Embedded Cooling Module Latent Fault Detection
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Solution Overview
Problem
Existing embedded computer chassis systems lack a method to detect latent faults in cooling modules, which can lead to undetected failures until they become active faults, compromising system reliability and availability.
Innovation Solution
The implementation of a fan controller latent fault checking algorithm and a full-speed latent fault checking algorithm that modify fan speed and detect changes via the fan tachometer and full-speed fan control circuit, bypassing the fan controller module, to identify latent faults before they become active, and generate an alarm signal for notification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fan tachometer monitoring is used to detect fan failures, then fan failure detection capability is provided, but latent faults cannot be detected and false readings may occur
Solution Approach 1:
The patent applies preliminary action by implementing latent fault checking algorithms that proactively detect faults before they manifest as active failures. The system performs diagnostic routines that test fan operation and monitor tachometer readings to identify potential issues prior to actual fan failure, thereby preventing undetected failures from occurring.
Solution Approach 2:
The patent implements feedback mechanisms through continuous monitoring of fan tachometer readings and implementation of diagnostic algorithms. The system compares expected fan behavior against actual measurements and provides feedback signals that trigger alarm conditions when latent faults are detected, enabling early warning before complete failure occurs.
2Reliability
If fan controller monitors fan speed continuously, then active faults can be detected, but latent faults remain undetected until activation
Solution Approach 1:
The system performs preliminary diagnostic actions through latent fault checking algorithms that continuously assess fan health without waiting for active failure symptoms. These algorithms monitor for subtle anomalies in fan operation patterns and tachometer readings that indicate emerging faults, enabling detection before the fault activates and causes system impact.
3Device complexity
If simple fan speed monitoring is used, then system complexity is minimized, but latent fault detection capability is lost
Solution Approach 1:
The patent applies universality by designing a multi-functional monitoring system where the fan controller performs both its primary function of controlling fan speed and the secondary function of detecting latent faults. The same hardware components (fan controller, tachometer, processing circuit) are utilized for both control and diagnostic purposes, avoiding the need for separate dedicated fault detection hardware while still enabling comprehensive monitoring.
Data Source
AI summary
A method of latent fault checking a cooling module of an embedded computer chassis may include prior to detection of an active fault in the cooling module, performing a fan controller latent fault checking algorithm and a full-speed latent fault checking algorithm. The fan controller latent fault checking algorithm may include attempting to modify a fan speed in the cooling module via a fan controller module in the cooling module, and determining if a change in the fan speed is detected. The full-speed latent fault checking algorithm may include attempting to modify the fan speed via a full speed fan control circuit, bypassing the fan controller module, and determining if the change in the fan speed is detected. If the change in the fan speed is not detected in at least one of the fan controller latent fault checking algorithm and the full-speed latent fault checking algorithm, a latent fault in the cooling module of the embedded computer chassis may be indicated.