Server Connector Alignment Design for Liquid Cooling
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Solution Overview
Problem
Conventional liquid cooling systems for server racks lack flexibility to accommodate various configurations of server chassis and electronic racks, requiring highly accurate co-design and being economically inefficient for dedicated servers, with existing solutions not supporting versatile configurations or redundant designs.
Innovation Solution
A connector assembly with a moveable alignment module and guiding structure that automatically aligns blind mate fluid connectors between server chassis and electronic racks, allowing for flexible configuration and integration with different cooling technologies and server types, while incorporating a leak detection arrangement for reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional liquid cooling systems are used for server racks, then thermal management is provided, but the systems lack flexibility to accommodate various configurations of server chassis and electronic racks
Solution Approach 1:
The connector assembly incorporates a moveable alignment module that can dynamically adjust its position to accommodate different configurations of server chassis and electronic racks. The alignment module includes a movable connector that can shift along the fluid connector body to align with different port positions, enabling the cooling system to adapt to various rack configurations without requiring custom designs for each scenario.
Solution Approach 2:
The connector assembly is designed as a universal solution that can interface with multiple types of server chassis and electronic rack configurations. The alignment module and movable connector enable a single connector design to serve multiple functions across different rack types, eliminating the need for configuration-specific connector designs and reducing overall system complexity.
2Reliability
If highly accurate co-design is implemented for connector alignment, then connection reliability is improved, but manufacturing and implementation costs increase
Solution Approach 1:
The alignment module incorporates self-aligning features including guide rails and movable alignment mechanisms that automatically position the connector correctly during installation. This self-service alignment capability ensures reliable connections without requiring highly precise manual positioning or expensive precision manufacturing tolerances, thereby improving reliability while maintaining manufacturing efficiency.
Solution Approach 2:
The connector assembly includes pre-configured alignment features and guide structures that prepare the connection path before the actual mating occurs. The movable alignment module is pre-positioned on guide rails that lead it to the correct alignment, ensuring reliable connection while allowing for easier manufacturing compared to requiring precise final-position tolerances.
3Adaptability or versatility
If fixed connector positions are used in cooling systems, then manufacturing precision is maintained, but adaptability to different server configurations is reduced
Solution Approach 1:
The connector assembly replaces fixed connector positions with a movable alignment module that can dynamically adjust its position along the fluid connector body. This dynamic positioning capability allows the connector to adapt to different server configurations while maintaining alignment precision through mechanical guide structures and controlled movement mechanisms, rather than relying on fixed positions that would require precise manufacturing for each configuration.
Data Source
AI summary
A connector assembly may include a plate to be attached to a server chassis of an electronic rack; a connection module; and a moveable alignment module having a guiding structure and configured to be coupled to the plate via the connection module. The moveable alignment module may house one or more fluid blind mate connectors that fluidly connect to one or more cold plates that are thermally coupled to one or more electronic server components of the server chassis. The connection module may enable the moveable alignment module to be moveable when the guiding structure engages a distribution manifold of the electronic rack to align and couple the one or more fluid blind mate connectors to either at least one of a supply line connector or a return line connector of the distribution manifold, thereby enabling fluid communication between the server chassis and the distribution manifold.