Liquid-Cooled Computer Test Scheduling for Dew Point Control

Solution Overview

Problem

High-end computer systems face system failure due to internal condensation in liquid cooled systems during manufacturing tests when the system setpoint temperature is set below the dew point of the surrounding environment, leading to wet circuitry and residue deposition.

Innovation Solution

A manufacturing test scheduling system predicts dew point forecasts using outdoor and indoor weather data, selecting time slots based on a pre-defined threshold to schedule tests, thereby avoiding condensation by rescheduling cold bias tests during reduced dew point times and hot bias tests during increased dew point times.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the system setpoint temperature is set below the dew point during cold bias testing, then the cooling system operates at maximum cooling capacity to ensure adequate cooling margin, but condensation forms on the plumbing leading to system failure

Engineering Contradiction:

Improvecooling system reliabilityVSAvoidcondensation formation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The system performs preliminary dew point forecasting using weather data before scheduling cold bias tests. By predicting future dew point conditions, the system proactively identifies suitable time slots for testing, preventing condensation issues before they occur during manufacturing tests

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system dynamically adjusts the test scheduling based on changing environmental parameters (outdoor temperature, humidity, dew point). By monitoring these parameters and selecting optimal test time slots, the system ensures tests occur when environmental conditions prevent condensation while still achieving adequate cooling stress testing

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If the system setpoint temperature is set at or above the dew point to avoid condensation, then condensation risk is eliminated, but the cooling system cannot achieve adequate cooling margin during cold bias testing

Engineering Contradiction:

Improvecondensation preventionVSAvoidcooling system testing adequacy

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The system performs preliminary dew point forecasting using weather data before scheduling cold bias tests. By predicting future dew point conditions, the system proactively identifies suitable time slots for testing, preventing condensation issues before they occur during manufacturing tests

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system dynamically adjusts the test scheduling based on changing environmental parameters (outdoor temperature, humidity, dew point). By monitoring these parameters and selecting optimal test time slots, the system ensures tests occur when environmental conditions prevent condensation while still achieving adequate cooling stress testing

Inventive Principle:

Principle #35Parameter changes

3Object-affected harmful factors

If cold bias testing is scheduled during high dew point conditions, then testing can proceed without condensation risk, but the test facility loses valuable testing time and productivity

Engineering Contradiction:

Improvecondensation avoidanceVSAvoidmanufacturing test throughput

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The system performs preliminary dew point forecasting using weather data before scheduling cold bias tests. By predicting future dew point conditions, the system proactively identifies suitable time slots for testing, preventing condensation issues before they occur during manufacturing tests

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements dynamic test scheduling that adapts to real-time and forecasted environmental conditions. Rather than using fixed schedules, the system continuously monitors weather parameters and flexibly adjusts test timing to exploit favorable conditions, maximizing both productivity and condensation avoidance

Inventive Principle:

Principle #15Dynamics

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 approach effectively prevents internal condensation in liquid cooled computer systems during environmental tests, reducing the risk of system failure and ensuring reliable testing by aligning test schedules with optimal dew point conditions.

Implementation Method 1

Liquid cooled systems often carry cold water set at a 'system setpoint' temperature to cool the internal components

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

condensation forms on the computer system's liquid cooled plumbing if the system setpoint temperature is set below the dew point of the surrounding air

Methodology Applied

Scientific EffectCondensation: Condensation

Data Source

PatentUS10257964B2Reducing condensation risk within liquid cooled computers

Publication Date: 2019.04.09 INTERNATIONAL BUSINESS MACHINE CORPORATION

AI summary

An approach is provided in which a manufacturing test scheduling system predicts a dew point forecast indoor a facility based upon outdoor weather data and indoor environment data. The manufacturing test scheduling system selects time slots in the dew point forecast based upon a pre-defined dew point threshold and, in turn, schedules tests of a liquid cooled computer system during the selected time slots.