Fan Controller Adaptive Airflow Prediction via Pressure Transducer

Solution Overview

Problem

Existing fan control algorithms in information handling systems are not adaptable to varying configurations of components within a server, leading to inaccurate airflow predictions and inefficient cooling.

Innovation Solution

A fan controller that learns and updates a pressure-airflow curve by determining airflow values at different duty cycles using a differential pressure transducer, creating a table for airflow versus duty cycle and updating an exhaust temperature control equation for optimized fan operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a fixed fan control algorithm is used, then the control logic is simple, but the airflow prediction becomes inaccurate when component configurations change

Engineering Contradiction:

Improveairflow prediction accuracyVSAvoidcontrol algorithm complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The system performs preliminary characterization by measuring airflow at multiple duty cycles during initialization or manufacturing, storing these measurements in a lookup table. This preliminary action creates a reference database that enables accurate airflow prediction without requiring complex real-time calculations, thus resolving the contradiction between accuracy and complexity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Instead of implementing complex physics-based airflow models, the system creates a simplified copy of the airflow characteristics through empirical measurements stored in lookup tables. These tables capture the essential airflow-duty cycle relationship for different component configurations, providing accurate predictions with minimal computational overhead.

Inventive Principle:

Principle #26Copying

2Productivity

If the fan control adapts to different component configurations, then the cooling efficiency improves, but the control system complexity increases

Engineering Contradiction:

Improvecooling efficiencyVSAvoidcontrol system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system performs preliminary characterization by measuring airflow at multiple duty cycles during initialization or manufacturing, storing these measurements in a lookup table. This preliminary action creates a reference database that enables accurate airflow prediction without requiring complex real-time calculations, thus resolving the contradiction between accuracy and complexity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system adapts to different component configurations by changing the parameters stored in the lookup tables based on detected component presence or configuration. Rather than redesigning the control algorithm, it adjusts the airflow-duty cycle characteristics in the lookup table to match the actual hardware configuration, maintaining simplicity while improving cooling efficiency.

Inventive Principle:

Principle #35Parameter changes

3Use of energy by moving object

If traditional fan control is used, then the system is easy to implement, but power consumption and acoustic output are not optimized

Engineering Contradiction:

Improvefan power consumptionVSAvoidcontrol algorithm complexity

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The system performs preliminary characterization by measuring airflow at multiple duty cycles during initialization or manufacturing, storing these measurements in a lookup table. This preliminary action creates a reference database that enables accurate airflow prediction without requiring complex real-time calculations, thus resolving the contradiction between accuracy and complexity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses exhaust temperature sensors to provide feedback on cooling effectiveness, allowing the fan controller to adjust duty cycles to achieve optimal power consumption. By comparing actual temperature readings with expected values from the lookup table, the system can fine-tune fan operation to minimize power usage while maintaining adequate cooling, without requiring complex real-time optimization algorithms.

Inventive Principle:

Principle #23Feedback

Applied Scientific Principles

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

Function Achieved in This Case

This solution allows for accurate airflow prediction and efficient cooling by adapting to the specific configuration of components within the server, optimizing airflow, power consumption, and acoustic output.

Implementation Method 1

A fan controller that learns and updates a pressure-airflow curve by determining airflow values at different duty cycles using a differential pressure transducer

Methodology Applied

Scientific EffectDifferential pressure measurement: Pressure Drop

Data Source

PatentUS9936614B2System and method for automated open loop fan control

Publication Date: 2018.04.03 DELL PROD LP

AI summary

An information handling system includes a pressure transducer and a fan controller. The pressure transducer produces a pressure reading in response to airflow through the information handling system. The fan controller is configured to communicate with the pressure transducer, the fan controller to operate a fan of an information handling system at a first duty cycle, to receive a first pressure reading from the pressure transducer, to determine a first airflow amount for the first duty cycle based on the first pressure reading, to create a first updated airflow-duty cycle table based on the first airflow amount at the first duty cycle, and to update a temperature control algorithm based on the first updated airflow-duty cycle table.