Integrating Liquid Cooling Solutions into Existing Military Rack Systems
Military racks are used to house and protect critical electronic equipment in harsh environments. As the power density of this equipment continues to rise, conventional air cooling methods may be insufficient. Incorporating a liquid cooling infrastructure into existing military rack systems is an efficient solution for managing thermal challenges and improving rack reliability.
At A&J Manufacturing, we’ve been delivering innovative electronic equipment racks and enclosures since 1953. Our liquid cooling systems adhere to military standards and can be custom-built according to your specifications.
Assess Current Rack System and Requirements
If you’re considering upgrading your racks to liquid cooling technology, the first step is to assess your current cooling system and its limitations. Conducting a thermal analysis can help you identify thermal challenges, like hotspots, that your new solution must address. Our team will help you establish new cooling system requirements and ensure that your liquid-cooled solution is compatible with existing equipment in terms of:
- Environmental challenges
- Power requirements
- Space availability
- Weight requirements
Next, you’ll need to consider your required rack dimensions, pump and flow rates, cooling infrastructure, and other factors.
Rack Dimensions and Configuration
Before installing liquid cooling technology into an existing rack, you’ll need to assess your rack system’s height, width, depth, and number of rack units available for equipment installation. You’ll also need to determine the heat load your equipment generates, as this will help in choosing the right liquid cooling system for your needs.
Pump and Flow Rates
Pump and flow rates play an important role in overall liquid cooling system performance. Your liquid cooling system must feature adequate pump and flow rates for preventing hotspots, ensuring efficient heat transfer, and maintaining system reliability.
Equipment Type and Power Consumption
Identify the types of equipment your existing racks house and their respective power consumption levels.
Cooling Infrastructure
Assess your rack’s current cooling system, including the type of cooling units (chillers, air conditioners, etc.), their location, and capacity.
Environmental Factors
Consider the environmental factors in and around your racks’s location, including humidity, ambient temperature, and other conditions.
Identifying Liquid Cooling Requirements
Your new liquid cooling system must be compatible with your existing rack and the equipment it houses. Consider factors like fault tolerance and maintainability to determine the level of redundancy you’d like within your new liquid cooling system. You should also take into account the energy efficiency and ongoing costs associated with different liquid cooling technologies.
Choose the Right Cooling Solution
There are several possible liquid cooling systems for military racks. Our team can help you identify the best option for your needs.
Direct-to-Chip Cooling
This technology is ideal for high-power density applications since it provides the most efficient heat removal capabilities. However, the precision engineering and manufacturing involved can increase project complexity and costs.
Cold Plate Cooling
Cold plate cooling is an efficient solution for cooling multiple components within an enclosure or rack. Although, it might not be the best option for extremely high heat loads.
Immersion Cooling
Immersion cooling is efficient and can handle high heat loads, making it well-suited for high-performance computing environments and military applications. However, ensuring safety and performance requires careful selection of coolants and containment systems.
Closed-Loop Systems
Closed-loop systems circulate coolant throughout a self-contained loop. The coolant is heated as it comes into contact with heat exchangers and then cooled by rejecting the heat to the outside environment. Because these systems are self-contained and don’t interact with external factors, they reduce the risk of corrosion and contamination. Additionally, closed-loop systems require less frequent maintenance and offer precise control of coolant temperature.
Open-Loop Systems
Open-loop systems circulate coolant between heat exchangers in the rack and an external cooling source, like a body of water or chiller. They can handle higher heat loads and are often less expensive to implement, especially if there is an existing external cooling source available.
Considerations and Upgrades
When designing and integrating a liquid cooling system into your military racks, keep in mind the following:
- Thermal sensors and monitoring. Consider utilizing thermal sensors to monitor coolant and equipment temperatures. This will enable cooling output adjustments based on thermal conditions.
- Rack modifications. It may be necessary to modify your existing rack to accommodate new liquid cooling components. For example, this might involve installing pump brackets, drilling pipe holes, or even upgrading to a new modular rack system for easier system upgrades.
- Component relocation. If space is limited, you may need to relocate components within the rack to reduce heat concentration and improve airflow.
Finally, before full deployment, it’s important to test your new system under operational conditions to ensure performance reliability. After installation, you’ll need to perform routine maintenance tasks like replacing filters, cleaning your components, and monitoring fluid levels.
Liquid Cooling Solutions into Existing Military Rack Systems from A&J Manufacturing
Liquid cooling systems offer enhanced cooling capacity and improved performance for military racks. A&J Manufacturing is your experienced partner for upgrading your existing rack system into something more robust and reliable. To get started, contact us with any questions or request a quote today.
