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浸沒(méi)式液冷：利用數(shù)據(jù)中心的現(xiàn)場(chǎng)事件技術(shù)
Immersion cooling: Harnessing live-event technology in data centers

2024 年 2 月 1 日，星期四

當(dāng) COVID-19 導(dǎo)致節(jié)日和現(xiàn)場(chǎng)活動(dòng)被迫取消時(shí)，庫(kù)拉索島的音頻技術(shù)初創(chuàng)公司 iXora 的前景一片黯淡。然而，在丹佛斯的幫助下，該公司很快意識(shí)到，他們的冷卻技術(shù)可以重新用于數(shù)據(jù)中心，成為可能改變游戲規(guī)則的解決方案。
加勒比海島國(guó)庫(kù)拉索島屬于熱帶氣候，對(duì)很多人來(lái)說(shuō)，這種氣候很宜人，但對(duì)電子產(chǎn)品來(lái)說(shuō)，卻可能是災(zāi)難性的。高溫、長(zhǎng)時(shí)間的陽(yáng)光直射，加上熱帶雨水和含鹽潮濕的空氣，會(huì)很快腐蝕電氣設(shè)備并損壞零部件。

活動(dòng)音頻初創(chuàng)公司的創(chuàng)始人艾克索拉在著手開(kāi)發(fā)高性能放大器系統(tǒng)時(shí)，他們充分意識(shí)到了這些挑戰(zhàn)。該解決方案不僅需要承受庫(kù)拉索島的惡劣氣候，而且還要為用戶(hù)提供從一個(gè)活動(dòng)到另一個(gè)活動(dòng)的便捷運(yùn)輸�？諝饫鋮s需要風(fēng)扇和其他易磨損的移動(dòng)部件，因此 iXora 尋找替代解決方案。該公司開(kāi)發(fā)了一種閉路浸沒(méi)式冷卻系統(tǒng)，該系統(tǒng)以極高的效率提供必要的冷卻。由于該系統(tǒng)是封閉的，因此也易于安裝、拆卸和運(yùn)輸，并且有效地保護(hù)電子元件免受環(huán)境條件的影響。

iXora 一切順利，直到 2020 年災(zāi)難降臨；COVID-19 幾乎在一夜之間摧毀了現(xiàn)場(chǎng)活動(dòng)。公司創(chuàng)始人 Vincent Beek 和 Vincent Houwert 決定利用這個(gè)機(jī)會(huì)搬遷到荷蘭，以尋求進(jìn)一步的投資并完善放大器系統(tǒng)的設(shè)計(jì)。

浸沒(méi)式冷卻：簡(jiǎn)介

近年來(lái)，加密貨幣和人工智能等數(shù)字技術(shù)從相對(duì)默默無(wú)聞發(fā)展成為主流，產(chǎn)生了大量數(shù)據(jù)。因此，數(shù)據(jù)中心一直在尋求增加容量，同時(shí)提高效率。空氣冷卻長(zhǎng)期以來(lái)一直是數(shù)據(jù)中心冷卻的常態(tài)，但許多數(shù)據(jù)中心設(shè)施已過(guò)渡到或正在探索液體冷卻，作為比空氣冷卻更高效、更具成本效益的替代方案。

液體冷卻主要有兩種方法：直接液體冷卻和浸沒(méi)式冷卻。直接液體冷卻涉及將冷卻劑循環(huán)到特定組件。雖然比空氣冷卻更有效，但它通常不適合高強(qiáng)度加工操作。浸沒(méi)式冷卻通常涉及將電子設(shè)備浸入非導(dǎo)電液體槽中。與空氣冷卻相比，它提供了更高的效率和冷卻密度，并且不需要風(fēng)扇或其他主動(dòng)冷卻組件。然而，設(shè)計(jì)通常很復(fù)雜、定制且昂貴，需要大型槽來(lái)將服務(wù)器機(jī)架完全浸沒(méi)其中。

轉(zhuǎn)向新模式

iXora 意識(shí)到他們的封閉系統(tǒng)可以為數(shù)據(jù)中心提供完美的解決方案。它可以大幅提高服務(wù)器硬件的效率和容量，而無(wú)需對(duì)基礎(chǔ)設(shè)施進(jìn)行重大重新設(shè)計(jì)，而且與當(dāng)時(shí)可用的浸沒(méi)式冷卻系統(tǒng)相比，成本要低得多。

該公司現(xiàn)已與數(shù)據(jù)中心專(zhuān)家喬布·維特曼 (Job Witteman) 聯(lián)手，開(kāi)始基于其現(xiàn)有的放大器冷卻解決方案為數(shù)據(jù)中心市場(chǎng)設(shè)計(jì)原型封閉式浸沒(méi)式冷卻系統(tǒng)。iXora 并未采用傳統(tǒng)的水平機(jī)架系統(tǒng)，而是尋求開(kāi)發(fā)一種包含垂直盒式磁帶的底盤(pán)，其中的介電油將冷卻電子元件。與 iXora 之前的音頻設(shè)備解決方案相比，這需要更為復(fù)雜的設(shè)計(jì)，并且需要深入了解典型數(shù)據(jù)中心運(yùn)營(yíng)的具體要求。此外，由于該原型是同類(lèi)產(chǎn)品中的首款，因此還需要設(shè)計(jì)和開(kāi)發(fā)針對(duì)該應(yīng)用的獨(dú)特新系統(tǒng)和組件。

原型挑戰(zhàn)

其中一個(gè)例子就是新系統(tǒng)的熱交換器，它需要將熱量從每個(gè)盒式磁帶中轉(zhuǎn)移出去。該設(shè)計(jì)要求每個(gè)盒式磁帶有兩個(gè)耦合器，以將它們連接到底盤(pán)和設(shè)施的更廣泛的冷卻設(shè)備。在這些耦合器中實(shí)現(xiàn)低壓降至關(guān)重要，因?yàn)槊總�(gè)小的壓降都可能導(dǎo)致冷卻性能中斷。盒式磁帶還需要易于連接和斷開(kāi)以進(jìn)行維護(hù)，并且零泄漏，因?yàn)槿魏闻c數(shù)據(jù)中心設(shè)備接觸的液體都可能對(duì)操作造成嚴(yán)重風(fēng)險(xiǎn)。

iXora 向丹佛斯尋求幫助，為其系統(tǒng)開(kāi)發(fā)定制聯(lián)軸器。除了零泄漏外，這些聯(lián)軸器還需要提供精確對(duì)準(zhǔn)、低連接力和緊湊尺寸。憑借其在聯(lián)軸器技術(shù)方面的豐富經(jīng)驗(yàn)，丹佛斯產(chǎn)品工程師能夠根據(jù)流量、最大聯(lián)軸器尺寸、壓力要求和熱交換率以及數(shù)據(jù)中心冷卻應(yīng)用特有的一系列其他因素準(zhǔn)確計(jì)算出所需的條件。根據(jù)這些計(jì)算，丹佛斯得出結(jié)論，鋁干式斷流器快速斷開(kāi)接頭是最合適的解決方案。然后丹佛斯按照規(guī)格制造了這些產(chǎn)品。

合作成功

原型取得了成功，丹佛斯聯(lián)軸器的表現(xiàn)優(yōu)于所有其他測(cè)試的聯(lián)軸器。iXora 的運(yùn)營(yíng)和銷(xiāo)售主管 Vincent Beek 解釋說(shuō)：“丹佛斯聯(lián)軸器實(shí)現(xiàn)了完全對(duì)準(zhǔn)、輕松連接和斷開(kāi)，而且至關(guān)重要的是，零泄漏。這對(duì)于維護(hù)至關(guān)重要。使用傳統(tǒng)的全浸沒(méi)系統(tǒng)，將服務(wù)器從液槽中取出可能很棘手。我們的系統(tǒng)實(shí)際上是即插即用的，因此您只需將其斷開(kāi)連接并直接將其帶到車(chē)間即可。

“我們現(xiàn)在正處于現(xiàn)場(chǎng)測(cè)試階段，今年將進(jìn)行全球試點(diǎn)，明年將擴(kuò)大規(guī)模進(jìn)行量產(chǎn)。如果沒(méi)有丹佛斯，這一切都不可能實(shí)現(xiàn)。作為一家初創(chuàng)公司，很難引起大公司的注意，尤其是在幫助研發(fā)方面。他們看到了我們的解決方案，立即接受了，我們從他們的專(zhuān)業(yè)知識(shí)中受益匪淺，”Beek 說(shuō)道。

丹佛斯動(dòng)力系統(tǒng)高級(jí)銷(xiāo)售開(kāi)發(fā)經(jīng)理 Jeroen Veraart 對(duì)雙方合作關(guān)系的發(fā)展感到滿(mǎn)意：“這是一次真正的合作。iXora 確實(shí)從我們這里受益匪淺，但我們也從他們身上學(xué)到了很多東西。通過(guò)與他們合作，我們找到了可以進(jìn)一步改進(jìn)和完善我們產(chǎn)品的新方法。

“與 iXora 合作是我們的夢(mèng)想，”Veraart 繼續(xù)說(shuō)道�！白鳛橐患页鮿�(chuàng)公司，總是存在風(fēng)險(xiǎn)，但他們充滿(mǎn)熱情，愿意學(xué)習(xí)，總是能提出創(chuàng)造性的想法和解決方案。最終，他們打造出了一個(gè)非常令人印象深刻的系統(tǒng)。浸沒(méi)式冷卻顯然是數(shù)據(jù)中心的未來(lái)，我預(yù)計(jì)，短短幾年內(nèi)，這個(gè)市場(chǎng)將大幅增長(zhǎng)。這對(duì)雙方來(lái)說(shuō)都是一次非常有益的合作，我期待看到它繼續(xù)蓬勃發(fā)展�！�

Immersion cooling: Harnessing live-event technology in data centers
Thursday, February 1, 2024

When COVID-19 wiped out festivals and live events, things were looking bleak for Cura?ao-based audio technology start-up iXora. However, with some help from Danfoss, the company soon realized that their cooling technology could be repurposed into a potentially game-changing solution for data centers.
The Caribbean island of Cura?ao enjoys a tropical climate, which may be pleasant for many people, but can be disastrous for electronics. Heat and long hours of direct sunlight, combined with tropical rains and salty, moist air, can very quickly corrode electrical equipment and ruin components.

The founders of event audio start-up iXora were well aware of these challenges when they set about developing their high-performance amplifier system. The solution needed to not only withstand the challenging Cura?ao climate, but also offer users easy transport from event to event. Air cooling requires fans and other moving parts that are subject to wear and tear, so iXora looked at alternative solutions. The company developed a closed-circuit immersion cooling system, which provided the necessary cooling at an extremely high efficiency. Because the system was closed, it was also easy to set up, take down, and transport, and it effectively shielded electronic components from ambient conditions.

Everything was going well for iXora until disaster struck in 2020; COVID-19 wiped out the live event scene almost overnight. Company founders Vincent Beek and Vincent Houwert decided to use the opportunity to relocate to the Netherlands to seek further investment and finesse the design of the amplifier system.

Immersion cooling: An introduction
In recent years, digital technologies such as cryptocurrency and artificial intelligence have emerged from relative obscurity to mainstream, producing vast amounts of data. As a result, data centers have sought to increase capacity while simultaneously improving efficiency. Air cooling had long been the norm for data center cooling, but many data center facilities have transitioned to or are exploring liquid cooling as a more efficient and cost-effective alternative to air cooling.

There are two main approaches to liquid cooling: direct liquid cooling and immersion cooling. Direct liquid cooling involves circulating coolants to specific components. While more efficient than air cooling, it is often not suitable for high-intensity processing operations. Immersion cooling typically involves submerging electronics in a bath of non-conductive liquid. It provides far greater efficiency and cooling density compared to air cooling and requires no fans or other active cooling components. However, designs are often complex, custom, and expensive, requiring large baths in which to submerge server racks entirely.

Pivoting to a new model
iXora realized that their closed system could provide the perfect solution for data centers. It could substantially improve the efficiency and capacity of server hardware without the need for significant infrastructure redesign — and at a much lower cost compared to the immersion cooling systems available at the time.

The company, now joined by data center expert Job Witteman, began designing a prototype closed immersion cooling system for the data center market, based on its existing amplifier cooling solution. Rather than the traditional horizontal rack system, iXora instead sought to develop a chassis containing vertical cassettes, in which dielectric oil would cool the electronic components. This required a vastly more sophisticated design compared to iXora’s previous solutions for audio equipment, and a deep understanding of the specific requirements of typical data center operations. Furthermore, because the prototype would be the first of its kind, it also required the design and development of new systems and components unique to the application.

Prototype challenges
One example of this was the new system’s heat exchanger, required to transfer heat away from each cassette. The design required two couplings per cassette to connect them both to the chassis, and to the facility’s wider cooling equipment. Achieving a low pressure drop in these couplings was vital, as each small pressure drop could cause disruptions in the cooling performance. Cassettes also required easy connection and disconnection for maintenance, with zero leakage, as any liquid coming into contact with data center equipment could pose a serious risk to operations.

iXora approached Danfoss for help in the development of custom couplings for their system. As well as zero leakage, these also needed to provide precision alignment, a low connect force, and a compact size. Drawing on its extensive experience in coupling technology, Danfoss product engineers were able to calculate exactly what was required based on the flow rate, maximum coupling size, pressure requirements, and heat exchange rate, alongside a range of other factors specific to data center cooling applications. Based on these calculations, Danfoss concluded that aluminum dry break quick-disconnect couplings would be the most suitable solution. These were then manufactured to specification by Danfoss.

Success in partnership
The prototype was a success, with the Danfoss couplings outperforming all other couplings tested. iXora’s head of operations and sales, Vincent Beek, explained: “The Danfoss couplings achieved full alignment, easy connection and disconnection and, crucially, zero leakage. This is vital for maintenance. With a conventional full immersion system, it can be tricky getting servers out of the liquid bath. Ours is effectively plug and play, so you can just disconnect it and carry it straight to the workshop.

“We’re now onto the field-testing stage, with a global pilot to follow this year, and then next year we’ll be scaling up to mass production. None of this would have been possible without Danfoss. As a start-up it can be difficult to get the attention of larger companies, particularly when it comes to help with R&D. They saw our solution, immediately bought into it, and we’ve benefited greatly from their expertise,” Beek said.

Jeroen Veraart, senior sales development manager, Danfoss Power Solutions, has been pleased with how the relationship developed: “This was a true partnership. iXora benefited from us for sure, but we’ve learned a lot from them as well. As a result of working with them we’ve identified new ways in which we can improve and refine our products further.

“iXora were a dream to work with,” Veraart continued. “With a start-up there’s always an element of risk, but they were enthusiastic, willing to learn, and always coming up with creative ideas and solutions. At the end of it they’ve got a really impressive system. Immersion cooling is clearly the future for data centers, and in just a few years I expect that market will grow considerably. This has been a really rewarding partnership for both parties, and I look forward to seeing it continue to flourish.”

關(guān)于我們

北京漢深流體技術(shù)有限公司是丹佛斯中國(guó)數(shù)據(jù)中心簽約代理商。產(chǎn)品包括FD83全流量自鎖球閥接頭，UQD系列液冷快速接頭、EHW194 EPDM液冷軟管、電磁閥、壓力和溫度傳感器及Manifold的生產(chǎn)和集成服務(wù)。在國(guó)家數(shù)字經(jīng)濟(jì)、東數(shù)西算、雙碳、新基建戰(zhàn)略的交匯點(diǎn)，公司聚焦組建高素質(zhì)、經(jīng)驗(yàn)豐富的液冷工程師團(tuán)隊(duì)，為客戶(hù)提供卓越的工程設(shè)計(jì)和強(qiáng)大的客戶(hù)服務(wù)。

公司產(chǎn)品涵蓋：丹佛斯液冷流體連接器、EPDM軟管、電磁閥、壓力和溫度傳感器及Manifold。
未來(lái)公司發(fā)展規(guī)劃：數(shù)據(jù)中心液冷基礎(chǔ)設(shè)施解決方案廠家，具備冷量分配單元（CDU）、二次側(cè)管路（SFN）和Manifold的專(zhuān)業(yè)研發(fā)設(shè)計(jì)制造能力。組建高素質(zhì)、經(jīng)驗(yàn)豐富的液冷工程師團(tuán)隊(duì)，為客戶(hù)提供卓越的工程設(shè)計(jì)和強(qiáng)大的客戶(hù)服務(wù)。