U.S. patent application number 14/447540 was filed with the patent office on 2016-02-04 for adaptable container mounted cooling solution.
The applicant listed for this patent is Amazon Technologies, Inc.. Invention is credited to Peter George Ross.
Application Number | 20160037685 14/447540 |
Document ID | / |
Family ID | 53836238 |
Filed Date | 2016-02-04 |
United States Patent
Application |
20160037685 |
Kind Code |
A1 |
Ross; Peter George |
February 4, 2016 |
ADAPTABLE CONTAINER MOUNTED COOLING SOLUTION
Abstract
A cooling apparatus for a container-based data center comprises
an air handling housing, at least one movable louver, a filter and
a fan. The housing is configured for suspending from a ceiling of
the container and comprises at least one heat exchanger. The louver
is movable to direct air flow along different paths within the
housing according to a selected operating mode. The fan is
positioned in the housing and controllable according to the
selected operating mode. The heat exchanger is configured in a
self-contained water chilling circuit positioned within the
container for use in a closed loop mode. The apparatus is
convertible for use in an economizer mode that draws outside air
into the container. An optional auxiliary heat exchanger element
has a cold side heat exchange portion positioned outside the
container and a connection through the ceiling to a hot side heat
exchange portion positioned within the housing.
Inventors: |
Ross; Peter George;
(Olympia, WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Amazon Technologies, Inc. |
Reno |
NV |
US |
|
|
Family ID: |
53836238 |
Appl. No.: |
14/447540 |
Filed: |
July 30, 2014 |
Current U.S.
Class: |
165/104.19 ;
165/121 |
Current CPC
Class: |
H05K 7/20836 20130101;
F28C 3/08 20130101; F28D 1/02 20130101; H05K 7/20827 20130101; H05K
7/2079 20130101; H05K 7/20718 20130101; H05K 7/20745 20130101; H05K
7/208 20130101 |
International
Class: |
H05K 7/20 20060101
H05K007/20; F28C 3/08 20060101 F28C003/08; F28D 1/02 20060101
F28D001/02 |
Claims
1. A multi-mode cooling apparatus adaptable to provide redundant
cooling operation modes for use in a container data center,
comprising: a housing configured for positioning adjacent a ceiling
of a container structure for the container data center; an air
inlet opening formed at a first end of the housing and in
communication with an interior of the container structure; a
cooling unit positioned in the housing downstream of the air inlet;
a filter positioned in the housing downstream of the cooling unit;
at least one fan positioned in the housing and downstream of the
air inlet, the cooling unit and the filter, the fan being
controllable to generate movement of air according to a selected
mode of operation; an air outlet opening formed at a second end of
the housing downstream of the fan and in communication with an
interior of the container structure; a louver positioned in the
housing between the air inlet opening and the cooling unit on one
side of the louver and the filter, fan and air outlet on an
opposite side of the louver, the louver being controllable to move
between at least a first open position establishing an air flow
path between the air inlet, cooling unit, filter, fan and air
outlet and a second closed position; an outside air module
positionable external to the container structure, the outside air
module having an outside air inlet and at least a filtration and
intrusion member positioned downstream of the outside air inlet,
the housing having at least one upper surface opening formed in an
upper surface of the housing that is selectively openable for
exchanging air between the outside air module and the housing; an
auxiliary heat exchanger having a cold side heat exchange portion
positionable external to the container structure and a hot side
heat exchange portion positionable within the housing and within
the air flow path of the air inlet, the cooling unit, the fan and
the outlet opening; wherein in a first closed loop mode, the louver
is opened and the fan is operable to draw air from the interior of
the container through the first inlet opening, the cooling unit and
the filter to convey cooled air through the air outlet opening into
the interior of the container structure; wherein in a second open
loop mode, the louver is closed, the upper surface opening is
opened and the fan is operable to draw outside air through the
outside air inlet and the filtration and intrusion member of the
outside air module and into the housing and through the filter and
air outlet opening into the interior of the container structure;
and wherein in a third auxiliary cooling mode, the louver is opened
and the fan is operable to draw air from the interior of the
container structure through the first inlet opening, the cooling
unit, the hot side heat exchange portion of the auxiliary heat
exchanger and the filter to convey cooled air through the air
outlet opening and into the interior of the container
structure.
2. The multi-mode cooling apparatus of claim 1, wherein the cooling
unit comprises at least one of a chilled water cooler and a direct
expansion cooler.
3. The multi-mode cooling apparatus of claim 1, wherein the
auxiliary heat exchanger comprises at least one of a thermal
siphon, a chilled water cooler, a direct expansion cooler and a
refrigerant based heat exchanger.
4. The multi-mode cooling apparatus of claim 1, wherein the outside
air unit comprises at least one external fan to assist in moving
air from the outside air unit and into the housing.
5. The multi-mode cooling apparatus of claim 1, wherein the outside
air unit comprises at least one heat exchanger.
6. The multi-mode cooling apparatus of claim 1, wherein the upper
surface opening comprises an upper surface inlet opening and a
separate upper surface outlet opening.
7. The multi-mode cooling apparatus of claim 1, wherein the housing
comprises a hinged panel for providing access to the fan.
8. The multi-mode cooling apparatus of claim 1, further comprising
ceiling panels removable to expose ceiling openings for air
flow.
9. The multi-mode cooling apparatus of claim 1, further comprising
a seal positioned along at least a portion of a lower periphery of
the housing and a server rack positioned below the housing.
10. The multi-mode cooling apparatus of claim 1, wherein the
housing is designed to have a vertical dimension to closely fit in
a vertical space above server racks and below the ceiling of the
container.
11. A container-based data center housing multiple server racks,
comprising: a container structure configured to standard shipping
container dimensional specifications and having walls, a ceiling
and a floor defining a bounded interior space; multiple server
racks arranged in the interior space; and a self-contained
multi-mode cooling apparatus selectively adaptable to operate in
multiple cooling operation modes to cool the interior space, the
cooling apparatus having an air handling housing mounted to the
ceiling of the container structure, a heat exchanger and an air
moving device, the housing extending downwardly from the ceiling
for positioning closely spaced above the server racks.
12. The container-based data center of claim 11, wherein the
cooling apparatus is operable in a closed loop mode to draw air
from the interior space into the housing by the air moving device,
to cool the air with the heat exchanger and to exhaust cooled air
from the housing into the interior space.
13. The container-based data center of claim 11, further comprising
an outside air opening formed in a ceiling of the container,
wherein the cooling apparatus is operable in an open loop mode to
draw in outside air through the outside air opening with the air
moving device and exhaust the outside air from the housing and into
the interior space.
14. The container-based data center of claim 11, wherein the
housing comprises a movable air directing member, and wherein the
movable air directing member is positioned in a first position to
allow air from the interior space to be drawn into the housing for
a first operation mode and in a second position restricting air
from the interior space from being drawn into the housing in a
second operation mode.
15. The container-based data center of claim 11, wherein the
cooling apparatus is convertible from a closed loop mode, wherein
air from the interior space is drawn into the housing, cooled by
the heat exchanger and exhausted from the housing into the interior
space, to a purge mode, wherein a pre-defined opening in the
ceiling of the container is opened and outside air is drawn in
through the pre-defined opening to cool the interior space.
16. The container-based data center of claim 11, wherein the
cooling apparatus is expandable to include a separate outside air
module positionable on an exterior of the container and in
communication with the interior space via at least one opening in
the ceiling, the outside air module having a filtration member and
at least one outside air moving device.
17. The container-based data center of claim 11, wherein the
cooling apparatus is expandable to include an auxiliary heat
exchanger having at least a cold side heat exchange portion
positioned external of the container and connected through at least
one connection extending through the ceiling of the container to a
hot side heat exchange portion positioned within the housing.
18. The container-based data center of claim 17, wherein the
auxiliary heat exchanger comprises at least one of a thermal
siphon, a dry cooler, a chilled water cooler, an evaporative cooler
and a refrigerant based heat exchanger.
19. The container-based data center of claim 11, wherein the stand
shipping container dimensional specifications correspond to an ISO
C shipping container.
20. A cooling apparatus for a container-based data center,
comprising: an air handling housing configured for suspending from
a ceiling of the container and comprising at least one heat
exchanger; at least one movable louver for directing air flow along
different paths within the housing according to a selected
operating mode; and a fan positioned in the housing and
controllable according to the selected operating mode, wherein the
heat exchanger is configured in a self-contained water chilling
circuit positioned within the container and the apparatus is
convertible for use in an economizer mode that draws outside air
into the container.
21. The cooling apparatus of claim 19, further comprising an
auxiliary heat exchanger element having a cold side heat exchange
portion positioned outside the container and a connection through
the ceiling of the container to a hot side heat exchange portion
positioned within the housing.
Description
BACKGROUND
[0001] Container-based data centers present difficult environmental
management challenges. As the containers are intended to be
movable, they have relatively fixed dimensions and cannot be
expanded in size. Customers continue to demand more computing power
from each container-based data center, so planned products specify
only minimal spacing between servers and related equipment and the
surrounding container. As a result of increasing the number,
capacity and/or computing power of the servers, the heat load
generated during their operation increases. This heat load must be
managed to promote high performance and long life of the
servers.
[0002] In addition, the cooling system for a container-based data
center should be adaptable to suit a range of different
requirements. For example, the cooling system should be adaptable
to provide sufficient cooling in different geographical areas, as
well as over different seasons and different times of day. As
customer needs change, the container may be fitted with a fewer
number or greater number of servers, which may affect the heat
load. Other types of equipment changes or technology advances may
also affect the heat load and consequently, the required cooling
capacity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 is a schematic perspective view of a cooling
apparatus for a container-based data center showing its ability to
be adapted among at least the three illustrated operating
modes.
[0004] FIG. 2 is an end view of a container-based data center
showing an implementation of the cooling apparatus adapted for a
closed loop operating mode.
[0005] FIG. 3 is an end view of a container-based data center
showing an implementation of the cooling apparatus adapted for an
open loop operating mode.
[0006] FIG. 4 is an end view of a container-based data center
showing an implementation of the cooling apparatus adapted for use
in an auxiliary cooling mode with an auxiliary heat exchanger.
[0007] FIG. 5A is a perspective view of an embodiment of the
cooling apparatus housing.
[0008] FIG. 5B is a side section view in elevation of the cooling
apparatus housing of FIG. 5A, but showing the louver in an opened
position and the air flow path down through a filter and laterally
through the fan and out an outlet.
[0009] FIG. 5C is a perspective view similar to 5A, except showing
the filter being removed for servicing or replacement.
[0010] FIG. 6A is an end elevation view of a cooling apparatus
according to another implementation with the housing material
removed to reveal the internal components and their
configuration.
[0011] FIG. 6B is a top plan view of the cooling apparatus of FIG.
6A.
[0012] FIG. 6C is a right side elevation view of the cooling
apparatus of FIGS. 6A and 6B.
DETAILED DESCRIPTION
[0013] Described below are implementations of a cooling system for
a container-based data center that is adaptable to operate in
different modes and has a ceiling-mounted housing configured to fit
in a space above existing server racks and other equipment. Within
the housing, a fan or other type of air mover draws air through a
cooling unit, which generally includes a heat exchanger. In some
implementations, this heat exchanger is configured to be part of a
self-contained chilled water cooling circuit within the container.
The cooling system can be operated in a closed loop mode using this
heat exchanger to cool the air within the container. The cooling
system can also be adapted between the closed loop mode and other
operating modes, such as an open loop mode that draws in outside
air and an auxiliary cooling mode that uses an auxiliary heat
exchanger having its cold side heat exchanger portion mounted
outside the container. These and other implementations are
described below in greater detail.
[0014] FIG. 1 is a perspective view showing a schematic depiction
of a container-based data center 100 with a multi-mode cooling
system 102 adaptable to operate in at least the three illustrated
modes 104, 106, 108. A representative container or container
structure 112 defines a footprint and serves to house multiple
server racks 114 and other equipment. As shown, the server racks
114 in this implementation are generally vertically oriented and
arranged approximately along a center longitudinal axis of the
container 112, although many other configurations are possible.
[0015] A housing 116 for the cooling system or apparatus 102 is
configured to occupy a space above the server racks 114 and below a
ceiling 118 of the container. In some implementations, the housing
116 is mounted to or suspended from the ceiling 118. In this way,
the housing 116 does not consume valuable floor space or footprint,
which is reserved for servers, other equipment and ensuring that
personnel can gain access to and maintain servers and
equipment.
[0016] In addition to its ceiling 118, the container 112 has side
walls 120, 122, end walls 124, 126 and a floor 128 that together
define an interior 130 as shown. In some implementations, the
container 112 has dimensions consistent with a shipping container,
such as, e.g., an ISO C container, although the cooling system 102
could of course be used with container-based or similar systems of
different sizes.
[0017] The cooling apparatus 102 and its housing 116 will be
described in more detail in connection with FIG. 1 and FIGS. 2-4,
which are separate end elevation views of the data center 100 with
the end wall 124 removed to show the three different operating
modes. The housing 116, which is shown in solid lines in FIG. 1,
generally extends along a majority of the length of the container
112. An inlet opening 132 is defined in the housing 116 at or near
a first end 134 (see, e.g., FIG. 2). In the illustrated
implementation, the inlet opening 132 is formed in an angled
surface of the housing 116 (see also, e.g., FIGS. 5A-5C).
[0018] Within the housing, there is a cooling unit 136 for cooling
air. In some implementations, the cooling unit 136 includes a heat
exchanger 137 having an air "hot side" for receiving hot air drawn
in through the inlet opening 132 and cooling it, and a cooling
fluid "cold side" for receiving heat from the hot air and
dissipating it. In some implementations, the cooling fluid is
chilled water, and the heat exchanger (also referred to herein as
"a chilled water cooler") is connected in series to other
components of a conventional chilled water loop, including other
heat exchanger(s), a pump, valves, sensors and other components. In
some implementations, the chilled water system is described as a
stand-alone 60-ton chilled water system. In other implementations,
the heat exchanger 137 could be a refrigerant-based heat exchanger
that uses R-134a or a similar refrigerant. Other types of heat
exchangers can also be used.
[0019] There is a fan 138 or other type or air mover for moving air
through the housing 116 and throughout the rest of the various air
flow circuits as shown by the arrows. In the illustrated
implementation, the fan 138 draws air into the housing 116 and
conveys it out through an outlet opening 146 positioned at or near
a second end 148 of the housing 116 into the interior 130 of the
container 112. A louver 140 or other air directing device is
positioned between the fan 138 and the outlet opening 146 on one
side, and the inlet opening 132 and the cooling unit 136 on the
other side, to selectively adapt the flow path according to the
desired operating mode. Referring to FIGS. 2-4, the louver 140 in
some implementations has blades two 142, 144, although it would be
possible to use a single blade or more than two blades. For
example, in FIG. 1, the louver has three blades. Further details
about the flow path are described below.
[0020] The outlet opening 146 can be designed as a specific
opening, or it can includes spaces in and around the fan 138 and
its mounting and enclosure. For example, as shown in FIG. 5A, there
can be a grille or grate 147 positioned in the area of the outlet
opening.
[0021] As best seen in FIG. 2, the multi-mode cooling apparatus 102
and housing 116 can be designed to have a vertical dimension V
designed to closely fit the space between an upper surface of a
tallest server rack (or other piece of equipment) and the ceiling
118 of the container. In some implementations, such as is shown in
FIG. 2, a bottom surface 150 of the housing 112 is fitted very
close to the server racks 114 such that only a small gap G between
the two exists. The gap can be filled with a seal S to promote flow
in the direction of the arrows as shown, which includes flow into
and through the server racks 114, e.g., from right to left as shown
in the figures without substantial air flow "short circuiting"
through the gap G. The airflow in the area of the racks 114 may be
supplemented by specific rack or server cooling systems (not
shown).
[0022] Referring to the upper left view in FIG. 1 and FIG. 2, the
multi-mode cooling apparatus is shown configured for a closed loop
operating mode 104. In the closed loop operating mode, hot air from
the interior 130 is drawn through the inlet opening 132 and cooling
unit 136 and through the louver 140 (in an open position as shown)
under the action of the fan 138. During the process, the cooling
unit 136 cools the hot air, such as by heat transfer to chilled
water circulating in the heat exchanger 137 of the cooling unit.
The cooled air is then exhausted from the housing through the
outlet opening 146 and back into the interior 130. The air flow
cycle is completed by the air flowing through the server racks 114
from right to left as shown by the arrows.
[0023] Referring to the upper right view in FIG. 1 and FIG. 3, the
multi-mode cooling apparatus is shown configured for an open loop
cooling mode 106. In the open loop cooling mode, cooling the hot
air in the interior 130 includes adding other air, e.g., air at a
lower temperature. In some implementations, the air that is added
is outside air, such as when outside air temperatures are favorable
or other circumstances warrant using outside air.
[0024] To admit outside air, there can be at least one opening 164
(FIG. 3) formed in the housing 116 and/or roof of the container
162. In most cases, it is desirable to provide filtration, which as
used herein broadly means preventing airborne matter (particles,
precipitation, objects, etc.), as well as preventing other
undesired objects (animals, trespassers, etc.) from entering the
container through the opening 164. Therefore, one or more filtering
elements (shown schematically at 174) is typically provided, in
addition to simply forming the opening in the container.
Conveniently, the filtering element 174 can be provided in a
separate housing called an outside air module 160. The outside air
module 160 is designed to be installed on the roof of the container
112. Referring to FIG. 3, the outside air module 160 can include a
duct 169 or other air directing member, such as to guide air from a
side opening to an opening 172 (as is described below in greater
detail).
[0025] Referring to FIG. 1, in some implementations, there are
first and second openings 166, 168 formed in the housing 116/roof
162 and aligned first and second openings 170, 172 formed in the
outside air module 160. In this way, better circulation through the
outside air module 160 can be achieved. In the illustrated
implementation, the louver 140 is changed to the closed position
for the open loop operating mode, which causes hot air to be drawn
from the interior 130, through the cooling unit 136, through the
openings 166, 170 and into the outside air module 160, through the
module 160 to mix with cooler outside air, and back through the
openings 172, 168 into the housing 112 and out through the outlet
opening 146 as cooler air.
[0026] The cooling unit 136 can be operated normally during the
open loop mode, in which case the addition of cooler outside air
serves as redundant cooling to supplement the cooling it normally
provides. Alternatively, the cooling unit 136 need not be operated,
such that only outside air is used, e.g., when conditions permit or
in an emergency (e.g., if the cooling unit 136 has failed). It
would also be possible in some implementations to include a heat
exchanger in the outside air module 160.
[0027] Referring to the lower center view of FIG. 1 and FIG. 4, the
multi-mode cooling apparatus is shown configured in an auxiliary
cooling mode 108. In the auxiliary cooling mode, the system is
configured as in the closed loop operating mode described above,
but additional cooling is provided by an auxiliary cooling unit
190. In some implementations, the auxiliary cooling unit 190 has an
auxiliary heat exchanger 192 with at least a cold side heat
exchange portion 194 positioned outside the container 112. A hot
side heat exchange portion 196 of the heat exchanger 192 is
positioned within the housing. As shown schematically in FIGS. 1
and 4, connections 198 link the functions of cold side heat
exchange portion 194 and the hot side heat exchange portion 196
together. Air that has been cooled by the cooling unit 136 is
further cooled by the heat exchanger 192 before flowing through the
louver 140 under the action of the fan and exiting out into the
interior 130 as cooler air.
[0028] The auxiliary heat exchanger 192 may be a thermal siphon
(e.g., a heat pipe), a chilled water cooler, a direct expansion
cooler and/or another form of refrigerant-based heat exchanger. As
is known, a direct expansion cooler/system uses a conventional
refrigerant vapor expansion/compression cycle. In some
implementations, the auxiliary heat exchanger 192 can be operated
without operating the cooling unit 136, such as when conditions
allow for it and/or if the cooling unit 136 has failed.
[0029] FIGS. 5A, 5B and 5C are various views of the multi-mode
cooling apparatus 102/housing 112 and internal components and
features. The housing 116 can be made of sheet metal or another
suitable material. One or more internal air directing surfaces 152
as shown in the sectioned elevation view of FIG. 5B can be added to
improve flow through the housing 112. In FIG. 5A, the louver 140 is
shown in the closed position. In FIGS. 5B and 5C, the louver 140 is
shown in the open position. As shown, the filter 141 can be
positioned approximately horizontally, and the air flow path within
the housing can be configured to cause flow to travel downwardly
through the filter 141 before traveling laterally to the fan 138
and the outlet opening 146.
[0030] The housing 116 can have a hinged portion covering the fan
138 that allows servicing of the fan and other components without
disassembling the entire cooling apparatus 102. By orienting the
filter 141 approximately horizontally, it can be removed from the
housing (such as for cleaning or replacement) by moving the hinged
portion out of the way (or detaching it), as is shown in FIG. 5C.
In addition, required filtering capacity can be provided without
requiring the vertical dimension of the housing 116 to be
enlarged.
[0031] FIGS. 6A, 6B and 6C are sectioned end elevation, top plan
and right side elevation views, respectively, of a multi-mode
cooling apparatus 202 according to another implementation. In
general, reference numerals in FIGS. 6A-6C have the same numeral
plus 100 as corresponding elements described above. As seen in FIG.
6A, the housing 216 can include a horizontal drip tray beneath the
cooling unit 236 and aligned with the bottom surface 250. The
liquid side connections for the heat exchanger 237 can be seen in
FIG. 6A. As best seen in FIGS. 6B and 6C, the cooling apparatus
includes four fans 238.
[0032] In general, the heat exchanger 137 of the cooling unit 136
is a chilled water cooler or a direct expansion cooler, but other
cooling technologies are of course possible. In general, the heat
exchanger 192 is a thermal siphon, a chilled water cooler, a direct
expansion cooler or another type of refrigerant-based heat
exchanger. It is also possible to implement so-called conductive
cooling technologies, such as the conductive cooling system
marketed by Inertech that uses "standard refrigerant" instead of
water and purportedly saves greatly on energy costs.
[0033] Although the operations of some of the disclosed methods are
described in a particular, sequential order for convenient
presentation, it should be understood that this manner of
description encompasses rearrangement, unless a particular ordering
is required by specific language set forth below. For example,
operations described sequentially may in some cases be rearranged
or performed concurrently. Moreover, for the sake of simplicity,
the attached figures may not show the various ways in which the
disclosed methods can be used in conjunction with other
methods.
[0034] The disclosed methods, apparatus, and systems should not be
construed as limiting in any way. Instead, the present disclosure
is directed toward all novel and nonobvious features and aspects of
the various disclosed embodiments, alone and in various
combinations and subcombinations with one another. The disclosed
methods, apparatus, and systems are not limited to any specific
aspect or feature or combination thereof, nor do the disclosed
embodiments require that any one or more specific advantages be
present or problems be solved.
[0035] In view of the many possible embodiments to which the
disclosed principles may be applied, it should be recognized that
the illustrated embodiments are only preferred examples and should
not be taken as limiting the scope of protection. Rather, the scope
of protection is defined by the following claims. We therefore
claim all that comes within the scope of these claims.
* * * * *