Cooling distribution unit pump efficiency optimization

Abstract

A cooling distribution unit pump efficiency optimization is provided in which a cooling distribution unit includes a primary closed loop, a secondary closed loop, and a heat exchanger configured to receive at least a portion of the primary closed loop, to receive at least a portion of the secondary closed loop, and to receive at least a portion of the secondary closed loop. And draw heat away from the portion of the secondary closed loop and conduct heat to the portion of the primary closed loop. A first pump is connected to the secondary closed circuit. A second pump is connected to the secondary closed circuit. The cooling distribution unit also includes a plurality of sensors and a controller. The controller is configured to optimize an operating parameter of the given pump based on a correlation of a thermal load of the given pump and a power consumption of the given pump.

Description

Cross-reference to related applications

[0001] This application claims priority to U.S. Provisional Application No. 63 / 709,123, filed October 18, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This disclosure generally relates to the control of a cooling distribution unit pump configured to help direct heat away from electrical components. Background Technology

[0003] Cooling distribution units (often called CDUs) are typically used in data centers to remove heat from computer components such as servers and server racks. Cooling distribution units can include, for example, both in-row units and in-rack units. In-row units remove heat from an entire row of server racks or other groups of electrical components, while in-rack units typically remove heat from a single rack or group of electrical components. Summary of the Invention

[0004] According to one example, a cooling distribution unit is provided, the cooling distribution unit comprising: a primary closed loop configured to allow a first fluid to flow through; a secondary closed loop configured to allow a second fluid to flow through; and a heat exchanger. The heat exchanger is configured to: receive at least a portion of the primary closed loop; receive at least a portion of the secondary closed loop; and draw heat away from the portion of the secondary closed loop and conduct the heat to the portion of the primary closed loop. A first pump is connected to the secondary closed loop. A second pump is connected to the secondary closed loop. The cooling distribution unit further comprises a plurality of sensors and a controller. The controller is configured to: store and update operating parameters of the first pump and the second pump in a memory; correlate the heat load of a given pump selected from the first pump or the second pump with the power consumption of the given pump; and optimize the operating parameters of the given pump based on the correlation between the heat load of the given pump and the power consumption of the given pump.

[0005] According to another example, a method includes: determining the energy consumption of a pump in a cooling distribution unit; determining the heat load of the pump; determining the efficiency of the pump by relating the energy consumption of the pump to the heat load of the pump; predicting optimized operating parameters of the pump based on stored system data and the determined pump efficiency; and optimizing the operating parameters of the pump based on the predicted optimized operating parameters of the pump.

[0006] Details of one or more aspects of this disclosure are set forth in the accompanying drawings and the following description. Other features, objects, and advantages of the technology described in this disclosure will be apparent from the description and drawings and from the claims. Attached Figure Description

[0007] Figure 1 This is a schematic diagram based on an example cooling distribution unit.

[0008] Figure 2 yes Figure 1 A perspective view of the cooling distribution unit.

[0009] Figure 3 yes Figure 1 Another perspective view of the cooling distribution unit.

[0010] Figure 4 yes Figure 1 Another perspective view of the cooling distribution unit.

[0011] Figure 5 It shows that according to some aspects Figures 2 to 4 Block diagram of the controller.

[0012] Figure 6 It shows Figure 1 The flowchart shows the automatic restart operation of the cooling distribution unit.

[0013] Figure 7 It shows the configuration to direct Figure 1 The transformer supplies power to the pressure-independent control valves of the cooling distribution unit.

[0014] Figure 8 It is shown in the figure. Figure 1 The service screen on the display of the cooling distribution unit.

[0015] Figure 9 It is shown in the figure. Figure 1 The main menu screen is displayed on the cooling distribution unit's display.

[0016] Figure 10 It is shown in the figure. Figure 1 The service screen on the display of the cooling distribution unit.

[0017] Figure 11 It is shown in the figure. Figure 1 The configuration screen on the display of the cooling distribution unit.

[0018] Figure 12 It is shown in the figure. Figure 1 The configuration screen on the display of the cooling distribution unit.

[0019] Figure 13 It is shown in the figure. Figure 1 The diagnostic screen on the display of the cooling distribution unit.

[0020] Figure 14 This demonstrates the optimization of pump operation in the cooling distribution unit to achieve Figure 1 A flowchart of a method for maximizing the energy efficiency of a cooling distribution unit. Detailed Implementation

[0021] Figures 1 to 4 An example of a cooling distribution unit 110 is shown. The cooling distribution unit 110 can be used in any of a variety of application environments, including, for example, server, data center, medical, semiconductor, and / or industrial applications. The cooling distribution unit 110 shown is an inline unit; however, any concepts described herein related to the cooling distribution unit 110 can alternatively be used with rack-mount units or with any other type of cooling distribution unit.

[0022] refer to Figure 1 The cooling distribution unit 110 typically includes a primary closed loop 114 and a secondary closed loop 118. The primary closed loop 114 circulates a first fluid (e.g., facility water located at and / or otherwise supplied at the data server center). The secondary closed loop 118 circulates a second fluid (e.g., a process aqueous solution comprising 25% propylene glycol and 75% water). Other examples include different first and second fluids within either the primary closed loop 114 or the secondary closed loop 118. Figures 2 to 4 As shown, the primary closed loop 114 includes a conduit (e.g., a stainless steel conduit) through which a first fluid circulates. The secondary closed loop 118 similarly includes a conduit (e.g., a stainless steel conduit) through which a second fluid circulates. In some examples, at least a portion of the conduit for the primary closed loop 114 and / or the secondary closed loop 118 is cylindrical in shape and / or has a circular cross-section. In some examples, at least a portion of the conduit for the primary closed loop 114 and / or the secondary closed loop 118 has linear sections and / or curved sections. Other examples include other types of conduits, including conduits made of other materials (e.g., metals or non-metals), or conduits having other shapes and configurations than those shown.

[0023] In some examples, the first fluid may consist of water or an aqueous solution of propylene glycol with a maximum concentration of 50%, or may include water or an aqueous solution of propylene glycol with a maximum concentration of 50%. In other words, the concentration of the aqueous solution of propylene glycol may have a maximum concentration of 10 mg / L. The second fluid may consist of water or a premixed solution of unsuppressed ethylene glycol or propylene glycol and water, or may include water or a premixed solution of unsuppressed ethylene glycol or propylene glycol and water. The first and second fluids may have a maximum particle size of less than 200 micrometers. Other examples may include other materials and / or material composition and / or particle size of the first and / or second fluids.

[0024] Continue to refer to Figure 1 The secondary closed loop 118 allows a second fluid to circulate through and / or across one or more electrical components 122 to absorb heat from the electrical components 122. The electrical components 122 may include, for example, computer chips or other heated electrical components in one or more servers or server racks. In some examples, a cold plate or other heating device may be positioned above the computer chip, and the conduit of the secondary closed loop may pass through the cold plate or other heating device to absorb heat from the electrical components 122. Once the second fluid in the secondary closed loop 118 has been heated by the electrical components 122, the heated second fluid is directed to the heat exchanger 126.

[0025] Continue to refer to Figure 1 Each of the primary closed loop 114 and the secondary closed loop 118 extends through the heat exchanger 126. In the example shown, the heat exchanger 126 is a liquid-liquid heat exchanger. The primary closed loop 114 extends in the first direction (e.g., as shown in the example). Figure 1 The first fluid is guided upwards (to the left) through the heat exchanger 126, while the secondary closed loop 118 is guided upwards in the second direction (e.g., as shown in the left direction). Figure 1 The second fluid is guided upwards (to the right) through heat exchanger 126. In the example shown, the first direction is parallel to and opposite to the second direction. In other examples, the first and second fluids may be guided in the same direction or in a transverse direction, or the first and second fluids may move in more than one direction within heat exchanger 126.

[0026] Within heat exchanger 126, heat is exchanged between a second fluid and a first fluid. Therefore, at least a portion of the heat absorbed from electrical component 122 is transferred from the second fluid to the first fluid within heat exchanger 126. In some examples, the conduit of the primary closed loop 114 does not contact the conduit of the secondary closed loop 118 within heat exchanger 126, and heat is exchanged through an intermediate material (e.g., through a thermally conductive material). Other examples may include various other types, numbers, or arrangements of heat exchangers 126 besides those shown.

[0027] Continue to refer to Figure 1 The primary closed loop 114 guides the first fluid (after it has been heated in the heat exchanger 126) away from the heat exchanger 126 and to the cooling structure 130. The cooling structure 130 may be located, for example, within a data server center. The cooling structure 130 can be any of a variety of different structures, including a cooling tower or other thermal equipment that removes or otherwise removes heat from the first fluid. In some examples, the cooling structure 130 may include cold plates, fins, and / or other heat-removing structures, and / or may use one or more fans to facilitate heat removal from the first fluid.

[0028] like Figure 1 As shown, once heat has been removed from the first fluid at cooling structure 130, the first fluid then circulates back towards heat exchanger 126. Similarly, once heat has been removed from the second fluid at heat exchanger 126, the second fluid circulates back towards electrical component 122. This circulation through each of the primary closed loop 114 and secondary closed loop 118 can continue (e.g., as long as electrical component 122 is generating heat), such that heat is continuously absorbed from the electrical component and transported to heat exchanger 126, where heat is then transferred to the first fluid and primary closed loop 114, and finally discarded at cooling structure 130.

[0029] Continue to refer to Figure 1Each closed loop in the primary closed loop 114 and the secondary closed loop 118 may include one or more pumps to pump a first fluid and a second fluid through conduits. In the illustrated example, the primary closed loop 114 includes one or more pumps (not shown) located within the data server center (e.g., at the location of cooling structure 130 or elsewhere within the data server center) to pump a first fluid (e.g., facility water) through the primary closed loop 114. The secondary closed loop 118 includes a first pump 134 and a second pump 138. The first pump 134 and the second pump 138 are redundant pumps, positioned along parallel conduits within the closed loop such that if one pump fails, the other pump can continue to operate the overall flow of the second fluid within the secondary closed loop 118. The first pump 134 and the second pump 138 can be any type of pump capable of pumping the second fluid. In some examples, the first pump 134 and the second pump 138 are identical pumps having the same dimensions and / or rated parameters. In some examples, one or more of the first pump 134 or the second pump 138 are centrifugal pumps. Other examples include other types of pumps and multiple pumps. For example, in some examples, the secondary closed loop 118 may include only a single pump, or it may include more than two pumps. Generally, the first pump 134 and / or the second pump 138 may generate flow rates, for example, between 25 gallons per minute (GPM) and 200 GPM, such as 25 GPM, 50 GPM, 100 GPM, 125 GPM, 140 GPM, 160 GPM, or other values ​​and ranges.

[0030] Continue to refer to Figure 1 In some examples, the secondary closed loop 118 includes a refill tank 142 and a replenishment pump 146 for adding additional second fluid to the secondary closed loop 118. Additionally, in some examples, the secondary closed loop 118 includes at least one expansion tank for controlling the total pressure and flow rate of the second fluid in the secondary closed loop 118. In the illustrated example, the secondary closed loop 118 includes a first expansion tank 150 and a second (e.g., redundant) expansion tank 154. Other examples may include only a single expansion tank or more than two expansion tanks.

[0031] Additionally, both the primary closed loop 114 and the secondary closed loop 118 may include one or more valves (e.g., pressure control valves, check valves, pressure-independent control valves, etc.) that operate to control the total pressure and / or flow rate of fluid passing through the cooling distribution unit 110. In the example shown, the primary closed loop 114 includes a pressure-independent control valve 158.

[0032] Continue to refer to Figure 1In the illustrated example, the cooling distribution unit 110 includes a housing 162 (e.g., an outer shell). The housing 162 may include a steel frame (e.g., with interconnected vertical and / or horizontal frame members), or it may be another type of frame, or be formed of a different material. In some examples, the housing 162 includes one or more doors (e.g., pivotally connected or otherwise attached to the frame). Other examples besides those shown may include housings 162 of various other types, sizes, and / or shapes. In the illustrated example, the housing 162 includes a first outlet 166, at which a primary closed loop 114 exits the housing, and a first fluid is delivered to the cooling structure 130. The housing 162 also includes a first inlet 170 at which the primary closed loop 114 enters the housing, and where the first fluid is then directed to a heat exchanger 126 (e.g., located within the housing 162). The housing 162 also includes a second outlet 174 and a second inlet 178, a secondary closed loop 118 exits the housing at the second outlet 174, and a second fluid is sent to the electrical component 122, enters the housing at the second inlet 178, and is then directed to the heat exchanger 126.

[0033] Continue to refer to Figure 1 In some examples, the cooling distribution unit 110 further includes one or more sensors that measure pressure, temperature, or other aspects of the cooling distribution unit 110. In the example shown, the cooling distribution unit 110 includes multiple pressure and temperature sensors generally located at a first outlet 166, a first inlet 170, a second outlet 174, and a second inlet 178. Figure 1 (marked as "PT" and "RTD" in Chinese). For example... Figure 1As shown, the cooling distribution unit 110 may include redundant pressure and temperature sensors (e.g., in case one or more sensors fail or provide inaccurate readings). In the example shown, two redundant pressure sensors PT3A and PT3B are mounted near the first inlet 170 of the primary closed loop 114, and are configured to sense the inlet pressure at the first inlet 170 of the primary closed loop 114. Two redundant pressure sensors PT2A and PT2B are also mounted near the second inlet 178 of the secondary closed loop 118, and are configured to sense the inlet pressure at the second inlet 178 of the secondary closed loop 118. Additionally, two redundant pressure sensors PT4A and PT4B are mounted near the first outlet 166 of the primary closed loop 114, and are configured to sense the outlet pressure at the first outlet 166 of the primary closed loop 114. Two redundant pressure sensors, PT2A and PT2B, are mounted near the second outlet 174 of the secondary closed loop 118, and are configured to sense the outlet pressure at the second outlet 174 of the secondary closed loop 118. Pressure sensor PT3F is mounted near the first input F3 of the heat exchanger 126, and pressure sensor PT2F is mounted near the second input F2 of the heat exchanger 126. Each pressure transducer can be used to measure the fluid pressure at a specific point in the system. In the example shown, the pressure transducers are rated from 0 to 100 psi (PSIG), but in other examples they may be rated for other PSIG ranges.

[0034] In the example shown, two redundant temperature sensors (e.g., resistive temperature detectors [RTDs]) T3A and T3B are installed near the inlet of the primary closed loop 114, and two temperature sensors (e.g., RTDs) T4A and T4B are installed near the outlet of the primary closed loop 114. Additionally, two redundant temperature sensors T2A and T2B are installed near the inlet of the secondary closed loop 118, and two temperature sensors RTDs T1A and T1B are installed near the outlet of the secondary closed loop 118. These temperature sensors are used to measure the fluid temperature at certain locations within the system. In the example shown, all temperature sensors are rated from 0°C to 150°C, but in other examples they may be rated for other temperature ranges.

[0035] In some examples, these sensors (e.g., wired or wireless) are connected to controller 182 ( Figures 1 to 4This controller 182 may be connected to other devices that receive signals regarding the pressure and temperature of the first and second fluids. In the illustrated example, the controller 182 is located on and / or within the housing 162 and may include a user interface (e.g., a graphical user interface, such as a color touchscreen). In some examples, the controller 182 is positioned remotely from the housing 162. In some examples, the controller 182 may be used to monitor pressure, monitor temperature, and / or control the flow rate and pressure differential of the second fluid.

[0036] Figure 5 It shows that according to some aspects Figures 2 to 4 A block diagram of controller 182. Controller 182 specifically includes an electronic processor 500, a memory 502, and an input / output (I / O) interface 504. The electronic processor 500, memory 502, and I / O interface 504 communicate via one or more control and / or data buses. Figure 5 Only one example of controller 182 is shown. Controller 182 may include more or fewer components and may perform functions other than those explicitly described herein.

[0037] In some examples, the electronic processor 500 is implemented as a microcontroller with a separate memory (such as memory 502). In other examples, the electronic processor 500 may be implemented as a microcontroller with memory 502 on the same chip. In still other examples, the electronic processor 500 may be implemented partially or entirely as, for example, a field-programmable gate array (FPGA), an application-specific integrated circuit (ASIC), etc., and may not require memory 502 or may be modified accordingly.

[0038] In the example shown, memory 502 includes a non-transitory computer-readable storage medium (or medium) storing instructions received and executed by electronic processor 500 to perform the functions of the cooling distribution unit 110 described herein. Memory 502 may include, for example, a program storage area and a data storage area. The program storage area and the data storage area may include combinations of different types of memory, such as non-volatile read-only memory, non-volatile flash memory, and volatile random access memory. The data storage area includes system data 505, which includes data collected from sensors 510, 512, 514, 516 of the cooling distribution unit 110 (e.g., temperature sensor 510, pressure sensor 512, dew point sensor 514, and flow meter 516), and also includes data on the settings and configurations of components of the cooling distribution unit 110 (e.g., pumps 134, 138, sensors 510, 512, 514, 516, expansion tanks 150, 154, various filters, various valves, various switches, etc.). In some embodiments, memory 502 stores differential pressure mode instruction 506 and flow rate mode instruction 508. When executing differential pressure mode instruction 506, electronic processor 500 can operate controller 182 according to the differential pressure mode, as described in more detail below. When executing flow rate mode instruction 508, electronic processor 500 can operate controller 182 according to the flow rate mode, as described in more detail below.

[0039] The controller 182 receives feedback regarding the status of the cooling distribution unit 110 from temperature sensor 510, pressure sensor 512, dew point sensor 514, and flow meter 516. For example, temperature sensor 510 is mounted near the inlet and outlet locations of the primary closed loop 114 and secondary closed loop 118 (e.g., first outlet 166, first inlet 170, second outlet 174, and second inlet 178). Temperature sensor 510 is configured to sense the fluid temperature at its respective location. Temperature sensor 510 is configured to provide the controller 182 with a temperature signal indicating the fluid temperature.

[0040] Pressure sensor 512 is also mounted near the inlet and outlet locations of the primary closed loop 114 and the secondary closed loop 118 (e.g., first outlet 166, first inlet 170, second outlet 174, and second inlet 178). Pressure sensor 512 is configured to measure fluid pressure at its respective location. Pressure sensor 512 is configured to provide a pressure signal indicating the fluid pressure to controller 182.

[0041] Dew point sensor 514 is configured to provide a dew point signal to controller 182 indicating the current dew point temperature and ambient air temperature. Flow meters 516 (e.g., flow meters FM1, FM2) are installed on the first outlet 166 and the second outlet 174, and these flow meters 516 are configured to provide a flow signal to controller 182 indicating the flow rate of fluid exiting housing 162 via the first outlet 166 and the second outlet 174.

[0042] The controller 182 can be configured to control the regulating valve 518 to control the flow rate of fluid within the cooling distribution unit 110. For example, the regulating ball valve 518 can be located at a first outlet 166, a first inlet 170, a second outlet 174 and / or a second inlet 178 to control the flow of fluid into and out of the primary closed loop 114 and / or the secondary closed loop 118.

[0043] The controller 182 may include and / or be electrically connected to a capacitor 519, which is used to store energy to provide power to the controller 182.

[0044] The human-machine interface 520 is connected to the controller 182 and configured to transmit user input to the controller 182. The human-machine interface 520 may include a display (e.g., a touchscreen) and may include buttons, knobs, sliders, toggle switches, and other types of input devices. As will be described in more detail below, the human-machine interface 520 is configured to display a graphical user interface that can provide feedback to the user when the user interacts with the input devices of the human-machine interface 520.

[0045] Figure 6 A flowchart of a method 600 for operating the cooling distribution unit 110 is shown. This method can be implemented by the controller 182 using, for example, an electronic processor 500.

[0046] In the event of a power outage, an automatic restart algorithm can be executed at step 610. The automatic restart algorithm begins when a power drop and / or power failure is detected for a given duration. During operation, method 600 includes storing the current operating settings in, for example, memory 502 at step 612. In one example, operating settings (e.g., operating parameters) are continuously stored in memory 502. At step 614, in the event of a detected power drop and / or power failure, the most recent operating settings are resent to the cooling distribution unit 110 upon power restoration.

[0047] Capacitor 519 ( Figure 5 The cooling distribution unit 110 is configured to store enough energy to provide power to operate for a given amount of time. In one example, the cooling distribution unit 110 can experience a full second of power outage without intervention.

[0048] Go to Figure 7 In one example, the cooling distribution unit 110 includes a transformer 700 that supplies 24V AC power to the pressure-independent control valve 158. For a 380V or 400V input power supply, the 400V tap 710 of the transformer 700 is connected to the pressure-independent control valve 158. For a 460V or 480V input power supply, the 460V tap 712 of the transformer 700 is connected to the pressure-independent control valve 158.

[0049] In one example, an automatic restart algorithm is implemented when the cooling distribution unit 110 is in remote mode. Figure 8 A service screen 800 of the cooling distribution unit 110 is shown, for example, on a display screen of the human-machine interface 520. The user can select a local / remote control button 810 to switch between local control mode and remote control mode. In one example, local control is active when the local / remote control button is selected. An option to set a local control timeout is available. If the local control timeout is activated, the cooling distribution unit 110 can switch to remote control mode after the timeout has elapsed. If the local control timeout is not activated, the cooling distribution unit 110 will remain in local control mode unless manually set to remote control mode.

[0050] Figure 9 A main menu screen 900 displayed on a display screen 901 of a human-machine interface 520 is shown. In the example shown, the main menu screen 900 includes a logout button 905, a data access button 910, a diagnostic button 915, a configuration button 920, a service button 925, and a process start / stop button 930. Each of the data access button 910, diagnostic button 915, configuration button 925, service button 925, and process start / stop button 930 is configured to be selected by a user via the human-machine interface 520. The login button 905 can be configured to cause the display screen 901 to display a login screen that acts as a gateway to the main menu screen 900. For example, the login screen may require the user to enter a personal identification number (PIN) or password. In response to the entered PIN or password, the display screen 901 can display the main menu screen 900. When the data access button 910 is selected, the display screen 901 can show data on the status of various components of the cooling distribution unit 110 (e.g., pumps 134, 138, expansion tanks 150, 154, various valves, filters, heat exchangers, etc.) collected from various sensors 510, 512, 514, 516 in the cooling distribution unit 110 or stored in system data 505. When the diagnostic button 915 is selected, the display screen 901 can show access to various diagnostic screens (e.g., diagnostic screen 1300, see...). Figure 13One or more shortcuts (e.g., buttons) to the diagnostic screens provide the user with diagnostic information related to the cooling distribution unit 110 via the display screen 901. When selected, the configuration button 920 can cause the display screen 901 to show access to various configuration screens (e.g., configuration screens 1100, 1200, see [link]). Figure 11 , Figure 12 One or more shortcuts (e.g., buttons) to the configuration screens provide the user with options for configuring various components of the cooling distribution unit 110 via the display screen 901. When selected, the service button 925 can cause the display screen 901 to show access to various service screens (e.g., service screen 1000, see...). Figure 10 The service screens provide the user with one or more shortcuts (e.g., buttons) via display screen 901 for servicing (e.g., manual control or preparation for replacement) various components of the cooling distribution unit 110. In the example shown, the main menu screen 900 also includes an optimization button 935 configured to cause the controller 182 to automatically optimize settings and configurations (e.g., settings and configurations of pumps 134, 138) to achieve maximum energy efficiency or maximum cooling capacity. The optimization process will be described in more detail below.

[0051] Figure 10A display screen 901 of a service screen 1000 is shown. The service screen 1000 is configured to receive user input to change pump control settings and reflects the user input via the display screen 901. The service screen 1000 includes a pump identification and statistics pane 1002, and multiple pump setting inputs (e.g., buttons, drop-down windows, text boxes, etc.) configured to display settings and setpoints of the pumps (e.g., pumps 134, 138, and a filling pump) in the secondary closed loop 118 of the cooling distribution unit, such as flow control type input 1004, flow indication and setpoint input 1006, pressure indication and setpoint input 1008, temperature control type input 1010, and temperature indication and setpoint input 1012. The service screen 1000 also includes a pump selection override input 1014, which is configured to allow a user to select a pump via pump selection input 1016 for direct manual control. In the example shown, the service screen allows the user to select a method of directly controlling a chosen pump via either the variable frequency drive proportional-integral-derivative override input 1018 or the motor voltage proportional-integral-derivative override input 1020. In response to selecting the variable frequency drive proportional-integral-derivative override input 1018, the service screen 1000 allows the user to set the duty cycle percentage 1021 for the variable frequency drive supplying power to the motor of the pump (e.g., pumps 134, 138). In response to selecting the motor voltage proportional-integral-derivative override input 1020, the service screen 1000 allows the user to set the percentage of the maximum motor voltage 1024 supplied to the pump's motor by the power supply. The process start / stop input 1022 is configured to cause the cooling distribution unit to start or stop one or more pumps using the settings displayed in the service screen 1000.

[0052] Figure 11 A display screen 901 is shown for a configuration screen 1100 configured to receive user input to change pump control settings and to reflect the user input via the display screen 901. The configuration screen 1100 includes multiple pump configuration inputs (e.g., buttons, drop-down windows, text boxes, etc.), such as a control mode input 1102, a flow setpoint input 1104, a differential pressure setpoint input 1106, a first low flow threshold warning input 1108, a second low flow threshold warning input 1110, a low differential pressure threshold warning input 1312, a low flow warning delay input 1314, a low differential pressure warning delay input 1316, and an overpressure setpoint input 1318.

[0053] In the example shown, control mode input 1102 is configured to switch between differential pressure control mode and flow control mode when operated by the user. Flow setpoint input 1104 is configured to switch between differential pressure control mode and flow control mode when operated by the user. In differential pressure control mode, cooling distribution unit 110 controls the operation of pumps 134, 138 based on the pressure difference between pressure readings from one of pressure sensors PT1A, PT1B and pressure sensors PT2A, PT2B. For example, differential pressure mode can be configured to control pumps 134, 138 to maintain a specific differential pressure (e.g., 5 PSI, 10 PSI, 15 PSI, etc.) defined in differential pressure setpoint input 1106 or to maintain the differential pressure within a defined range (e.g., a range defined in the differential pressure setpoint input: 5-10 PSI, 10-15 PSI, etc.). In flow control mode, the cooling distribution unit 110 controls the operation of pumps 134, 138 based on readings from flow meter 516 (e.g., flow meter FM1) (e.g., gallons per minute [GPM] readings), which indicate the flow rate of fluid through the secondary closed loop 118. For example, the flow mode can be configured to control pumps 134, 138 to maintain a flow rate defined in the flow setpoint input 1104 (e.g., 20 GPM, 30 GPM, 40 GPM, etc.) or to maintain the flow rate within a defined range (e.g., 10-20 GPM, 20-30 GPM, 30-40 GPM, etc., defined in the flow setpoint input). A first low flow threshold warning input 1108, a second low flow threshold warning input 1110, and a low differential pressure threshold warning input 1112 each allow the user to establish a threshold (as a percentage of the setpoint) for the cooling distribution unit 110 to issue warnings (e.g., generate noise, send a text message, generate a visual alarm on display 901, etc.). Low flow warning delay input 1114 and low differential pressure warning delay input 1116 allow users to set a delay for the associated warning. Overpressure setpoint input 1118 allows users to establish the pressure value at which overpressure in the cooling distribution unit 110 is discharged from the system (e.g., via an outlet or valve).

[0054] Figure 12 A display screen 901 is shown for a configuration screen 1200, which is configured to receive user input to change pump operation rotation and reflects the user input via the display screen 901. A first pump assignment input 1202 and a second pump assignment input 1204 allow the user to set which pump (e.g., pump 134) is the primary pump and which pump (e.g., pump 138) is the standby pump for the secondary closed loop 118. A first pump operation cycle time input 1206 and a second pump operation cycle time input 1208 allow the user to select the appropriate operating time for each pump before cycling between pumps.

[0055] Figure 13A display screen 901 is shown as a diagnostic screen 1300, configured to display diagnostics of various sensors in the cooling distribution unit 110. In the example shown, component identification (ID) numbers 1302 for various sensors (e.g., pressure sensor 512) in the cooling distribution unit 110 are shown. A description 1304 for each sensor, the amount of electrical power drawn by each sensor 1306, and the amount of pressure experienced by each sensor 1308 are also shown. Although the diagnostic screen 1300 shown only displays diagnostic values ​​for the sensors of the cooling distribution unit 110, some examples of the diagnostic screen 1300 also include data related to the operation of certain components of the cooling distribution unit 110, provided by the controller 182 (e.g., retrieved from memory 502). In some examples of the diagnostic screen 1300, power consumption and the amount of fluid handled by pumps (e.g., pumps 134, 138) may be displayed, in addition to items such as pump motor voltage or current.

[0056] Return to reference Figure 5 The controller 182 can be configured to calculate the efficiency of various pumps (e.g., pumps 134, 138) by comparing the power consumption of a pump (e.g., pump 134) with the heat load carried by fluid via a secondary closed loop 118 to or away from heat exchanger 126, said heat load being determined as the difference between temperature readings at temperature sensors T1A or T1B and temperature readings at temperature sensors T2A, T2B. (Return to Reference) Figure 9 The optimization button 935 allows the controller to adjust the settings and configurations of one or more pumps (e.g., pumps 134, 138) in the secondary closed loop 118. Figures 11 to 13 As shown), to balance or rebalance the fluid pumping workload among the pumps, thereby maximizing energy efficiency or cooling capacity. For example, in response to a user selecting the optimization button 935, controller 182 can determine that at 50% power, pump 134 carries heat to the heat exchanger with maximum energy efficiency (e.g., relatively high cooling capacity achieved by the pump with relatively low power consumption), thus causing pump 134 to operate at a specific power level (e.g., 50% of the maximum value). In some examples, in response to selecting the optimization button 935, controller 182 can optimize multiple pumps for a collective objective (e.g., maximum power efficiency or cooling capacity), and for example, operate pump 134 at 30% power (e.g., via a variable frequency drive) and pump 138 at 70% power. As another example, in response to a user selecting the optimization button 935, controller 182 can make pump 134 operate at 100% power (e.g., via a variable frequency drive) and pump 138 operate at 0% power. Controller 182 can automatically adjust... Figures 11 to 13 The settings and configurations shown are used to achieve these optimizations.

[0057] In some examples, controller 182 can be configured to periodically generate a heartbeat signal containing any data collected by sensors 510, 512, 514, 516 or contained in memory 502 (e.g., Figures 11 to 13 (The settings and configurations shown). Controller 182 can transmit heartbeat signals to other cooling distribution units (e.g., other cooling distribution units installed in the same row as cooling distribution unit 110), and the other cooling distribution units can adjust their settings or configurations in response to the heartbeat signals.

[0058] Figure 14 A flowchart 1400 is shown of a method for optimizing the operation of a pump (e.g., pump 134) in a cooling distribution unit 110 to achieve maximum energy efficiency.

[0059] At block 1410, the method includes using controller 182 to determine the energy consumption of a pump (e.g., pump 134). Similar to the sensors for the cooling distribution unit 110 shown on the diagnostic screen 1300, controller 182 can track the amount of electrical energy consumed by each pump (e.g., pumps 134, 138) of the cooling distribution unit 110. For example, controller 182 can store and update data (e.g., operating parameters in memory 502) indicating the amount of electrical power delivered to each pump in response to control signals (e.g., motor control signals) generated by controller 182.

[0060] At box 1420, the method includes using controller 182 to determine the heat load of the pumps. Similar to the sensors shown on the diagnostic screen 1300 regarding the cooling distribution unit 110, controller 182 can track the amount of heat pumped to heat exchanger 126 by each pump (e.g., pumps 134, 138) of cooling distribution unit 110. For example, the controller can use temperature sensor 510 to determine that a single pump directs (e.g., via pumping fluid) a specific amount of heat (e.g., 130 British thermal units [BMU] or joules) to heat exchanger 126 per predetermined time unit (e.g., 1 second).

[0061] At block 1430, the method includes using controller 182 to determine pump efficiency by relating pump energy consumption to pump thermal load. For example, controller 182 may determine the ratio between pump energy consumption and pump thermal load.

[0062] At block 1440, the method includes using controller 182 to predict optimal operating parameters for the pump based on stored system data (e.g., system data 505 in memory 502) and the determined pump efficiency. For example, controller 182 may extrapolate stored system data (e.g., previously associated pump energy consumption and heat load) to predict a pump power level (e.g., 50%) that will result in maximum energy efficiency of the pump.

[0063] At block 1450, the method includes optimizing the pump using controller 182 based on predicted optimized operating parameters of the pump. For example, based on the predicted optimized operating parameters of the pump, controller 182 may transmit control signals to a variable frequency drive connected to the pump to drive the pump to achieve the predicted optimized operating parameters.

[0064] In the example shown, the cooling distribution unit 110 has overall dimensions of 31.5 inches × 47.4 inches × 84.5 inches and a total weight of approximately 1400 pounds. Other examples may include a variety of different sizes and weights, including those smaller and larger than those shown, and those smaller or larger than those shown. Additionally, in the example shown, the cooling distribution unit 110 can provide a cooling capacity of 550 kW (approaching a temperature difference of 4°C) and 1100 kW (approaching a temperature difference of 8°C). Other examples may include other values ​​and ranges of cooling capacity, including those smaller or larger than those shown.

[0065] Although various aspects and examples have been described in detail with reference to certain examples shown in the accompanying drawings, variations and modifications exist within the scope and spirit of one or more independent aspects described and shown.

Claims

1. A cooling distribution unit, comprising: A primary closed loop, the primary closed loop being configured to allow a first fluid to flow through it; A secondary closed loop, the secondary closed loop being configured to allow a second fluid to flow through it; Heat exchanger, the heat exchanger being configured to: Receive at least a portion of the primary closed loop. Receive at least a portion of the secondary closed loop, and Heat is drawn away from the portion of the secondary closed loop and conducted to the portion of the primary closed loop; A first pump, which is connected to the secondary closed loop; A second pump is connected to the secondary closed loop; Multiple sensors; as well as, The controller is configured to: The operating parameters of the first pump and the second pump are stored and updated in the memory; The heat load of a given pump, selected from the first pump or the second pump, is associated with the power consumption of the given pump. as well as The operating parameters of the given pump are optimized based on the correlation between the heat load of the given pump and the power consumption of the given pump.

2. The cooling distribution unit according to claim 1, wherein, Optimizing the operating parameters includes adjusting the settings of the first pump and the second pump to rebalance the fluid pumping workload between the first pump and the second pump, thereby maximizing the energy efficiency of the first pump and the second pump.

3. The cooling distribution unit according to claim 1, wherein, Optimizing the operating parameters includes adjusting the settings of the first pump and the second pump to rebalance the fluid pumping workload between the first pump and the second pump, thereby maximizing the thermal load of the first pump and the second pump.

4. The cooling distribution unit according to claim 1, wherein, The controller is configured to generate a heartbeat signal.

5. The cooling distribution unit according to claim 4, wherein, The heartbeat signal contains data collected by the plurality of sensors.

6. The cooling distribution unit according to claim 5, wherein, The multiple sensors include a temperature sensor, a pressure sensor, a dew point sensor, and a flow meter.

7. The cooling distribution unit according to claim 4, wherein, The controller is configured to transmit the heartbeat signal to another cooling distribution unit.

8. The cooling distribution unit according to claim 1, wherein, The multiple sensors include a temperature sensor, a pressure sensor, a dew point sensor, and a flow meter.

9. The cooling distribution unit of claim 1 further includes a service screen configured to receive user input to change pump control settings and reflect user input.

10. The cooling distribution unit according to claim 1, wherein, The operating parameters include the amount of electrical power transmitted to each of the first and second pumps.

11. The cooling distribution unit according to claim 1, wherein, Optimizing the operating parameters includes operating the first pump at 50% power.

12. The cooling distribution unit according to claim 1, wherein, Optimizing the operating parameters includes operating the first pump at 30% power and operating the second pump at 70% power.

13. The cooling distribution unit according to claim 1, wherein, Optimizing the operating parameters includes operating the first pump at 100% power and operating the second pump at 0% power.

14. The cooling distribution unit according to claim 1, wherein, The controller is configured to determine the ratio between the energy consumption of the first pump and the heat load of the first pump.

15. The cooling distribution unit according to claim 1, in, The plurality of sensors include a temperature sensor, and The heat load is configured to be calculated based on data from the temperature sensor.

16. A method comprising: Use the controller to determine the energy consumption of the pumps in the cooling distribution unit; The controller is used to determine the heat load of the pump; The efficiency of the pump is determined by using the controller to correlate the energy consumption of the pump with the heat load of the pump; The controller is used to predict the optimal operating parameters of the pump based on the stored system data and the determined efficiency of the pump. as well as The controller is used to optimize the pump's operating parameters based on the predicted optimal operating parameters of the pump.

17. The method according to claim 16, wherein, The step of determining the heat load includes collecting data from a temperature sensor.

18. The method according to claim 16, wherein, The steps to optimize the operating parameters include operating the pump at 0% power or at 100% power.

19. The method of claim 16, wherein, The steps to optimize the operating parameters include operating the pump at a certain power level that is greater than 0% and less than 100% of the power.

20. The method of claim 16, further comprising transmitting a control signal to a variable frequency drive connected to the pump to drive the pump to achieve the predicted optimized operating parameters.

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