Cooling distribution unit with modular sensors

Abstract

A cooling distribution unit comprises a primary closed circuit configured to circulate a first fluid, a secondary closed circuit configured to circulate a second fluid over electrical components to absorb heat from the electrical components, a heat exchanger configured to exchange heat between the second fluid and the first fluid so that some of the heat absorbed by the electrical components is transferred from the second fluid to the first fluid, a modular sensor block comprising a variety of sensors configured to generate output signals regarding the first and second fluids, and an electronic control unit configured to provide power, operational control, and protection for the cooling distribution unit.The electronic control unit is further configured to receive output signals from the multitude of sensors and to generate a warning based on the received output signals.

Description

CROSS-REFERENCE TO RELATED REGISTRATIONS

[0001] This application claims priority over preliminary US application No. 63,708,559, filed on October 17, 2024, the entire contents of which are incorporated herein by reference. AREA

[0002] The present disclosure relates generally to cooling distribution units for dissipating heat from electrical components. BACKGROUND

[0003] Cooling distribution units (CDUs) are commonly used in data centers to remove heat from computer components (such as servers and server racks). CDUs can include both in-row and in-rack units. In-row units remove heat from an entire row of server racks or other sets of electrical components, while in-rack units typically remove heat from a single rack or set of electrical components. SUMMARY

[0004] According to one example, a cooling distribution unit comprises a primary closed circuit configured to circulate a first fluid, a secondary closed circuit configured to circulate a second fluid over one or more electrical components to absorb heat from the electrical components, a heat exchanger configured to exchange heat between the second fluid and the first fluid so that some of the heat absorbed by the electrical components is transferred from the second fluid to the first fluid, a modular sensor block comprising a variety of sensors configured to generate output signals regarding the first and second fluids, and an electronic control unit configured to provide power, operational control, and protection for the cooling distribution unit.The electronic control unit is further configured to receive output signals from the multitude of sensors and to generate a warning based on the received output signals.

[0005] The details of one or more aspects of the disclosure are set forth in the accompanying drawings and the following description. Other features, functions, and advantages of the techniques described in this disclosure will become apparent from the description, the drawings, and the claims. BRIEF DESCRIPTION OF THE DRAWINGS Fig. Figure 1 is a schematic view of a cooling distribution unit according to an example. Fig. Figure 2 is a perspective view of the cooling distribution unit of Fig. 1. Fig. Figure 3 is another perspective view of the cooling distribution unit of Fig. 1. Fig. Figure 4 is another perspective view of the cooling distribution unit of Fig. 1. Fig. 5 is a control system for the cooling distribution unit of Fig. 1. DETAILED DESCRIPTION

[0006] Fig. Figures 1-4 illustrate an example of a Cooling Distribution Unit 110. The Cooling Distribution Unit 110 can be used in any of a variety of settings, including, for example, a server, a data center, a medical, a semiconductor, and / or an industrial application. The illustrated Cooling Distribution Unit 110 is a row unit, although any of the concepts described herein that relate to the Cooling Distribution Unit 110 can alternatively be used with a rack unit or with any other type of cooling distribution unit.

[0007] With reference to Fig. 1. The cooling distribution unit 110 generally comprises a primary closed circuit 114 and a secondary closed circuit 118. The primary closed circuit 114 circulates a first fluid (e.g., plant water located at a data center and / or supplied by other means). The secondary closed circuit 118 circulates a second fluid (e.g., a process water solution comprising 25% propylene glycol and 75% water). Other examples include different first and second fluids within either the primary closed circuit 114 or the secondary closed circuit 118. As in Fig. As illustrated in Figures 2-4, the primary closed circuit 114 comprises piping systems (e.g., stainless steel piping systems) through which the first fluid circulates. Similarly, the secondary closed circuit 118 comprises piping systems (e.g., stainless steel piping systems) through which the second fluid circulates. Other examples include other types of piping systems, including piping systems made of different materials or with different shapes and configurations than those illustrated.

[0008] In some examples, the first fluid may consist of or comprise water or propylene glycol-water solutions with a maximum concentration of 50%. In other words, the glycol-water solution may have a maximum concentration of 10 mg / L. The second fluid may consist of or comprise water or a premixed solution of uninhibited ethylene glycol or propylene glycol and water. Both the first and second fluids may have a maximum particle size of less than 200 µm. Other examples may include different materials and / or compositions of materials and / or particle sizes for the first and / or second fluids.

[0009] With further reference to Fig. 1. The secondary closed circuit 118 circulates the second fluid through and / or over 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, cold plates or other thermal devices may be positioned over the computer chips, and the piping of the secondary closed circuit 118 may pass through the cold plates or other thermal devices to absorb the heat from the electrical components 122. Once the second fluid in the secondary closed circuit 118 has been heated by the electrical components 122, the heated second fluid is directed to a heat exchanger 126.

[0010] With further reference to Fig. 1. Both the primary closed circuit 114 and the secondary closed circuit 118 extend through the heat exchanger 126. In the illustrated example, the heat exchanger 126 is a liquid-to-liquid heat exchanger. The primary closed circuit 114 directs the first fluid in a first direction (e.g., to the left, as shown in Figure 1). Fig. (as considered in 1) through the heat exchanger 126, and the secondary closed circuit 118 directs the second fluid in a second direction (e.g. to the right, as in Fig. (1 considered) through the heat exchanger 126. In the illustrated example, the first direction is parallel to and opposite to the first direction. In other examples, the first fluid and the second fluid can be guided in the same direction or in a transverse direction, or the first and second fluids can move in more than one direction in the heat exchanger 126.

[0011] Within the heat exchanger 126, heat is exchanged between the second fluid and the first fluid. Accordingly, at least some of the heat absorbed by the electrical components 122 is transferred from the second fluid to the first fluid within the heat exchanger 126. In some examples, the piping of the primary closed circuit 114 does not touch the piping of the secondary closed circuit 118 within the heat exchanger 126, and the heat is exchanged through an intermediate material (e.g., a thermally conductive material). Other examples may include various other types, numbers, or arrangements of heat exchangers 126 than those illustrated.

[0012] With further reference to Fig. 1. The primary closed circuit 114 directs the first fluid (after it has been heated in the heat exchanger 126) away from the heat exchanger 126 and to a cooling structure 130. The cooling structure 130 may be located, for example, within a data center. The cooling structure 130 can be any of a variety of different structures, including a cooling tower or other thermal device that removes heat from the first fluid. In some examples, the cooling structure 130 may include a cold plate, fins, and / or other structures that remove heat, and / or may use a fan or blower to facilitate the removal of heat from the first fluid.

[0013] As in Fig. As illustrated in Figure 1, once the heat has been removed from the first fluid at the cooling structure 130, the first fluid is then circulated back to the heat exchanger 126. Similarly, once the heat has been removed from the second fluid at the heat exchanger 126, the second fluid is circulated back to the electrical components 122. This circulation can continue through both the primary closed circuit 114 and the secondary closed circuit 118 (e.g., as long as the electrical components 122 are generating heat), so that heat is continuously absorbed from the electrical components and supplied to the heat exchanger 126, where the heat is then transferred to the first fluid and the primary closed circuit 114 and finally deposited at the cooling structure 130.

[0014] With further reference to Fig. 1. Both the primary closed circuit 114 and the secondary closed circuit 118 can include one or more pumps to circulate the first fluid and the second fluid through the piping system. In the illustrated example, the primary closed circuit 114 includes one or more pumps (not illustrated) located within the data center (e.g., at the location of the cooling structure 130 or elsewhere within the data center) to circulate the first fluid (e.g., system water) through the primary closed circuit 114. The secondary closed circuit 118 includes both a first pump 134 and a second pump 138.The first and second pumps 134 and 138 are redundant pumps positioned along parallel lines within the closed loop, so that if one of the pumps fails, the other can continue to supply the total 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 handling the second fluid. In some examples, the first pump 134 and the second pump 138 are identical pumps of the same size and / or design. In some examples, one or more of the first pump 134 or the second pump 138 is a centrifugal pump. Other examples include different types and numbers of pumps. For example, in some examples, the secondary closed loop 118 may contain only a single pump or it may contain more than two pumps.In total, the first pump 134 and / or the second pump 138 can generate a flow rate of, for example, between 25 gallons per minute (GPM) (95 liters per minute (l / min)) and 200 GPM (757 l / min) (e.g., 25 GPM (95 l / min), 50 GPM (189 l / min), 100 GPM (379 l / min), 125 GPM (473 l / min), 140 GPM (530 l / min), 160 GPM (606 l / min) or other values ​​and ranges).

[0015] With further reference to Fig. In some examples, the secondary closed circuit 118 includes a refill tank 142 and a filling pump 146 to add additional second fluid to the secondary closed circuit 118. Additionally, in some examples, the secondary closed circuit 118 includes at least one expansion tank to regulate the overall pressure and flow of the second fluid in the secondary closed circuit 118. In the illustrated example, the secondary closed circuit 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.

[0016] Additionally, both the primary closed circuit 114 and the secondary closed circuit 118 can include one or more valves (e.g., pressure control valves, check valves, pressure-independent control valves, etc.) that serve to control the overall pressure and / or fluid flow through the cooling distribution unit 110. In the illustrated example, the primary closed circuit 114 includes a pressure-independent control valve 158.

[0017] With further reference to Fig. In the illustrated example, the cooling distribution unit 110 comprises a housing 162 (e.g., an outer housing). The housing 162 may comprise a steel frame (e.g., with interconnected vertical and / or horizontal frame elements) or may be a different type of frame or be made of different materials. In some examples, the housing 162 includes one or more doors (e.g., pivotally coupled or otherwise connected to the frame). Other examples may include various other types, sizes, and / or shapes of the housing 162 than those illustrated. In the illustrated example, the housing 162 includes a first outlet 166, where the primary closed circuit 114 exits and the first fluid is conveyed to the cooling structure 130. The housing 162 also includes a first inlet 170, where the primary closed circuit 114 enters and where the first fluid then flows to the heat exchanger 126 (e.g.,(located within the housing 162). The housing 162 also includes a second outlet 174, where the secondary closed circuit 118 exits and the second fluid is conveyed to the electrical components 122, and a second inlet 178, where the second fluid enters and is then directed to the heat exchanger 126.

[0018] As in Fig. As illustrated in Figure 5, the cooling distribution unit 110 in some examples includes a plurality of sensors 186 that measure pressure, temperature, and / or other aspects of the system. In the illustrated example, the plurality of sensors 186 is positioned in at least one sensor block 190. The sensor block 190 can be a cube-shaped (or otherwise shaped) container configured to protect and house the plurality of sensors 186. In some examples, the sensor block or blocks 190 are generally positioned at the first outlet 166, the first inlet 170, the second outlet 174, and / or the second inlet 178. In other examples, the sensors 186 are positioned individually (e.g., outside of any sensor block) at the first outlet 166, the first inlet 170, the second outlet 174, and / or the second inlet 178.

[0019] In some examples, one or more of the sensor blocks 190 are positioned and housed within the heat exchanger 126 to save space within the cooling distribution unit 110. In other examples, one or more of the sensor blocks 190 are positioned within other components within the cooling distribution unit 110. Storing each of the multiple sensors 186 in the sensor block 190 enables modularity, allowing a user to place the sensor block 190 (e.g., modular sensor block) in a desired position within the cooling distribution unit 110. Accordingly, the sensor block 190 is configured to house multiple sensors in one section, rather than distributing the multiple sensors 186 throughout the entire cooling distribution unit 110. Therefore, the sensor block 190 is configured to enable efficient use of space and a standardized sensor arrangement within the cooling distribution unit 110.Other examples include various locations within the cooling distribution unit 110 for the sensor block or blocks 190 and / or any individual sensors (e.g. pressure sensors, temperature sensors, fluid quality sensors, etc.).

[0020] With further reference to Fig. 5. The multiple sensors 186 can, in some examples, include redundant pressure sensors 192 and / or temperature sensors 193 (e.g., in case one or more of the sensors fail or provide inaccurate readings). In the illustrated example, the cooling distribution unit 110 includes three (3) or more temperature sensors 193 (e.g., a first temperature sensor 193A, a second temperature sensor 193B, and a third temperature sensor 193C). Including multiple (e.g., at least three) temperature sensors 193A-C within the cooling distribution unit 110 allows a user or an electronic controller 182 to monitor the performance of each temperature sensor 193 to detect whether a sensor is inaccurate or defective. In particular, the electronic controller 182 can be configured to compare sensor readings or output signals of the temperature sensors 193A-C.For example, if the performance of the first temperature sensor 193A is detected to differ significantly from the performance of the second temperature sensor 193B and the third temperature sensor 193C, the first temperature sensor 193A is considered inaccurate. In some examples, implementing three temperature sensors 193A-C can allow the user or the controller 182 to quickly detect an inaccurate temperature sensor 193 by comparing it to the two remaining temperature sensors 193. Upon detecting an inaccurate temperature sensor 193, the controller 182 can be configured to generate a warning to notify the user that a temperature sensor 193A-C is inaccurate, allowing the inaccurate sensor to be replaced.Accordingly, the temperature sensors 193A-C are configured to provide greater sensor reliability within the cooling distribution unit 110 and to eliminate variability that can occur as a result of implementing only two temperature sensors 193. In the illustrated example, the temperature sensors 193 are designed for -50°C to 150°C, although other examples may include different configurations. In some examples, the cooling distribution unit 110 may similarly include three (3) or more pressure sensors 192. In some examples, the cooling distribution unit 110 additionally or alternatively includes two, three, or more redundant pressure sensors 192.

[0021] In the illustrated example, the multitude of sensors 186 are connected to the controller 182 ( Fig. 2-5) or coupled to another device (e.g., wired or wireless) that receives signals regarding the pressure and temperature of the first fluid and the second fluid. In the illustrated example, the controller 182 is located on and / or inside the housing 162 and may include a user interface 184 (e.g., a graphical user interface, such as a color touchscreen). In some examples, the controller 182 is located remotely from the housing 162. In some examples, the controller 182 may be used to observe pressure, temperature, and / or a flow and pressure differential of the second fluid.

[0022] The controller 182 comprises a variety of electrical and electronic components that provide power, operational control, and protection for the components and modules within the controller 182 and / or the cooling distribution unit 110. For example, the controller 182 includes, among other things, a processing unit 198 (e.g., a microprocessor, a microcontroller, or another suitable programmable device), a memory 202, input units 206, and output units 210. The processing unit 198 includes, among other things, a control unit 214, an arithmetic logic unit (“ALU”) 226, and a variety of registers 218 (in Fig. 5 as a group of registers) and is implemented using a known computer architecture (e.g., a modified Harvard architecture, a von Neumann architecture, etc.). The processing unit 198, the memory 202, the input units 206, and the output units 210, as well as the various modules or circuits connected to the controller 182, are connected by one or more control and / or data buses (e.g., a common bus 222). The control and / or data buses are generally shown in the following diagrams for illustrative purposes: Fig. 5 shown.

[0023] The memory 202 can be a non-volatile, computer-readable medium and may, for example, comprise a program memory area and a data memory area. The program memory area and the data memory area may comprise combinations of different types of memory, such as a ROM, RAM (e.g., DRAM, SDRAM, etc.), EEPROM, flash memory, a hard disk, an SD card, or other suitable magnetic, optical, physical, or electronic storage devices. The processing unit 198 is connected to the memory 202 and executes software instructions that may be stored in a RAM of the memory 202 (e.g., during execution), a ROM of the memory 202 (e.g., on a generally permanent basis), or another non-volatile, computer-readable medium, such as another memory or disk.Software included in the implementation of the cooling distribution unit 110 can be stored in the memory 202 of the controller 182. This software includes, for example, firmware, one or more applications, program data, filters, rules, one or more program modules, and other executable instructions. The controller 182 is configured to retrieve and execute instructions from memory 202 relating to the control processes and procedures described herein. In other designs, the controller 182 includes additional, fewer, or different components.

[0024] With further reference to Fig.5 The multitude of sensors 186 can further include a multitude of fluid quality sensors 194 configured to detect the quality of the first fluid and / or the second fluid. The sensors 194 can generate output signals indicative of the quality. In the illustrated example, the fluid quality sensors 194 are optional and can be added and removed by the user. Accordingly, the fluid quality sensors 194 are configured for modularity, allowing the user to quickly remove and add the fluid quality sensors 194 to the sensor block 190. In other examples, the fluid quality sensors 194 can be permanently mounted within the cooling distribution unit 110.In other examples, the fluid quality sensors 194 may not be contained within the sensor block 190 and may instead be positioned within or adjacent to any other suitable component of the cooling distribution unit 110. In some examples, a plurality of ports 228 for water quality sampling may be provided within the cooling distribution unit 110. The plurality of ports 228 may communicate with the fluid quality sensors 194 to enable sampling of fluid detected by the fluid quality sensors 194. In still other examples, the plurality of ports 228 may be provided for fluid sampling outside the cooling distribution unit 110.

[0025] In some examples, the fluid quality sensors 194 are coupled to the controller 182, allowing the controller 182 to read the fluid quality sensors 194 and monitor the quality of the fluid circulating within the cooling distribution unit 110, the primary closed loop 114, and / or the secondary closed loop 118. In response to low fluid quality, the controller 182 can be configured to generate an alert to notify the user that the fluid quality is low. Implementing the fluid quality sensors 194 provides several advantages. For example, monitoring the quality of the fluid circulating within the cooling distribution unit 110 allows the user or the controller 182 to know when the fluid quality is low and to replace the fluid. Low water quality can affect the performance of the pumps 134 and 138 over time.For example, poor water quality can increase the operating time of the cooling distribution unit 110. Therefore, the inclusion of fluid quality sensors 194 can prevent poor performance of the cooling distribution unit 110.

[0026] In the illustrated example, the cooling distribution unit 110 has overall dimensions of 31.5" (80.0 cm) by 47.4" (120.4 cm) by 84.5" (214.6 cm) and a total weight of approximately 1400 pounds (635 kg). Other examples may include various different sizes and weights, including sizes and weights smaller and larger than those illustrated. Additionally, the cooling distribution unit 110 in the illustrated example can provide a cooling capacity of 550 kW (at an approximate temperature difference of 4 °C) and 1100 kW (at an approximate temperature difference of 8 °C). Other examples may include different values ​​and ranges of cooling capacity, including cooling capacities smaller or larger than those illustrated.

[0027] Although various aspects and examples have been described in detail with reference to specific examples illustrated in the drawings, variations and modifications exist within the scope and technical content of one or more independent aspects that are described and illustrated.

Claims

[1] A cooling distribution unit comprising: a primary closed circuit configured to circulate a primary fluid; a secondary closed circuit configured to circulate a second fluid over electrical components to absorb heat from the electrical components; a heat exchanger configured to exchange heat between the second fluid and the first fluid, so that some of the heat absorbed by the electrical components is transferred from the second fluid to the first fluid; a modular sensor block comprising a variety of sensors configured to generate output signals regarding the first fluid and the second fluid; and an electronic control unit configured to provide power, operational control and protection for the cooling distribution unit, wherein the electronic control unit is further configured to: to receive the output signals from the multitude of sensors, and to generate a warning based on the received output signals. [2] The cooling distribution unit according to claim 1, wherein the modular sensor block is positioned inside the heat exchanger. [3] The cooling distribution unit according to claim 1 or 2, wherein the plurality of sensors comprises one or more pressure sensors and one or more temperature sensors. [4] The cooling distribution unit according to claim 3, wherein the one or more temperature sensors comprise a first temperature sensor, a second temperature sensor and a third temperature sensor. [5] The cooling distribution unit according to claim 4, wherein the electronic control unit is further configured to compare output signals of the first temperature sensor, the second temperature sensor and the third temperature sensor in order to detect an inaccurate sensor. [6] The cooling distribution unit according to claim 5, wherein, in response to the electronic control unit detecting that an output signal of the first temperature sensor differs from that of the second temperature sensor and the third temperature sensor, the electronic control unit is configured to recognize the first temperature sensor as inaccurate. [7] The cooling distribution unit according to claim 6, wherein the warning is configured to notify a user that the first temperature sensor is inaccurate. [8] The cooling distribution unit according to claim 1 or 2, wherein the plurality of sensors comprises a plurality of fluid quality sensors. [9] The cooling distribution unit according to claim 8, wherein the output signals are an indication of the quality of the first fluid or the second fluid. [10] The cooling distribution unit according to claim 9, wherein the warning is configured to notify a user that the quality of the first fluid or the second fluid is low. [11] The cooling distribution unit according to one of claims 8 to 10, wherein the plurality of sensors further comprises one or more pressure sensors and one or more temperature sensors. [12] The cooling distribution unit according to claim 11, wherein the one or more temperature sensors comprise a first temperature sensor, a second temperature sensor and a third temperature sensor. [13] The cooling distribution unit according to claim 12, wherein the electronic control unit is further configured to compare output signals of the first temperature sensor, the second temperature sensor and the third temperature sensor in order to detect an inaccurate sensor. [14] The cooling distribution unit according to claim 13, wherein, in response to the electronic control detecting that an output signal of the first temperature sensor differs from that of the second temperature sensor and the third temperature sensor, the electronic control unit is configured to recognize the first temperature sensor as inaccurate. [15] The cooling distribution unit according to claim 14, wherein the warning is configured to notify a user that the first temperature sensor is inaccurate. [16] The cooling distribution unit according to any one of claims 1 to 15, wherein the cooling distribution unit comprises a housing, wherein the primary closed circuit is configured to exit and enter the housing, and wherein the secondary closed circuit is also configured to exit and enter the housing. [17] The cooling distribution unit according to claim 16, wherein the housing comprises a first outlet where the primary closed circuit leaves the housing and the first fluid is conveyed to a cooling structure, and wherein the housing also comprises a first inlet where the primary closed circuit enters the housing and where the first fluid is then directed to the heat exchanger. [18] The cooling distribution unit according to claim 17, wherein the housing comprises a second outlet where the secondary closed circuit leaves the housing and the second fluid is conveyed to the electrical components, and a second inlet where the second fluid enters the housing and is directed to the heat exchanger. [19] The cooling distribution unit according to claim 18, wherein the modular sensor block is generally positioned at one of the first outlet, the first inlet, the second outlet, the second inlet or the heat exchanger. [20] The cooling distribution unit according to claim 19, wherein the modular sensor block is a first modular sensor block, wherein the cooling distribution unit comprises a plurality of modular sensor blocks, which are generally positioned at one or more of the first outlet, the first inlet, the second outlet, the second inlet or the heat exchanger.

Images