is optimized. The time-series total power sampling value includes the total power setting value of each server under test arranged in time sequence.

[0184] Step S44: Based on the time-series total power sampling value, perform adaptive optimization continuous testing on multiple servers under test.

[0185] Specifically, this embodiment is applicable to implementing a more optimized configuration strategy when performing continuous liquid cooling tests on server clusters.

[0186] The server cluster can be multiple servers under test belonging to the same data center, or multiple servers under test belonging to different data centers. The complete technical solution constructed in this embodiment, from data acquisition, curve generation, power allocation, combined calculation to sequence optimization, is beneficial for solving the equipment wear and tear problem under dynamic simulation of multiple servers.

[0187] The switching action cost is determined based on the total switching frequency in the switching state combination of each single-phase load module in each phase, and is used to determine the number of switching operations for each single-phase load module in each phase.

[0188] In the eighth embodiment of the liquid-cooled dummy load control method of the present invention, and in the ninth embodiment of the liquid-cooled dummy load control method of the present invention, step S44 includes:

[0189] Step S441: Obtain the set key thermal parameters of the liquid cooling system, and establish a thermal steady-state basis based on the key thermal parameters;

[0190] Step S442: After the three-phase power supply system switches to the current total power setting value in the time-series total power sampling value, continuously monitor the changes in key thermal parameters;

[0191] Step S443: The actual test duration of the current total power setting value in the current test phase is determined based on whether the key thermal parameters have reached thermal steady state.

[0192] Among them, the key thermal parameters can be the temperature difference between the inlet and outlet of the coolant main channel or other liquid cooling parameters; the thermal steady state criteria include: the rate of change of the key thermal parameters is continuously lower than the rate of change threshold for a predetermined time, or the instantaneous value of the key thermal parameters enters the permissible fluctuation bandwidth around the expected steady state value.

[0193] According to the above embodiments, in addition to adaptively determining the timing total power sampling value of the server cluster, the test duration under each total power setting value in the timing total power sampling value can also be adaptively controlled. For example, the test duration can be maintained at the second total power setting value for 2 hours and at the second total power setting value for 5 hours, thereby forming a complete configuration strategy for the server cluster under test without the need to manually set the holding time of each total power setting value.

[0194] The actual test duration for each total power setting can also be used to determine the duration for the liquid cooling equipment to reach thermal steady state, thus providing a basis for controlling the heat dissipation of the liquid cooling equipment under different heat generation and power consumption conditions.

[0195] Of course, the actual test duration for each total power setpoint can also be a set duration, which is adaptively sorted according to the order of each total power setpoint in the time-series total power sampling values ​​to form a corresponding control duration sequence.

[0196] For liquid cooling equipment, the corresponding liquid cooling test parameters can be automatically sorted according to the time-series total power sampling value to form time-series liquid cooling test parameters. Thus, the present invention can adaptively switch the liquid cooling test parameters as the total power setting value in the time-series total power sampling value changes, thereby further improving the intelligence of liquid cooling testing.

[0197] In the eighth embodiment and the tenth embodiment of the control method for liquid-cooled dummy load based on the present invention, the switching action cost is calculated in the following manner:

[0198] Step S421: Obtain the switching status of single-phase load modules of different power levels corresponding to each total power setting value;

[0199] Step S422: Calculate the similarity of the switching control of the three-phase power supply system with different total power settings based on the similarity of the switching states of single-phase load modules with different power levels in the three phases.

[0200] Step S423: Calculate the switching action cost based on the similarity of the three-phase power supply system switch control according to each total power setting value.

[0201] Specifically, the switching state of single-phase load modules of different power levels is determined according to the configuration strategy of single-phase load modules in each phase.

[0202] Each single-phase load module has a unique serial number, and its switching state is represented by a status symbol. The on state is marked with an "on" status symbol, and the off state with a "off" status symbol. Therefore, in a three-phase power supply system, each single-phase load module will generate a switching state matrix when executing the configuration strategy according to the determined total power setting. .

[0203] ;

[0204] in, This indicates the status symbol of the single-phase load module with sequence number i in phase A; This indicates the status symbol of the single-phase load module with sequence number i in phase B; This indicates the status symbol of the single-phase load module with sequence number i in phase C; 1≤i≤n, where n is the number of single-phase load modules in each phase.

[0205] If we set the on state symbol to 1 and the off state symbol to 0, then taking the total power setting of 18kW in the fourth embodiment as an example, with one 4kW single-phase load module and one 2kW single-phase load module per phase, the switching state matrix... for:

[0206] ;

[0207] Among them, the switch state matrix In each phase, the first three element positions represent the first single-phase load module, the fourth to sixth element positions represent the second single-phase load module, and the seventh to eighth element positions represent the third single-phase load module.

[0208] For any two total power settings and The corresponding switch state matrices are as follows: and The cost of switching between the two can be calculated based on the number of differences in the switching states of single-phase load modules of different power levels, the total number of single-phase load modules of each power level, and the magnitude of the switching impact of single-phase load modules of each power level:

[0209] ;

[0210] in, Indicates two total power settings and Cost of switching actions between them; Let J be the switching influence coefficient of the single-phase load module of the j-th power level in a three-phase power supply system, 1≤j≤J, where J is the number of power levels of the single-phase load module in the three-phase power supply system. Total power setting value Corresponding switch state matrix and total power setting value Corresponding switch state matrix In the example, the number of switching state differences of the single-phase load module of the j-th power level; Let be the number of single-phase load modules of the j-th power level in a three-phase power supply system.

[0211] One total power setting is selected from multiple total power settings as the starting total power setting (for example, the minimum total power setting, the maximum total power setting, or a selection condition for the starting total power setting can be set, and the starting total power setting will be automatically selected based on the selection condition). The remaining total power settings can then be sorted according to the calculation of the switching action cost relative to the previous total power setting, thereby forming a time-series total power sampling value. It can be set according to the power level to indicate the switching intention of single-phase load modules of different levels (the switching intention represents the degree of equipment loss caused by the switching). Of course, it can also be set to the power level of single-phase load modules corresponding to different power levels. Set them to be equal.

[0212] To achieve the above objectives, the present invention also proposes a liquid-cooled dummy load control system for executing the control method of the liquid-cooled dummy load; the system includes:

[0213] The input module is used to obtain the total power setting value determined based on the server's heat dissipation and power consumption.

[0214] The calculation module is used to perform single-phase load module balancing allocation to the three-phase power supply system according to the total power setting value and the preset phase-to-phase balancing allocation strategy, so as to calculate the three-phase power allocation value. The sum of the three-phase power allocation values ​​is the total power setting value, and the absolute value of the difference between the power of any two phases does not exceed a preset threshold. Based on the three-phase power allocation value and the configuration of single-phase load modules in each phase of the three-phase power supply system, the module calculates the configuration strategy of the single-phase load modules in each phase, so as to make the sum of the power of each phase equal to the corresponding power allocation value, and not exceed the limit of the number of single-phase load modules in each phase.

[0215] The control module is used to perform single-phase load module switching control on each phase of the three-phase power supply system according to the configuration strategy.

[0216] Of course, the liquid-cooled dummy load control system may further include a monitoring module, which includes a current sensor, a voltage sensor, and a temperature sensor.

[0217] Specifically, the system implementation method is as follows:

[0218] The control system of this invention can be implemented based on an embedded system, and the hardware platform includes:

[0219] Main controller: ARM Cortex-M series or similar microcontroller;

[0220] Input interfaces: touch screen, buttons, or communication interfaces (Modbus, Ethernet, etc.);

[0221] Output control: relay array or solid-state relay;

[0222] Monitoring modules: current sensor, voltage sensor, temperature sensor;

[0223] Communication module: Supports remote monitoring and data transmission;

[0224] Furthermore, the software implementation of the present invention includes: a user interface program; a core control algorithm program; a communication protocol stack; and a data recording and analysis program.

[0225] In terms of industrial applicability, this invention has been applied in actual liquid-cooled dummy load testing equipment with significant results:

[0226] 1. In the test of a liquid cooling system in a data center, the control method of this invention was used to control the three-phase balance deviation within 0.5kW, and the test efficiency was improved by 60%.

[0227] 2. In the R&D testing of a liquid-cooled air conditioner manufacturer, the application of this invention achieved automated load simulation, shortening the testing cycle by 30%.

[0228] 3. The equipment operates stably, the module lifespan is significantly extended, and maintenance costs are reduced.

[0229] This invention is not only applicable to liquid-cooled dummy load testing equipment, but can also be extended to other fields that require three-phase balanced load control, such as power system testing and power supply aging testing.

[0230] Compared with the prior art, the present invention has the following beneficial effects:

[0231] 1. When simulating the actual heat dissipation of the server, ensure three-phase balance: automatically calculate the three-phase power distribution through mathematical algorithms to ensure that the three-phase power deviation does not exceed 1kW, thereby improving the stability of the power grid and the safety of the equipment.

[0232] 2. Simple and efficient operation: Automatically calculates the optimal module configuration, reducing manual operation and shortening test preparation time by more than 60%.

[0233] 3. Optimize module usage: Prioritize the use of large single-phase load modules to reduce the number of switching operations and extend equipment life.

[0234] 4. Precise control: The algorithm can achieve precise power control with an accuracy of ±0.1%.

[0235] 5. Good real-time performance: Fast calculation speed, with an average calculation time of less than 10ms, suitable for real-time control systems.

[0236] 6. Strong robustness: The algorithm considers all possible power values, guaranteeing the existence and uniqueness of the solution.

[0237] 7. High scalability: The algorithm framework can be extended to dummy load devices of different sizes.

[0238] Through the above description of the embodiments, those skilled in the art can clearly understand that the methods of the above embodiments can be implemented by means of software plus necessary general-purpose hardware platforms. Of course, they can also be implemented by hardware, but in many cases the former is a better implementation method. Based on this understanding, the technical solution of the present invention, or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product is stored in a computer-readable storage medium (such as ROM / RAM, magnetic disk, optical disk) as described above, and includes several instructions to cause a terminal device to enter the methods described in the various embodiments of the present invention.

[0239] In the description of this specification, references to terms such as "one embodiment," "another embodiment," "other embodiments," or "first embodiment to Xth embodiment," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, method steps, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0240] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or system that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or system. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or system that includes that element.

[0241] The sequence numbers of the above embodiments of the present invention are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments.

[0242] The above are merely preferred embodiments of the present invention and do not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A control method for a liquid-cooled dummy load, characterized in that, The method is applied to a liquid-cooled dummy load testing device, which includes a three-phase power supply system, wherein each phase of the three-phase power supply system is configured with multiple single-phase load modules of different power levels; the method includes the following steps: Obtain the total power setting value determined based on the server's heat dissipation and power consumption; Based on the total power setpoint and the preset phase-to-phase balance distribution strategy, single-phase load modules are balanced and distributed to the three-phase power supply system to calculate the three-phase power distribution value. The sum of the three-phase power distribution values ​​is the total power setpoint, and the absolute value of the difference between any two phases does not exceed a preset threshold. The phase-to-phase balance distribution strategy is used to adaptively perform balance distribution to each phase of the three-phase power supply system according to the server's heat dissipation and power consumption. Combined with the configuration strategy of the single-phase load modules in each phase, the single-phase load module switching control is executed to enable the server's heat dissipation and power consumption to be adaptively balanced and distributed to the three-phase power supply system, so as to simulate the server's heat dissipation under real three-phase electrical load conditions. Based on the three-phase power allocation value and the configuration of single-phase load modules in each phase of the three-phase power supply system, calculate the configuration strategy of the single-phase load modules in each phase, so as to make the sum of the power of each phase equal to the corresponding power allocation value and not exceed the limit of the number of single-phase load modules in each phase. According to the configuration strategy, single-phase load module switching control is performed on each phase of the three-phase power supply system.

2. The control method for liquid-cooled dummy load according to claim 1, characterized in that, The method for calculating the three-phase power distribution value includes the following steps: Set the total power setting to an integer value; Calculate the integer k and remainder r of the average power distribution in the three-phase power distribution: k = floor(P / 3), r = P-3k; Where P is the total power setting value; Based on the value of the remainder r, allocate the three-phase power: If r=0, then the power of each phase in the three-phase power is k; If r=1, then the power of one phase is k+1, and the power of the other two phases is k; If r=2, then the power of two phases is k+1, and the power of the other phase is k.

3. The control method for liquid-cooled dummy load according to claim 2, characterized in that, In a three-phase power supply system, each phase is configured with the following single-phase load modules: the first single-phase load module consists of 3 modules with a power of 4kW; the second single-phase load module consists of 3 modules with a power of 2kW; the third single-phase load module consists of 2 modules with a power of 1kW; the maximum power of each phase is 20kW; and the sum of the maximum power of the three phases is 60kW.

4. The control method for liquid-cooled dummy load according to claim 3, characterized in that, The method for calculating the configuration strategy of the single-phase load module in each phase includes the following steps: For each phase power allocation value p, let x be the number of first single-phase load modules used, y be the number of second single-phase load modules used, and z be the number of third single-phase load modules used; where... , , ; ； Determine x, y, and z using the following steps: Step (1): Determine the z value: If p is odd, then let z = 1; If p is even and p≤18, then let z=0; If p=20, then let z=2; Step (2): Calculate the remaining power q = p - z; Step (3): Calculate x = min(3, floor(q / 4)); Step (4): Calculate y = (q - 4x) / 2.

5. The control method for liquid-cooled dummy load according to claim 1, characterized in that, The liquid-cooled dummy load testing equipment also includes a current sensor and a voltage sensor separately installed for each phase; the method further includes: The actual power output of each phase is detected using current and voltage sensors. The switching state of the single-phase load module in each phase is adjusted by comparing the actual power output of each phase with the three-phase power distribution value.

6. The control method for liquid-cooled dummy load according to claim 1, characterized in that, The liquid-cooled dummy load testing equipment also includes a temperature sensor for monitoring the temperature of each single-phase load module; the method further includes: Monitor the operating status and temperature of each single-phase load module; Determine whether each phase outputs the corresponding power allocation value based on the working status of each single-phase load module; Based on the temperature of each single-phase load module, determine whether to perform switching control on the single-phase load module with abnormal temperature.

7. The control method for liquid-cooled dummy load according to any one of claims 1 to 6, characterized in that, The liquid-cooled dummy load control method is used for continuous testing of a server cluster under test, which includes multiple servers under test; the step of obtaining the total power setpoint determined based on the server's heat dissipation and power consumption includes: Establish a running status feedback link to communicate with each server under test in the server cluster to be monitored, and obtain the actual power consumption data of each server under test in real time. Dynamic power consumption simulation curves are generated based on the actual power consumption data of each server under test. Based on the dynamic power consumption simulation curve of each server under test, the total power sampling value that needs to be tested separately for each server under test is obtained.

8. The control method for liquid-cooled dummy load according to claim 7, characterized in that, The step of performing single-phase load module switching control on each phase of the three-phase power supply system according to the configuration strategy includes: Based on each total power sample value, the phase-to-phase balance distribution strategy, and the configuration strategy of the single-phase load module in each phase, a three-phase power distribution value corresponding to each total power sample value and a configuration strategy of the single-phase load module in each phase are generated. Based on the configuration strategy of the single-phase load module in each phase, the switching state combination of each single-phase load module in each phase is determined under each total power sample value. Evaluate the switching action cost between combinations of switching states for each total power sample value; With the goal of minimizing the cost of switching actions and satisfying the phase-to-phase balance distribution strategy and the configuration strategy constraints of the single-phase load module of each phase, the test sequence of the total power sampling value is optimized to generate the time-series total power sampling value after the test sequence is optimized. The time-series total power sampling value includes the total power setting value of each server under test arranged in time sequence. Based on the time-series total power sampling value, perform adaptive optimization continuous testing on multiple servers under test.

9. The control method for liquid-cooled dummy load according to claim 8, characterized in that, The step of performing adaptive optimization continuous testing on multiple servers under test based on the time-series total power sampling value includes: Obtain the set key thermal parameters of the liquid cooling system, and establish a thermal steady-state basis based on the key thermal parameters; After the three-phase power supply system switches to the current total power setpoint in the time-series total power sampling value, the changes in key thermal parameters are continuously monitored; The actual test duration for the current total power setting value in the current test phase is determined by whether the key thermal parameters have reached thermal steady state.

10. A liquid-cooled dummy load control system, characterized in that, A control method for performing a liquid-cooled dummy load as described in any one of claims 1 to 9; the system includes: The input module is used to obtain the total power setting value determined based on the server's heat dissipation and power consumption. The calculation module is used to perform single-phase load module balancing distribution to the three-phase power supply system according to the total power setpoint and the preset inter-phase balancing distribution strategy, so as to calculate the three-phase power distribution value. The sum of the three-phase power distribution values ​​is the total power setpoint, and the absolute value of the difference between any two phases does not exceed a preset threshold. Based on the three-phase power distribution value and the configuration of single-phase load modules in each phase of the three-phase power supply system, the module calculates the configuration strategy of the single-phase load modules in each phase, so as to make the sum of the power of each phase equal to the corresponding power distribution value, and not exceed the limit of the number of single-phase load modules in each phase. The inter-phase balancing distribution strategy is used to adaptively perform balancing distribution to each phase of the three-phase power supply system according to the server's heat dissipation and power consumption, and combined with the calculated configuration strategy of the single-phase load modules in each phase, execute the switching control of the single-phase load modules, so that the server's heat dissipation and power consumption are adaptively balanced and distributed to the three-phase power supply system, thereby simulating the server's heat dissipation under real three-phase electrical load conditions. The control module is used to perform single-phase load module switching control on each phase of the three-phase power supply system according to the configuration strategy.

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