Category Archive: Electronic Equipment Rack Features

Integrating Rack Consoles: Enhancing Your Rack Enclosure’s Usability

In today’s fast-paced technological landscape, the efficiency and usability of your equipment are paramount, especially in environments that demand high reliability and quick access to systems. In this post, we will explore how integrating rack consoles can optimize your rack enclosures for better performance and user experience.

What Are Rack Consoles?

Rack consoles are essential components that allow users to interface with rack-mounted equipment easily. Typically housed in a rack enclosure, these consoles can include various input devices, such as keyboards, touchscreens, and monitors. By consolidating control and access to multiple devices in one location, rack consoles streamline operations and improve workflow.

Benefits of Incorporating Rack Consoles

Incorporating rack consoles into your setup can significantly enhance the management and operation of your electronic equipment. Here are the key benefits and considerations to keep in mind:

1. Centralized Control

• Streamlined Management: Rack consoles integrate multiple control interfaces—such as keyboard, monitor, and mouse—into a single unit, allowing operators to manage multiple servers or devices from one location.
• Efficient Monitoring: Provides a consolidated view of your equipment, making it easier to monitor performance and troubleshoot issues.

2. Space Optimization

• Rack-Mounted Solution: By housing the keyboard, monitor, and mouse in a single, rack-mounted unit, you save valuable floor and desk space. This is particularly beneficial in data centers or server rooms where space is at a premium.
• Organized Environment: Reduces clutter and keeps control equipment neatly contained within the rack, contributing to a more organized workspace.

3. Enhanced Accessibility

• Easy Access: Rack consoles allow for quick and easy access to the control interface of your equipment. This is especially useful for performing maintenance tasks or making configuration changes.
• Retractable Design: Some rack console designs feature a retractable or sliding design, which means you can pull out the console when needed and push it back in to save space.

4. Improved Ergonomics

• Adjustable Positions: Consoles can be designed with adjustable or ergonomic features that enhance user comfort during prolonged use. For instance, some models offer adjustable screen angles and keyboard heights.
• Reduced Physical Strain: Consolidating control functions into one unit minimizes the need to move between different devices, reducing physical strain on the operator.

5. Increased Security

• Lockable Designs: Many rack consoles come with lockable doors or drawers, which can enhance security by restricting access to sensitive control interfaces.
• Reduced Risk of Unauthorized Access: By integrating control interfaces into a rack-mounted solution, you can better secure access to the equipment and reduce the risk of unauthorized tampering.

6. Customization and Scalability

• Tailored Solutions: Rack consoles can be customized to fit specific needs, such as adding additional ports or incorporating specialized controls.
• Modular Design: Many rack consoles are designed to be modular, allowing for easy upgrades or expansions as your needs change.

Considerations When Incorporating Rack Consoles

When integrating rack consoles into your rack enclosure, there are several factors to keep in mind:

• Compatibility: Ensure that the rack console is compatible with the equipment housed in the enclosure. Consider the specific dimensions, mounting options, and connectivity requirements.
  • Equipment Integration: Check that the console is compatible with your existing KVM switches, servers, or other equipment.
  • Interface Compatibility: Ensure that the console’s interfaces (e.g., USB, VGA, HDMI) match the requirements of your equipment.
  • Rack Units (U): Ensure the console fits within the allocated rack space. Common sizes are 1U or 2U, but you’ll need to choose based on your specific setup.
  • Depth and Dimensions: Verify that the depth and overall dimensions of the console are compatible with your rack and equipment.
• Ergonomics: Choose a design that promotes ergonomic access, allowing operators to interact with the console comfortably, even during extended use.
• Cooling and Ventilation: Consider the heat generated by both the rack-mounted equipment and the console itself. Proper ventilation and cooling solutions should be in place to prevent overheating and ensure reliable operation.
  • Heat Management: Consider the heat generated by the console and ensure adequate ventilation to prevent overheating of both the console and the surrounding equipment.
  • Airflow Design: Choose a console design that does not obstruct airflow within the rack.
• Security: In military or sensitive environments, security is paramount. Look for rack consoles with locking mechanisms and tamper-resistant features to protect your equipment.

• Expandability: Consider whether the console will accommodate future expansions or upgrades to your equipment. Modular or flexible designs can be advantageous in this regard.

Incorporating rack consoles into your setup can offer numerous benefits, including centralized control, space optimization, improved accessibility, and enhanced security. However, it’s essential to carefully consider factors such as size, compatibility, cooling, and cost to ensure that the console meets your specific needs and integrates seamlessly into your existing infrastructure. By evaluating these aspects, you can make an informed decision that enhances your equipment management and operational efficiency.

Innovations in Rack Enclosure Design: Trends and Technologies Shaping the Future

In the rapidly evolving world of technology, rack enclosures play a crucial role in housing and protecting electronic equipment. Recent advancements and trends in rack enclosure design and technology are enhancing performance, efficiency, and user experience. Here’s an exploration of the latest innovations shaping the future of rack enclosures:

1. Enhanced Cooling Solutions

• Precision Airflow Management: Modern rack enclosures are incorporating advanced airflow management systems, including hot and cold aisle containment, to improve cooling efficiency. These systems ensure that hot air generated by equipment is effectively separated from cool air, reducing the risk of overheating.
• Liquid Cooling Integration: Liquid cooling systems are becoming more prevalent, allowing for higher-density configurations and more efficient cooling compared to traditional air cooling methods. These systems use liquids to absorb and dissipate heat more effectively.

2. Smart and Connected Enclosures

• IoT Integration: Rack enclosures are increasingly equipped with Internet of Things (IoT) sensors and connectivity. These smart enclosures can monitor environmental conditions, track equipment performance, and provide real-time alerts for issues such as temperature fluctuations or unauthorized access.
• Remote Management: Advanced rack enclosures offer remote management capabilities, allowing administrators to control and monitor equipment from anywhere. This feature enhances operational efficiency and reduces the need for on-site intervention.

3. Modular and Scalable Designs

• Modular Rack Systems: Modular designs allow for flexibility and scalability, enabling users to easily expand or reconfigure their rack setups as needs change. Modular racks can be adapted to accommodate different types of equipment and varying space requirements.
• Expandable Rack Units: Some modern enclosures offer expandable units that can be added or removed based on the user’s needs. This scalability supports dynamic IT environments and helps future-proof infrastructure investments.

4. Improved Security Features

• Advanced Access Control: Enhanced security features, such as biometric access control and electronic locks, are being integrated into rack enclosures to protect sensitive equipment. These systems provide higher levels of security and ensure that only authorized personnel can access critical equipment.
• Tamper-Evident Designs: New enclosure designs include tamper-evident features that alert users to any unauthorized attempts to access the enclosure. This helps prevent tampering and ensures the integrity of the housed equipment.

5. Sustainable and Eco-Friendly Materials

• Recycled and Eco-Friendly Materials: There is a growing emphasis on using sustainable materials in rack enclosure manufacturing. Manufacturers are incorporating recycled metals and eco-friendly materials to reduce the environmental impact of production.
• Energy Efficiency: Modern enclosures are designed with energy efficiency in mind, including features that reduce power consumption and improve overall operational efficiency. This trend aligns with broader efforts to create more sustainable data centers and IT infrastructure.

6. Advanced Cable Management Solutions

• Integrated Cable Management: Enhanced cable management features are being built into rack enclosures to streamline cable routing and organization. These solutions help reduce clutter, improve airflow, and make maintenance easier. Examples include: channels or ducts to route cables along specific paths via doors or panels, and integrated cable spools.
• Toolless Cable Management: New designs include toolless cable management systems that allow for quick and easy adjustments without the need for additional tools. This feature simplifies setup and maintenance processes.

7. Aesthetic and Ergonomic Considerations

• Customizable Aesthetics: Rack enclosures are increasingly available with customizable aesthetics, allowing users to match the design to their brand or workspace. Options include various colors, finishes, and branding opportunities.
• Ergonomic Designs: Modern enclosures are being designed with user ergonomics in mind, including features like adjustable shelves, easy-access panels and integrated control panels. These enhancements improve usability and make equipment management more efficient.

8. Enhanced Durability and Protection

• Improved Construction Materials: Advances in materials science have led to the development of more durable and protective enclosures. These materials offer better resistance to environmental factors, such as temperature extremes and electromagnetic interference (EMI).
• Sealed and Shielded Designs: Some enclosures now include sealed and shielded designs to protect sensitive equipment from dust, moisture, and electromagnetic interference. These features enhance the reliability and longevity of the housed equipment.

The latest advancements in rack enclosure design and technology are driving improvements in cooling efficiency, security, scalability, and sustainability. By incorporating these innovations, businesses can better manage and protect their equipment, optimize their data center operations, and adapt to changing technological needs. Staying informed about these trends will help you make informed decisions and leverage the best solutions for your rack enclosure requirements.

Custom vs. Standard Rack Enclosures: When to Choose Each Option

Deciding between a custom or standard enclosure for your electronic equipment involves evaluating several factors to determine which option best meets your specific needs. Here’s a comprehensive guide to help you make an informed decision:

Understanding Standard vs. Custom Enclosures

• Standard Enclosures:

  • Pre-Designed: Built to common specifications and sizes, typically available off-the-shelf.
  • Cost-Effective: Generally less expensive due to mass production and lower manufacturing costs.
  • Quick Turnaround: Readily available and often ships quickly.
  • Limited Customization: Limited options for modifications or personalization.

• Custom Enclosures:

  • Tailor-Made: Designed specifically to meet your unique requirements and specifications.
  • Higher Cost: More expensive due to the need for specialized design and manufacturing.
  • Longer Lead Time: Requires more time for design, prototyping, and production.
  • Fully Customizable: Allows for specific modifications, materials, and features.

Assessing Your Requirements

A. Equipment Specifications

• Size and Dimensions: Measure the size and dimensions of your equipment. Custom enclosures can be designed to fit irregularly sized or non-standard equipment, while standard enclosures may have fixed dimensions that need to match your equipment.
• Weight: Consider the weight of your equipment. Custom enclosures can be designed with specific load-bearing capacities to accommodate heavier equipment.

B. Functional Needs

• Cooling and Ventilation: Determine if your equipment requires specific cooling solutions. Custom enclosures can be designed with tailored ventilation and cooling systems, whereas standard enclosures may offer limited options.
• Accessibility: Consider how frequently you need to access your equipment. Custom enclosures can include features like removable panels or doors, while standard models might not offer the same level of accessibility.

C. Evaluating Environmental Conditions

• Operating Environment: Assess the environment in which the enclosure will be used (e.g., temperature, humidity, dust). Custom enclosures can be built with materials and features to withstand harsh conditions, whereas standard enclosures may offer limited environmental protection.
• Compliance Requirements: Check if there are specific industry standards or regulations you must meet. Custom enclosures can be designed to comply with specific regulations, whereas standard enclosures may not always meet niche compliance needs.

D. Budget Considerations

• Initial Cost: Compare the cost of standard enclosures, which are typically less expensive, with custom enclosures, which involve higher initial costs due to design and manufacturing.
• Long-Term Value: Evaluate the long-term value and potential cost savings. Custom enclosures might offer better durability and functionality, reducing the need for future modifications or replacements.

E. Lead Time and Availability

• Project Timeline: Consider your project timeline. Standard enclosures are readily available and have shorter lead times, while custom enclosures require additional time for design and production.
• Urgency: If you need an enclosure quickly, a standard model may be the best choice. Custom enclosures require time for design iterations, prototyping, and manufacturing.

F. Customization Options

• Design Flexibility: Determine if you need specific design features such as custom mounting solutions, cable management, or specialized cooling. Custom enclosures offer the flexibility to incorporate these features, while standard enclosures have fixed designs. Read more about our engineering support services.
• Aesthetic Requirements: If aesthetics or branding are important, custom enclosures can be designed to match your specific requirements, including color and finish.

G. Future Needs and Scalability

• Scalability: Consider whether you might need to expand or modify your setup in the future. Custom enclosures can be designed with modular features to accommodate future changes, while standard enclosures might require replacement if needs evolve.
• Flexibility: Custom designs allow for adjustments and reconfigurations based on future needs, whereas standard enclosures offer less flexibility.

H. Vendor Support and Warranty

• Support: Evaluate the level of support and warranty offered by vendors. Custom enclosure manufacturers often provide comprehensive support during design and production, while standard enclosure suppliers might offer limited support.
• After-Sales Service: Consider the availability of after-sales service for maintenance and repairs. Custom manufacturers may offer tailored support services.

Decision-Making Summary

Choose a Standard Enclosure if:

• You need a cost-effective solution with a quick turnaround.
• Your equipment fits standard sizes and dimensions.
• The functional, environmental, and compliance requirements can be met by available standard models.
• Your project timeline is tight and you need an immediate solution.

Choose a Custom Enclosure if:

• Your equipment has unique dimensions, weight, or cooling needs.
• You require specific features or design elements not available in standard models.
• The operating environment requires specialized materials or construction.
• You are willing to invest in a higher initial cost for a tailored solution with long-term benefits and scalability.

By carefully assessing your requirements, budget, and timeline, you can make an informed decision between standard and custom enclosures, ensuring you select the best fit for your needs.

An Introduction to Liquid Cooling for Rack Enclosures

Power densities in electronic subsystems continue to increase, driving demand for more extreme cooling power. System engineers are increasingly exploring liquid cooling to optimize thermal management efficiency, sustainability and reliability.

Liquid cooling is replacing air cooling for several reasons: 3,500 to 4,000 times more efficient at transferring heat; noise reduced due to slower fan speed; 85% reduction in carbon footprint; and significant cost savings results from more efficient cooling because less energy is required. Read more about IBM’s experiment from 2010 in Scientific American.

Fluids commonly used in cooling applications

• Water – excellent heat transfer, low viscosity, non-flammable and low cost. Susceptible to freezing or boiling and biological fouling.
• Ethylene glycol (EG) – controls biological growth, lowers freezing point and elevates boiling point when used in solution with water. Lower cost that refrigerants or dielectrics. Highly toxic and requires careful handling.
• Propylene glycol (PG) – controls biological growth when used in solution with water. Lower cost than refrigerants or dielectrics. Lower thermal conductivity and higher viscosity than EG. Low toxicity for easier handling and disposal.
• Mineral oil – odorless, non-toxic and chemically inert. No evaporation or volatility. Potential incompatibility with copper or some elastomers.
• Refrigerants – lightweight with excellent thermal transfer properties. Higher cost (R-1234yf and R-1336)
• Dielectrics – non-conductive engineered fluids that enable full immersion of electronics in single-phase, two-phase and direct-to-chip applications. Low boiling point and higher chemical stability. Higher cost. Potential incompatibility with thermoplastics or elastomers.

Factors to consider when choosing a coolant for your liquid cooled rack or enclosure

Choosing a coolant is a focal point when designing a liquid cooling system.

Start by looking at operating and storage temperatures. You’ll want to identify a fluid with properties that are compatible with your application’s environment, such as boiling point of the thermal load and thermal efficiency needed without exceeding the critical heat flux. It’s also critical to check low temperature characteristics during storage and shipping or other environmental exposures.

We recommend considering the ozone depletion and global warming potentials when selecting a fluid. Over the last decade, the World Health Organization guidelines have increased emphasis on these parameters, prompting the development of greener alternatives, such as 3M Novec (will be discontinued in 2025), FHE coolant and fourth generation hydrofluoroolefin refrigerants.

In addition to thermal stability and chemical compatibilities, consider coolant toxicity, flammability, cleanliness requirements, environmental impact, and cost.

Component construction materials commonly used

Polymers

• Commodity plastics – includes HDPE, POM, PP, PS and PVC. Relatively low cost and readily available. Potential flammability in high-temperature applications or thermal degradation and shrinkage in some environments.
• Engineered thermoplastics – includes PEEK, PEI, PESU, PPSU, PSU. Improved mechanical and thermal properties, with a higher cost than commodity plastics.
• Elastomers – includes CR, EDPM/EPM, FKM, HNBR, silicone. May be modified to enhance flame retardance, durability or chemical resistance. Some types may leach into fluids during thermal cycling or exposure to certain solvents, negatively impacting coolant performance.

Metal alloys

• Aluminum – durable, lightweight metal with strong thermal properties. Potential for galvanic corrosion, especially with water-based coolants and in presence of copper. Anodization increases corrosion resistance.
• Brass – durable and strong thermal properties. Relatively low cost and often plated with nickel or chrome for improved corrosion resistance.
• Copper – durable and strong thermal properties. Galvanic corrosion potential, especially with water-based coolants.
• Stainless steel – Highest in durability and stability, but lower thermal conductivity and higher costs. Passivation increases corrosion resistance.

Material and coolant compatibility

When considering components in a liquid cooling system, the following combinations are:

• A = recommended. Little to no potential for chemical reaction or corrosion.
• B = good options. Minor potential for chemical reaction or corrosion, with limited affect on system performance.
• F = not recommended. Mild to severe chemical or corrosive reactions likely. May impede system performance.

Connectors for a liquid cooled rack enclosure

Connectors are critical to the safe and reliable operation of liquid cooling systems. A well-design fluid connector should easily facilitate connection, disconnection and rerouting of fluid; support 100% uptime during installation, reconfiguration and maintenance; and allow secure, efficient, reliable and leak-free management of fluids within the cooling system.

Connector type

• Quick disconnects (QDs) – increasingly used because they’re easier to install/uninstall than other connectors
• Socket/plug; male/female; body/insert – connector halves fit together by one side inserting into the other. They’re intuitive to use and requires force to connect, which increases as the system pressure increases
• Latched – integrated thumb latches can ease connection/disconnection by allowing one-handed operation; enables hot swapping
• Blind mate – requires a separate retention mechanism, such as a sever blade latch; releasing force disconnects the QD and works best in difficult to see/access locations
• QDs with elbows, swivel joints – integrated swivel joints and elbows eliminate tube kinking and allow easier connection and disconnection in tight spaces

Flow rate, pressure and pressure drop

• Flow rate – flow rates are typically low at the server (o.5 l/min) and much higher at the coolant distribution unit (up to 70 l/min); actual-use flow rates that exceed the connector’s maximum flow rate capacity can lead to seal failure or accelerated part erosion.
• Connector size – specify appropriate connector sizes from server to CDU. They range from 1/8 inch at the server to 1 inch at the CDU. QDs of the same size can deliver significantly different flow performance. Also consider physical space available at the front or back to ensure adequate room for connections, disconnections and ongoing use.
• Pressure – operating break and safety burst pressures should all be assessed. Operating pressure defines the usual and customary pressure ranges during regular system use. Break pressure indicates the point at which a component no longer maintains pressure, which is a higher threshold than safety burst pressure.
• Pressure drop – both flow rate and connector size affect pressure drop

Stop-flow / dripless performance

• Straight-through connectors – neither connector half features a valve necessitating flow stop prior to disconnection
• Single shut-off valve – one side of the QD contains a valve
• Double shut-off valve – both QD halves contain valves; poppet valves trap a small amount of liquid within the coupling body that can drip when disconnected
• Flush-face valves – most dripless/drybreak/non-spill QDs feature flush-face valves that allow no more than a coating of coolant on valve surfaces
• Seal type – many QDs feature O-rings; some connectors feature multilobed seals that offer better shape retention over time, protection against leakage, greater resistance to debris or foreign contaminants, and require less force to connect

Reliability

• Helium vacuum leak test – verifies sealing performance at specific temperatures
• Elevated temperature burst test – demonstrates adequate safety margins above rated operating pressure at higher than ambient temperatures
• Creep rupture test – demonstrates safe use at continuous higher-than-rated pressures and temperatures for an extended period
• Flow rate test – determines CV values
• Drip leak testing and spillage testing – under specific temperature and pressure conditions, measure evidence of drip leaks during simulated use conditions or spillage at disconnection
• Disconnect under flow – quantify resistance of connectors to water hammer and fluid acceleration caused by disconnecting units under flow
• Cycle testing – verifies connector sealing performance after repeated connection/disconnection cycles; some manufacturers conduct 10,000 cycles to validate leak-free performance
• Connect force testing – characterize the force to connect with varying pressures in the disconnected body and insert prior to connection

Identifying the Correct Electrical Enclosure Gasketing

First, let’s identify if or why you need to use electrical enclosure gasketing. The function of a gasket is to not only protect electronic components contained in electrical housings from outside elements such as weather, but also to prevent electrical hazards from escaping the unit. The proper gasket will provide a tight seal in both indoor and outdoor enclosure applications, with the ability to withstand the life of the product.

Poor seals and low-quality gaskets can cause damage and serious safety issues. An inefficient design can allow gases and liquids to leak into your devices, it can cause system failures that require time-consuming repairs or even fires that put your facility and employees at risk.

Ensuring proper performance for your enclosure gasketing

Before you make material selections and/or installation options, it’s important to understand your specific application requirements. Most applications need to comply with various ratings such as NEMA, UL and IP or military standards.

Ask the following questions:

• Temperature – what temperature range will be required?
• Location – will the application be indoor or outdoor?
• Flame resistance – will the material require a certain flame rating?
• Outgassing – will material outgassing harm the internal components?
• Gap spacing – what is the area needed to be filled by the gasket?
• Gasket function – what protection will the gasket need to provide? (air, liquid, vibration, EMI shielding)

Additional engineering design considerations:

• Protect the gasket – a flange on the door that protects the gasket from a direct pressure blast will diffuse the force and greatly improve the chances of passing a wash down test
• Door latching – helps provide a proper means of compressing the gasket
• Material selection – ensure the appropriate gasket material is used for your environmental requirements
• Gasket rebound – rebound or resistance to taking a compression set can be critical, especially on door gaskets that are being unseated regularly
• Functional life – longevity of the gasket will depend on how the material is used: exposure to UV, ozone, temperature, chemicals, and mechanical wear
• Venting – pooled water can get sucked into an enclosure during a rain shower from the vacuum affect from cool rain on a hot box

Material selection for your enclosure gaskets

There are a variety of materials to choose from when it comes to providing the perfect seal on an enclosure. Look for an option that is both cost-effective and delivers optimum performance.

Common materials used:

• closed cell sponge rubber (neoprene, PVC)
• cellular urethane
• polyethylene
• silicone

Which application process should you utilize?

There are three common types of gaskets:

• Foam-in-place – they require a special liquid polyurethane spray to be applied to the edges of the mating, that once dried and hardened can provide a good deal. A downside to this option is that it can easily be damaged and can be a costly application process
• Strips – these are typically used as a temporary solution until a better gasket option can be found. It often leaves gaps and leaks.
• Custom water jet cut – they can be cut from a variety of materials to the precise size and thickness you need

NEMA / UL 50 Enclosure Gaskets

Technically there aren’t any NEMA gaskets since the enclosure is evaluated as a whole, but there are gaskets and gasket materials that will help an enclosure pass a specified test.

IP Enclosure Gaskets

The intentions of the IP code are similar to NEMA and UL. The first digit (IP 6X) refers to solid particle. The second digit (IP X1) refers to water. For example, IP%$ refers to an electronic enclosure capable of sealing out dust, water and protect against vertically dripping water.

EMI Enclosure Gaskets

Commercial applications, not held to military specifications, typically yse nicel graphite filled silicone. The Nickel particles are mixed into silicone polymers and cured into conductive rubber sheets or rolls. Larger EMI gaskets can be made with strips or interlocking strips to maximize the yield.

For gaskets required to meet MIL-DTL-83528, the polymer and conductive fill are defined by specification types:

• Type A – silver coated copper + silicone (65 durometer)
• Type B – silver coated aluminum + silicone (65 durometer)
• Type C – silver coated copper + flurosilicone (75 durometer)
• Type D – silver coated aluminum + fluorosilicone (70 durometer)
• Type M – silver coated glass + silicone (65 duromater)

Keep your electronics interference-free

At A&J we use a .140 diameter tubular gasket (210-1130) that is added to the extrusion grooves and consists of a silicone inner core that is plated with silver / aluminum for the seams between the frame members that are joined together.

Our enclosures are attenuated to 60 DB from 150 Hz to 1 million Hz and 40 DB from 1-2 million Hz in accordance with MIL-STD-461G for EMI/RFI shielding. Our team of professionals can help you determine the type of shielding your rack or enclosure needs and install it quickly and efficiently. Contact us today!

Optimal Airflow in Electronic Enclosures; and 4 Design Tips

Thermal management for sophisticated electronics in protective enclosures starts with one fundamental element: airflow. Optimal airflow in electronic enclosures, both within and throughout, can mean the difference between successfully maintaining and cooling your sensitive components and risking costly downtime associated with failures.

Equipment has specific operating temperature ranges and when put inside of cabinets and enclosures, temperature can become a big issue. Cooling should be considered early in the design process, but having an effective cooling strategy can help in adequately dealing with heat dissipation.

First: Understanding Heat Transfer

Heat transfer takes place in three ways: through radiation, conduction and natural or forced convection.

Heat transfer via radiation occurs through electromagnetic waves, similar to the sun’s energy reaching the earth.

Heat can also be transferred through conduction between objects. A common example of this is a microprocessor chip cooled using a heat sink, making direct contact with the chip.

Most systems remove heat through a combination of methods. Going back to the microprocessor chip, it may be cooled using a heat sink (conduction) that includes a fan (forced convection).

The most commonly used cooling methods for enclosures, in order of increasing cost, are natural convection, forced convection and air conditioning.

Second: Understanding Airflow

Natural Convection

This is the most basic form of airflow. When heat rises, cold air is pushed to the bottom of a space. If convection isn’t properly addressed, a hot spot will form at the top of the enclosure.

Natural convection cooling is adequate for most applications that generate mild heat. But, an easy solution is passive ventilation, or louvres.

Louvres are open, unfiltered vents positioned to allow ambient air to be drawn into the enclosure through openings positioned low on the enclosure surface, and to exit through similar openings positioned high on the same surface. They’re also a popular option because they provide some protection against dust entry.

Forced Convection

Using the same principles as described above with natural convection, forced convection adds a fan, blower or compressed air to force the warmed air through the enclosure and out through the upper vent.

Three devices are commonly used: fans, blowers and fan trays

Axial fans are typically capable of delivering high volumes of air at medium to low pressure

Blowers, or centrifugal fans, change the direction of the air, typically 90 degrees, and push the air out through a ducted system. They offer higher pressure with a lower flow.

Fan trays are used to direct airflow to hot spots when there is restricted airflow due to servers, drawers or shelves. It’s basically a chassis with a fan cooling module that can be mounted directly below the sensitive equipment or a hot spot. At A&J we’ve created a separate sub assembly that support fans with related parts such as EMI and dust filters.

Air Conditioning

For critical and thermally sensitive applications, or sealed cabinets, air conditioners provide the greatest capacity to transfer heat. Most air-conditioned cabinets are sealed with only inside air circulated inside to prevent moist air from entering and causing condensation.

Basic Airflow Calculations

For For ∆T in degrees F: Airflow (ft3/min) = BTU/hr / (1.08 × ∆ΤF) = (3170 × kW) / ∆ΤF

For ∆T in degrees C: Airflow (ft3/min) = BTU/hr / (1.95 × ∆ΤC) = (1760 × kW) / ∆Τc

Typical values for ∆Τ are 10C and 18F. Add 25 percent for a safety margin (12.5C and 23F). Note that ∆Τ represents the temperature rise over ambient air temperature. If ambient is too high, it may be difficult or impossible to maintain a safe operating temperature without air conditioning.

Airflow Calculator

Design Tips for Component Placement

• Components with significant heat generation should be given extra space to exhaust the heat and allow for proper airflow around them. Place these items closer to the intake of the AC, if using.
• Components that run cooler can be stacked closer together. Airlfow is less of a requirement with these pieces because they have minimal effect on overall heat within the enclosure.
• There should be clearance to walls and doors; keeping the hotter components away from walls of the enclosure allows for better circulation of air within the space.
• When a component has an active airflow through internal fans, directing the airflow towards the AC intakes will help the cooler to perform more efficiently. It is more beneficial to get the hot air from the equipment into the AC, than it is to get the cold from the AC to the equipment.
• Special consideration should be made when components have internal fans mounted on its front panel. It is common to recess the front retma bars and/or specify a deeper door to ensure proper airflow facing the front of the rack.

Thermal Management Solutions to Consider

When planning your next project design, consider these three solutions:

1. Fans – one of the oldest solutions to help boost natural ventilation. An air filter should always be used to minimize dust and debris, but ensure that the free-airflow rate (CFM) is three times grater than the calculated flow rate.
2. Enclosure air conditioners – a viable option when the capacity requires over 1000 BTUH and especially beneficial if you’re operating in an environment that has wide temperature fluctuations.
3. Air to air heat exchangers – a low-energy and low-maintenance solution that uses a heat pipe to absorb the heat inside the enclosure and transfer it to the outside via a phase-changing liquid under vacuum. However, it requires that the ambient air outside the enclosure be lower than the air inside.

EMI / RFI shielding: what it does and why it’s important

EMI, or electromagnetic interference, and RFI, or radio-frequency interference, are both types of electromagnetic radiation. EMI is emitted by electronic devices and can interfere with the proper functioning of other electronic devices, while RFI is emitted by radio waves and can interfere with radio signals.

EMI and RFI shielding is a process of enclosing electronic devices in a material that absorbs or reflects electromagnetic radiation to protect the devices from interference.

It can prevent everything from minor crackling during broadcasting to deadly malfunctions in aircraft safety equipment. If left unmitigated, it can disrupt the essential functions of electronic devices or erase or damage data. Even satellites in space need to be shielded from EMI/FRI to function properly.

Common sources of EMI/RFI include cell phones, microwaves, power lines and computer circuits. There are all natural causes of these signals such as auroras, solar flares or lightning.

What is EMI / RFI shielding, and what does it do?

EMI/RFI shielding is a process or material used to protect electronic equipment from EMI and RFI. EMI/RFI shielding can protect against various sources, including radio waves, microwaves, and electrical currents.

EMI/RFI shielding creates a barrier between the electronic equipment and the source of interference. This barrier can be made with a variety of materials.

Materials used for EMI/RFI shielding

For EMI/RFI shielding, a variety of materials can be employed. The following are the most frequent materials:

• Metals
• Conductive plastics
• Carbon-loaded plastics
• Conductive coatings
• Metal mesh

Metals are the most common material used for EMI/RFI shielding. They are effective because they reflect and absorb electromagnetic radiation.

Importance of EMI / RFI shielding in electronic devices

EMI/RFI shielding is essential in electronic devices because it can help to reduce or eliminate interference that can lead to errors, data loss, and equipment damage. Shielding can also help improve electronic device performance by reducing interference from outside sources.

EMI/RFI shielding creates a barrier between the electronic equipment and the source of interference. This barrier is produced with various materials, including metals, conductive plastics, and special coatings.

How to choose the right EMI / RFI shielding for your needs

When choosing EMI/RFI shielding for your electronic devices, it is vital to consider the type of interference you are trying to protect against, the level of protection you need, and the environment in which the electronic devices will be used.

Some EMI/RFI shielding types, such as metal shielding, can block a wide range of frequencies. However, metal shielding can also block signals you may want to receive, such as radio waves. In addition, metal shielding can interfere with the proper functioning of some electronic devices.

Other EMI/RFI shielding types, such as conductive plastics and special coatings, can be customized to block specific frequencies while allowing others to pass through. These materials can also be used in various environments, including wet or humid ones.

Common applications for EMI / RFI shielding

EMI/RFI shielding is used in a variety of industries, including:

• Automotive
• Aerospace
• Telecommunications
• Medical
• Mass transit systems
• Navigation and vehicular control systems

Keep your electronics interference-free

If you’re looking for ways to protect your electronic devices from interference, look no further than EMI and RFI shielding. Enclosed devices in a material designed to absorb or reflect electromagnetic radiation to keep them functioning correctly. At A&J we use a .140 diameter tubular gasket (210-1130) that is added to the extrusion grooves and consists of a silicone inner core that is plated with silver / aluminum for the seams between the frame members that are joined together.

Our enclosures are attenuated to 60 DB from 150 Hz to 1 million Hz and 40 DB from 1-2 million Hz in accordance with MIL-STD-461G for EMI/RFI shielding. Our team of professionals can help you determine the type of shielding your rack or enclosure needs and install it quickly and efficiently. Contact us today!

Rack Mounting Options for your Electronic Equipment

A rack mount is a description of a hardware device capable of being mounted in an equipment rack. All types of electronics and computing devices come in rack-mounted packages including servers, test instruments, telecommunications components, which are bolted to the side frames of the rack. Note: shelves are available for equipment that is not rack mounted.

Measuring cabinet dimensions, specifically depth

Before ultimately choosing a rack mounting option, let’s first review how to properly measure your rack space. As a reminder, cabinets or enclosures are traditionally referred to by their external dimensions. But in most cases, the rack depth is 4 to 6 inches less than the external cabinet depth.

To measure the rack depth, measure the distance between the forward-most part of the front rail to the rear-most point of the rear rail. A&J typically recommends 34 in. (86.36 cm) or greater cabinets for use with equipment that have an average depth of 28 in. (71.12 cm). The 6 inches (15.24 cm) at the back between the equipment and the back door or panel allows for cable management, airflow and maintenance access.

Equipment mounting options

Originally mounting holes were tapped with a particular screw thread, but has since become problematic where equipment is frequently changed because the threads are easily damaged or the mounting screws can break off. Both problems render the mounting hole unusable.

Tapped-holes were then replaced by clearance-hole racks. Holes are large enough to permit a bolt without binding and fastened in place using cage nuts.

The third innovation has been square-hole racks. These racks allow boltless mounting where the weight of the equipment and small retention clips are all that is necessary to hold equipment in place.

The structural support

A key structural weakness of front-mounted support is the bending stress placed on the both the rack itself and the mounting brackets of the equipment. Our A&J racks can incorporate front and rear rails that may be moved forwards and backwards that allows equipment to be supported by four posts, but also easily installed and/or removed.

Our standard AJR 150 Series 4-post racks are 22.31″ (566.6 mm) wide with three depths: 26″, 30″, 36″ (660.4 mm to 914.4 mm). The extra width and depth enables cabling to be routed with ease and deeper equipment to be installed. It can also accommodate “Zero-U” accessories such as PDUs and vertical cable managers in the space between the rear rails and the side of the enclosure.

Rails (slides)

Often used for heavy equipment that requires regular servicing, a pair of rails can be mounted directly onto the rack which allows the component to slide into the rack along the rails. The equipment can then be bolted to the rack (as described above) or the rails may also be able to fully support the equipment in a position where it has been slid clear of the rack. Consider purchasing a cable management arm, which folds the cables attached to the server or component and allows them to expand neatly when the rail is slid out, without being disconnected.

Tools required

You will need some of the following tools to rackmount your equipment:

• Philips No. 1, No. 2, and No. 3 screwdrivers
• Flat-blade No. 1 and No. 2 screwdrivers
• Allen and adjustable wrenches
• Needlenose pliers
• Level
• Electrostatic discharge (ESD) wrist strap
• ESD mat

Rack Mounting Tips & Guidelines

• Install the heaviest equipment and storage devices in the lowest position in the rack to prevent the rack from becoming too-heavy and prone to tipping over.
•  Install any remaining equipment from the lowest system upward into the rack.
• For applications that require high-density cabling, you may need 1U of horizontal cable management for every 1U of patch panels or switches.
• Ensure the rack is properly secured to the floor or ceiling and level before installing any components.

Benefits of a Modular Enclosure

Because the Industrial Internet of Things (IIOT) has accelerated the evolution of industrial engineering, it’s generally a good idea to err on the side of versatility. But there are several misconceptions or misunderstandings about the traits and attributes of a modular enclosure. A fully realized modular enclosure will help you respond better to market demands, supply chain logistics and other variant-rich environments with greater flexibility, agility and speed.

What a Modular Enclosure Is and Isn’t

There are specifically three terms that are used incorrectly.

Unibody Enclosure – Often constructed with welded steel or other heavy sheet metal, their rigid design can hamper maintenance, repair or modification of the enclosure and the equipment within it.

Modified Enclosure – While a modified enclosure can have some of the same traits as a modular enclosure, it simply encompasses an enclosure with custom holes or tapping

Modular Enclosure – an industrial enclosure with accessories or panels that can easily be reconfigured or rearranged within its standard frame. It virtually eliminates costly machining and fabrication as your device components change.

Benefits of a Modular Enclosure

1. Infinite configurations – Modular frames come with pre-drilled holes using the EIA’s standardized unit of measurement. And common accessories or network devices can be added to the interior without additional drilling or welding. Plus, these frames can easily be bayed together to create nearly infinite configurations.
2. Faster mounting & installation – Using rails, an integrator can easily slide panels into or out of the front, side or rear openings of an enclosure. Mounting becomes easier and faster when compared to the unibody technique of laying an enclosure on its back and lifting the panel with a forklift or crane. This all adds up to saving you time and money.
3. Built to last – Due to its vertical framing, a modular cabinet won’t lose any of its strength or protective qualities.
4. Flexibility – A designer, integrator, engineer and end user each have the freedom to make assemblies as basic or as complex as a job requires. Again, components can be arranged without the need to cut or weld. This allows for varied and unique configurations inside, while also allowing flexible cable or maintenance entry. Any enclosure can be adapted to meet your  needs.
5. Maximizes floor space – Space is a premium and all floor designers / engineers want to maximize the square-footage at their disposal. Modular enclosures can be customized or tailored to fit specific applications in a variety of environments. They unlock efficiencies and flexibility though both inner and outer mounting levels, multiple baying opportunities and accommodate a variety of connection configurations.

Core Elements of a Modular Enclosure

The prime characteristics of a modular enclosure include:

1. Protection of enclosed devices / equipment – There are several physical stressors present in any given environment: tampering, water, mold, corrosion. And just like traditional unibody designs, a modular enclosure can be certified to rugged industry standards (MIL-S-901D, NEMA). Properly assess local weather conditions, corrosive substances and even resistance levels of internal components.
2. Compartmentalization – A modular design allows you to compartmentalize separate pieces of IT equipment or add thermal accessories to help with climate control. It removes the need to source several cabinets or climate-control systems. It also saves floor space!
3. Ease of modification – It’s easier to scale up or scale down manufacturing needs based on production sequence, customer demand, space or other factors with a modular design. And users can easily swap parts out for new ones and modify panels.
4. Mounting panels – The most commonly modified part of any enclosure, the mounting panel in a modular design allows for the addition of rails, making it possible to slide the panel into and out of the front, side or rear openings. It eliminates the need to lay the enclosure on its back and lifting the panel with a crane or forklift.
5. Availability of sizes and types – While available in traditional sizes, it can also be configured to specific applications with full size or partial doors, multiple mounting panels and entry points.

Thinking About a Custom Rack Design? Here’s What to Consider

Racks help organize IT equipment into more collective assemblies that free up space and make efficient use of resources. A rack typically consists of two or four vertical rails for mounting, along with a supporting framework that secures the rails. Both the framework and rails tend to feature aluminum or steel construction, which makes them capable of supporting up to thousands of pounds of IT equipment. The rails also include round or square holes that make it easy to use screws for mounting rack equipment.

If standard rack designs don’t work for your application, you may benefit from a custom server rack. When creating your custom rack design, there are many key factors to consider to ensure the best possible rack for your needs.

Things to Consider with Custom Racks & Enclosures

When in the market for a custom electronic rack, there are certain items to consider to inform your design.

Size
One element that will go into a custom rack design is the desired size. Obviously all of your electronic components need to fit comfortably inside, but you also need to consider the space between them to avoid interference. Your rack or enclosure should also accommodate the necessary space needed for maintenance and device assembly or installation.

Regarding external size dimensions, the primary limitation is that the bend radius must not be less than the enclosure material’s thickness. Through CNC machining, we can manufacture enclosures as small as 11.75″ x 16.5″ x 9.5″. We encourage you to contact us about your design to discuss it further with our design engineering team.

Environment
Depending on the application, you’ll need to account for any industry standards or ratings that enclosures must meet to protect equipment from dust or water. For instance, equipment may need to meet NEMA and military standards or have an IP rating.

Accessories
Consider the different accessories available to you, which could include:

• Cooling — Blowers, fans, and fan trays
• Power Management — Cable support, distribution, and power strips
• Internal Slide Hardware — Slide brackets and mounting brackets
• External Panels & Hardware — Blank panels, nuts, screws, and washers
• Shelves & Drawers — Sliding and fixed shelves and sliding drawers
• Shock, Vibration, and Seismic Resistance — Open-frame racks and enclosure racks
• Secure Racks — Blanking panels

Standard Options vs. Custom Design

Oftentimes, you may not need a custom rack cabinet if you can benefit from using standard equipment, which is why this is one of the first determinations to make. Customers may also be able to fit a stock enclosure with various custom features instead of designing an entire custom rack, saving more time and resources.

A&J’s racks are modular, which makes them easy to adapt to various hardware and technology.

Other factors to consider include:

• Expandability. At A&J, our kits allow us to gang cabinets together to form a “suite,” which helps increase stability and enables easier management of interconnecting cables.
• Accessibility. Our cabinets’ bolted-together design makes it easy to remove side panels from the exterior, allowing easy access to interior cabling and components.
• Cable Management. Most equipment on a rack requires cabling for operational or network connectivity purposes. Our cable management accessories offer a key solution in these situations.

Benefits of Custom Enclosures from A&J

A&J’s custom enclosures offer the following advantages:

Lower Upfront Costs
Although you can create custom enclosures in-house, it can be very costly to invest in the required equipment, manufacturing tools, and materials. This equipment can take up a lot of space in your facility and may require lots of trial and error to produce an effective enclosure. Our expertise at A&J can help you avoid these challenges, saving you time and money.

Greater Process Knowledge
Our engineers possess the necessary techniques and expertise to drill into aluminum rack materials without causing any damage.

Lower Labor Costs
When creating custom racks in-house, your staff may have less time to focus on primary goals. It will also make employees work beyond their expertise, leading to reduced productivity. A&J will help reduce labor costs by enabling your staff to spend more time on the tasks they can effectively handle.

Customizing Your Enclosure with A&J

At A&J, we offer custom CNC machining to manufacture custom electronic racks. This allows for precise cuts, reduced scrap, and advanced capabilities. In addition, you’ll benefit from engineering support as well as a wide selection of standard rack sizes and models with accessories that we can easily modify to suit different applications.

To order a custom or standard rack, you can take the following steps:

1. Browse our selection of standard rack enclosures and accessories to locate the ideal choice
2. Submit a quote with basic specifications
3. Upload a drawing, ideally a CAD drawing, for our engineering team to review, or we can draft an initial design with the help of our design engineering services
4. Place your order, and we’ll ship your rack to the designated final destination

Get in Touch with A&J Today

Want to get started on selecting or designing an electronic rack for your application? Request a quote or talk to an engineer today.