Modular Data Center Cooling Unit with Air-to-Air Heat Exchanger
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Solution Overview
Problem
Data centers face challenges in efficiently cooling IT equipment due to heat buildup, with existing cooling systems often requiring significant infrastructure and capital investment, and being limited by single points of failure and inefficiencies in air-side economization.
Innovation Solution
A modular cooling system comprising ISO frame-based air handling units with air-to-air heat exchangers, evaporative cooling, and mechanical cooling systems, which operate in parallel to provide scalable, redundant, and efficient cooling by circulating IT air through tubes with outdoor air and using fans to deliver treated air back to the data center.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional CRAC units are used for cooling data centers, then cooling capacity is provided, but infrastructure complexity and capital investment increase significantly
Solution Approach 1:
The cooling system is divided into multiple independent modular units, each capable of providing cooling capacity. These modules can be deployed independently or in combination, allowing the system to scale with cooling needs while maintaining simplicity in each individual unit.
Solution Approach 2:
The modular cooling units are designed to perform multiple functions including cooling, heating, and air circulation within a single integrated package. This multi-functionality reduces the need for separate specialized equipment, thereby simplifying overall infrastructure.
2Temperature
If traditional CRAC units are deployed around the periphery of the data center, then cooling is provided, but single points of failure and reduced redundancy occur
Solution Approach 1:
The cooling system is segmented into multiple independent modular units distributed throughout the data center. Each module operates autonomously, so if one unit fails, others continue to provide cooling coverage, eliminating single points of failure and improving system redundancy.
Solution Approach 2:
Cooling modules are strategically positioned to provide localized cooling zones rather than relying on centralized perimeter units. This distribution ensures that each area has its own cooling capability, improving reliability by preventing widespread outages from a single failure point.
3Use of energy by moving object
If air-side economization is implemented in traditional systems, then energy efficiency is improved, but system complexity and control difficulties increase
Solution Approach 1:
The modular cooling units dynamically adjust their operation based on real-time environmental conditions such as outdoor temperature and humidity. This dynamic adaptability enables energy-efficient economization mode when conditions permit, while automatically switching to mechanical cooling when needed, all through simple integrated controls in each module.
Solution Approach 2:
Each modular cooling unit incorporates its own control system that autonomously manages economization and mechanical cooling transitions based on sensor inputs. This self-service capability eliminates the need for complex centralized control systems, reducing overall system complexity while maintaining energy efficiency.
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
The modular cooling system effectively addresses heat management in data centers by providing scalable, efficient, and fault-tolerant cooling solutions, reducing the need for extensive infrastructure and capital investment while improving cooling capacity and redundancy.
Implementation Method 1
an air-to-air heat exchanger supported by the housing to cool IT air generated by the data center, the air-to-air heat exchanger having at least one tube configured to direct IT from one end of the air-to-air heat exchanger to an opposite end of the air-to-air heat exchanger and configured so that outdoor air circulates around the at least one tube
Implementation Method 2
Each cooling sub-system module further comprises an evaporative cooling apparatus supported by the housing, the evaporative cooling apparatus being configured to spray water on the at least one tube
Implementation Method 3
a mechanical cooling system supported by the housing. The mechanical cooling system is configured to receive IT air treated by the air-to-air heat exchanger and to provide further cooling to the treated IT air
Implementation Method 4
The at least one fan includes a first fan configured to direct outdoor air to the at least one tube and a second fan configured to direct IT air into the at least one tube
Data Source
AI summary
A modular cooling system configured to treat IT air generated by a data center includes a frame and a plurality of cooling sub-system modules supported by the frame. The plurality of cooling sub-system modules are configured to operate in parallel to achieve total cooling effect or a lesser cooling effect with some level of redundancy within the data center. Each cooling sub-system module includes a housing configured to support cooling equipment, an air-to-air heat exchanger supported by the housing to cool IT air generated by the data center, the air-to-air heat exchanger having at least one tube configured to direct IT from one end of the air-to-air heat exchanger to an opposite end of the air-to-air heat exchanger and configured so that outdoor air circulates around the at least one tube, and a mechanical cooling system supported by the housing. The mechanical cooling system is configured to receive IT air treated by the air-to-air heat exchanger and to provide further cooling to the treated IT air. Other embodiments of the cooling system and methods of cooling are further disclosed.