US20160037687A1 - Airfoil to provide directed cooling - Google Patents
Airfoil to provide directed cooling Download PDFInfo
- Publication number
- US20160037687A1 US20160037687A1 US14/447,248 US201414447248A US2016037687A1 US 20160037687 A1 US20160037687 A1 US 20160037687A1 US 201414447248 A US201414447248 A US 201414447248A US 2016037687 A1 US2016037687 A1 US 2016037687A1
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- US
- United States
- Prior art keywords
- housing
- airfoil
- airflow
- data storage
- active element
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- G—PHYSICS
- G11—INFORMATION STORAGE
- G11B—INFORMATION STORAGE BASED ON RELATIVE MOVEMENT BETWEEN RECORD CARRIER AND TRANSDUCER
- G11B33/00—Constructional parts, details or accessories not provided for in the other groups of this subclass
- G11B33/14—Reducing influence of physical parameters, e.g. temperature change, moisture, dust
- G11B33/1406—Reducing the influence of the temperature
- G11B33/1413—Reducing the influence of the temperature by fluid cooling
- G11B33/142—Reducing the influence of the temperature by fluid cooling by air cooling
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/20—Modifications to facilitate cooling, ventilating, or heating
- H05K7/20709—Modifications to facilitate cooling, ventilating, or heating for server racks or cabinets; for data centers, e.g. 19-inch computer racks
- H05K7/20718—Forced ventilation of a gaseous coolant
- H05K7/20736—Forced ventilation of a gaseous coolant within cabinets for removing heat from server blades
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/14—Mounting supporting structure in casing or on frame or rack
- H05K7/1485—Servers; Data center rooms, e.g. 19-inch computer racks
- H05K7/1488—Cabinets therefor, e.g. chassis or racks or mechanical interfaces between blades and support structures
Definitions
- an apparatus in accordance with some embodiments, includes a housing having opposing first and second ends.
- a first active element is mounted within the housing adjacent the first end, and a second active element mounted within the housing adjacent the second end.
- a fan assembly is mounted within the housing adjacent the second end to establish an airflow through the housing adjacent the first and second active elements for cooling thereof.
- An airfoil is mounted within the housing between the first and second active elements to accelerate and direct the airflow proximate the second active element.
- an apparatus in further embodiments, includes a multi-device storage enclosure housing with a first end configured for placement proximate a cold aisle and an opposing second end configured for placement proximate a warm aisle.
- a plurality of data storage devices are configured to store and retrieve user data from a host device, with the data storage devices being housed within the housing proximate the first end.
- a control board supports at least one integrated circuit (IC) device to control said storage and retrieval of the user data.
- the control board is housed within the housing proximate the second end.
- a fan assembly is mounted within the housing adjacent the second end and configured to establish an airflow through the housing.
- An airfoil is mounted within the housing between the data storage devices and the at least one IC device to accelerate and direct the airflow proximate the at least one IC device.
- FIG. 1 is a functional representation of a networked mass storage system to illustrate a suitable operational environment for various embodiments of the present disclosure.
- FIG. 2 is a top plan representation of a storage enclosure from FIG. 1 .
- FIG. 3 is a storage enclosure with an airfoil to provide directed cooling in accordance with various embodiments.
- FIG. 4 is an isometric depiction of the storage enclosure of FIG. 3 .
- FIG. 5 is a side elevational depiction of operation of an airfoil of the storage enclosure in some embodiments.
- FIG. 6 is a schematic representation of the airfoil of FIG. 5 .
- FIGS. 7A-7C illustrate alternative configurations for a midplane of the storage enclosure in accordance with some embodiments.
- FIGS. 8A-8C provide alternative configurations for the airfoil in accordance with some embodiments.
- FIG. 9 illustrates another configuration of the storage enclosure which uses airflow ingress apertures in the storage enclosure housing.
- FIG. 10 is a side view representation of the storage enclosure configuration of FIG. 9 .
- the present disclosure generally relates to directed cooling of active elements such as in a networked mass storage system.
- Mass storage systems often employ multiple data storage devices which are operationally arranged to provide a relatively high data capacity memory storage space.
- the devices may be grouped together into a mass storage assembly (MSA) or other module that can be removably installed into a rack system (server cabinet).
- MSA mass storage assembly
- server cabinet rack system
- Mass storage systems can take a variety of forms including servers, cloud storage modules, RAID (redundant array of independent discs) systems, extended memory systems (JBODs, or “just a box of drives”), etc.
- the storage systems can be accessed locally or over a network including a local area network (LAN), a wide area network (WAN), the Internet, etc.
- a storage enclosure can include various active elements such as storage devices, control boards, power supplies, fans, boot devices, etc.
- the storage enclosure may be configured with a housing adapted to be mounted within a rack system between a cold aisle (front) and a warm aisle (rear).
- the housing supports a number of active elements including multiple storage devices, power supplies, control boards, boot devices, etc.
- One or more fan assemblies located adjacent the rear of the housing operate to establish a cooling airflow through the storage enclosure housing.
- the airflow passes various storage devices and a midplane.
- An airfoil downstream from the midplane channels and directs the airflow adjacent an active element, such as one or more integrated circuit (IC) devices on a control board.
- the airflow then passes to the fan assemblies and is exhausted out the rear of the housing to the warm aisle.
- IC integrated circuit
- FIG. 1 generally depicts a networked mass storage system 100 in accordance with some embodiments.
- the system 100 includes a storage assembly 102 coupled to a computer 104 which in turn is connected to a network 106 .
- the computer 104 can take a variety of forms such as a work station, a local personal computer, a server, etc.
- the storage assembly 102 includes a server cabinet (rack) 108 and a plurality of modular storage enclosures 110 .
- the storage rack 108 is a 42 U server cabinet with 42 units (U) of storage, with each unit comprising about 1.75 inches (in) of height.
- the width and length dimensions of the cabinet can vary but common values may be on the order of about 24 in. ⁇ 36 in. Other sizes can be used.
- Each storage enclosure can be a multiple of the storage units, such as 2U, 3U, 5U, etc.
- Fully populating the rack 108 with storage enclosures 110 can provide several Petabytes (10 15 bytes) of storage or more for the computer 104 and/or network applications. An example configuration for a selected storage enclosure 110 is shown in FIG. 2 .
- the storage enclosure 110 takes a 36/2U configuration with 36 (3 ⁇ 4 ⁇ 3) data storage devices 112 in a 2 U form factor height storage enclosure housing 114 .
- Other heights can be used as well, such as 3U, 4U, 5U, etc. While 1U height storage enclosures are contemplated, it has been found in some cases that a thicker enclosure housing (e.g., 2U or greater) provides improved structural stability and vibration response.
- the storage devices 112 can take a variety of forms, such as hard disc drives (HDDs), solid-state drives (SSDs), hybrid drives, etc. Each storage device 112 includes a controller and computer memory to provide storage of user data, such as represented by rotatable disc memory 112 A and controller 112 B. In a cloud computing environment, data may be stored in the form of objects (partitions) of selected size and duplicated a number of times in different zones in different storage devices. It is contemplated that the storage devices 112 in FIG. 2 are 3.5 inch (in.) form factor HDDs with nominal length and width dimensions of 5.75 in. ⁇ 4.0 in. Other styles and form factors of storage devices can be used, including but not limited to 2.5 in. form factor devices with nominal dimensions of 4.0 in. ⁇ 2.88 in.
- Retractable sleds 116 are used to secure multiple sets of the storage devices 112 .
- the sleds can be individually extended and retracted from the housing 114 , as shown for a selected sled 116 A which has been partially extended from the housing 110 .
- the sleds 116 may include sled electronics (not separately shown) to provide status indications and other control features during enclosure operation.
- the sleds 116 are shown to support the storage devices 112 in a horizontal orientation (e.g., the length and width dimensions of the storage devices are parallel to the overall length and width dimensions of the storage enclosure housing 114 ), the sleds 116 can alternatively support the storage devices 112 in a vertical orientation (e.g., “on edge” so that the length and width dimensions of the storage devices are orthogonal to the length and width dimensions of the storage enclosure).
- a midplane 118 extends in a transverse direction across the housing 114 to provide electrical interconnection paths for the various storage devices 112 and sled electronics.
- the midplane may take the form of a fixed multi-layer printed circuit board assembly (PCBA) with various electrical connectors, signal traces and vias to establish the necessary electrically conductive signal and power paths.
- PCBA printed circuit board assembly
- the midplane may take a flexible configuration in which flex circuits (e.g., cables, etc.) are used to maintain electrical interconnection with the storage devices and sleds.
- flex circuits e.g., cables, etc.
- extension of a sled e.g., sled 116 A
- Extension of a sled using a flexible midplane may allow the associated storage devices in the extended sled to remain powered up and operational.
- control boards 120 can take a variety of forms depending on the configuration of the storage enclosure 110 , such as a server, a network switch, a router, a RAID controller, etc.
- the multiple control boards can be used in a dual mode operation to support failover and failback operations, or as a master/slave arrangement so that one control board provides control operations and the other board operates in a standby mode ready to take over operation should a fault be detected in the main control board.
- Dual redundant power supplies are represented at 122 .
- the power supplies 122 provide electrical power for the control boards 120 and other active elements of the storage enclosure 110 such as the storage devices 112 .
- the electrical power is supplied at suitable voltage levels (e.g., 3V, 5V, 12V, etc.). Redundancy is provided such that each power supply 122 is rated to supply power for the entire enclosure, should the remaining power supply or supplies be temporarily taken off line.
- the control boards 120 include one or more integrated circuit (IC) devices 124 .
- the IC devices 124 generate significant amounts of heat during operation, requiring the use of active cooling to maintain the devices in a suitable temperature range.
- the storage devices 112 can generate significant amounts of heat during operation depending upon system loading.
- the storage enclosure 110 of FIG. 2 further incorporates a number of electrical fans.
- Forward located fans 126 are provisioned near the midplane 118 at an intermediate location within the storage enclosure housing 114
- rearward located fans 128 are provisioned at the rear of the storage enclosure housing 114 .
- the respective fans 126 , 128 may be nominally identical or may be provided with different operational characteristics.
- vent apertures are provisioned in respective front and end facing surfaces 130 , 132 of the storage enclosure housing 114 .
- the apertures permit cooling airflow from the cold aisle to be drawn into the front of the housing 114 so as to flow adjacent the storage devices 112 and midplane 118 , through the front fans 126 , adjacent the control boards 120 and power supplies 122 , and through the rear fans 128 out the rear of the housing to the warm aisle.
- the power supplies 122 may similarly incorporate fans to direct airflow through the power supply housing.
- the location of the front fans 126 within the intermediate portion of the housing can present challenges from a servicing standpoint should one or more of the fans require replacement.
- the use of the retractable sleds 116 permits relatively easy access to the individual storage devices 112 .
- the other active elements such as the control boards 120 , the power supplies 122 and the rear fans 128 can be easily accessed through the rear side 132 of the housing 114 .
- the front fans 126 are not easily accessible from either the front or rear sides 130 , 132 of the housing 114 .
- one service option is to remove the rear fans 128 and one or both of the control boards 120 from the rear of the housing 114 in order to reach in, remove and replace the failed fan(s) 126 .
- This requires the storage enclosure to be powered down for a significant amount of time and provides a risk that one or more of the active components may be damaged or reinstalled improperly.
- Another service option is to mount the storage enclosure 110 on a set of rails, allowing the storage enclosure to be extended forward from the storage cabinet 108 (see FIG. 1 ).
- a service door (such as represented at 134 in FIG. 1 ) in the top cover of the storage enclosure housing 114 can then be opened to provide access to the forward fans 126 .
- This approach is also associated with a number of difficulties, including the fact that the storage enclosure will likely need to be powered down prior to extension.
- the enclosure can also be unwieldy from a weight standpoint (some storage enclosures can weigh several hundred pounds), making such service operations difficult to carry out in a fast and efficient manner.
- FIG. 3 is a top plan representation of a storage enclosure 140 constructed and operated in accordance with various embodiments.
- the storage enclosure 140 utilizes various active elements such as discussed above, and is configured for mounting in a storage cabinet such as 108 in FIG. 1 .
- the storage enclosure 140 includes an enclosed storage housing 142 .
- the storage housing 142 has a 3 U height and houses a total of 42 data storage devices 144 (14 ⁇ 3 ⁇ 1).
- the data storage devices 144 are contemplated as comprising 3.5 in form factor HDDs, although other styles, types, sizes, numbers and orientations of storage devices can be used.
- the storage devices are arranged in a vertical orientation, with groups of three (3) devices being supported by individual sleds 146 .
- a total of 14 sleds are provided, with the sleds being configured for sliding retraction from a front surface 148 of the housing to provide access to the devices 144 during service events as discussed above.
- Access is provided from a rear surface 149 of the housing 142 to facilitate servicing of other active elements of the storage enclosure 160 , including dual redundant control boards 150 , power supplies 152 and fans 154 .
- the fans 154 are electrically powered fans with rotatable fins configured to establish an airflow at a selected rate, and collectively form a fan assembly.
- Each of the control boards 150 electrically and mechanically support a number of active elements, such as IC devices 156 A and 156 B.
- the control board can operate as a controller to control the storage and retrieval of data from the storage devices 144 with a host device.
- a midplane 158 extends in a transverse direction across a width direction of the housing 142 and provides electrical and mechanical interconnection of the various active elements of the enclosure 140 .
- the midplane 158 is a rigid midplane having a multi-layer printed circuit board assembly (PCBA) which supports various connectors and conductive traces (not separately shown) to interconnect the various active elements.
- PCBA printed circuit board assembly
- the diverter 160 also referred to herein as an airfoil, operates to provide directed cooling for the storage enclosure 140 during operation in a manner discussed below.
- the airfoil 160 generally comprises a planar member which extends in a transverse direction across the width of the storage enclosure housing 142 downstream from the midplane 158 .
- the airfoil 160 can be formed of any suitable rigid material such as sheet metal, plastic, etc.
- the airfoil 160 extends at a selected skew angle (e.g., an acute angle) with respect to the control boards 150 to accelerate and direct airflow established by the fans 154 proximate the control boards.
- the angle of the airfoil 160 is nominally 45 degrees with respect to a length direction of the housing 142 from the first end 148 to the second end 149 .
- the forced airflow enhances the cooling of the IC devices 156 A and 156 B.
- the airflow can be directed toward other active elements of interest.
- Arrows 162 in FIG. 5 represent airflow that enters the enclosure housing 142 through apertures (not shown) in the front facing surface 148 of the housing. This airflow 162 passes between the adjacent sleds 146 to provide cooling for the storage devices 144 ( FIG. 3 ).
- the storage devices 144 and sleds 146 have been omitted from FIGS. 4-5 for clarity, but are housed within storage device zone 164 in the manner set forth in FIG. 3 .
- the airflow 162 continues past the storage devices 144 and flows through spaced-apart apertures 166 that extend through the midplane 158 ( FIG. 4 ) to pass into an airfoil entry zone 168 ( FIG. 5 ).
- the airflow passes along the length of the airfoil 160 to an airfoil exit zone 170 , and accelerates along the way due to the continuous decrease in the cross-sectional area available to the airflow caused by the airfoil 160 .
- the accelerated airflow (represented by arrows 172 ) is jetted toward and across IC device 156 B to provide cooling thereof.
- some additional airflow 174 may bypass the airfoil 160 and flow to other areas within the housing 142 downstream from the midplane 158 .
- the airflow 174 may pass between a top flange 176 of the airfoil 160 and an interior surface 178 of the housing 142 through a gap defined therebetween.
- the fans 154 will pull an exhaust airflow 182 through an annular fan channel 184 established by rotation of fins (not separately shown) of the fan out the rear surface 149 of the housing 149 to the warm aisle.
- the fans 154 are dual-fin fans having an overall size of nominally 60 millimeters, mm ⁇ 60 mm ⁇ 54 mm and are commercially available from Sanyo Denki Co. LTD, Tokyo, Japan.
- FIG. 6 is a schematic depiction of the airfoil 160 of FIG. 5 .
- the airfoil entry zone 168 upstream of the airfoil 160 has an overall height of distance D 1 from a lower base surface 186 (e.g., lower surface of housing 142 ) to the upper interior surface 178 .
- the airfoil entry zone 168 may be a zone of relatively low pressure as airflow is pulled through the respective midplane apertures 166 .
- a first end 188 of the airfoil at the entry zone 168 is a second, smaller distance D 2 from the base surface 186 .
- An opposing, second end 190 of the airfoil at the exit zone 170 is a third smaller distance D 3 , where D 3 is significantly smaller than D 2 (e.g., D 2 ⁇ D 3 ).
- the base surface at the exit zone may be a top surface of the control board 150 and/or components disposed thereon, such as the IC device 156 B. This substantial narrowing of the clearance distance from D 2 to D 3 results in the rapid acceleration of the airflow.
- control board 150 extends under the airfoil 160 so that the upstream IC device 156 A is located between the entry and exit zones 168 , 170 whereas the downstream IC device 156 B is located adjacent the exit zone 170 . It is contemplated albeit not necessarily required that the downstream device 156 B dissipates heat at a greater rate than the upstream device 156 A, so that the greater airflow velocity proximate the downstream device 156 B can help to dissipate this generated heat. As desired, heatsink devices such as 192 on upstream device 156 A can be used to increase the surface area and hence, convective cooling of the devices.
- the airfoil 160 as configured in FIGS. 3-6 is configured to generally direct the flow of the airflow 172 exiting the airfoil 160 .
- the airfoil and associated components can be arranged to induce turbulence in the airflow in the vicinity of active elements that generate relatively large amounts of heat.
- turbulent airflow tends to increase heat transfer between the active element and the airflow.
- turbulence comes at the price of increasing overall pressure losses within the system and can reduce the volume of airflow passing through the system. Accordingly, the directed cooling arrangements disclosed herein can be readily adapted to a given application to provide proper levels of heat dissipation, pressure loss and volumetric flow as required.
- FIGS. 7A-7C illustrate alternative configurations of midplanes 166 A, 166 B and 166 C, respectively, that can be used in the storage enclosure 140 .
- the midplane 166 A in FIG. 7A has a “turret” configuration with apertures 194 extending between adjacent projections 196 to allow airflow to pass therethrough.
- the overall height of the midplane 166 A can be adjusted to facilitate passage of airflow from the data storage device zone 164 at the desired rate.
- the midplane 166 B in FIG. 7B has a “low wall” configuration with a shortened upper surface 198 established to facilitate passage of airflow from the data storage device zone 164 at the desired rate.
- FIG. 7C shows yet another midplane 166 C with a number of spaced apart apertures 199 extending through a medial extent of the midplane to admit airflow from the storage devices.
- Other configurations are contemplated and will readily occur to the skilled artisan in view of the present disclosure.
- flexible midplanes formed of various flexible components (e.g. cables, flex circuits, etc.) can be used so that a rigid PCBA is not necessarily required.
- FIGS. 8A-8C show various alternative airfoil configurations that can be used with the storage enclosure 140 to provide directed cooling as discussed herein.
- FIG. 8A shows an airfoil 160 A adjacent a base surface 200 and having a continuously curvilinear planar surface 201 to channel an airflow 202 between the airfoil and the base surface.
- FIG. 8B shows an airfoil 160 B with opposing planar surfaces characterized as discrete linear segmented surfaces.
- FIG. 8C shows a linear airfoil 160 C generally similar to the airfoil 160 discussed above and having opposing linear planar surfaces surfaces 204 , 206 .
- the surface 204 contactingly engages the airflow 202 to channel the airflow as discussed above, while surface 206 contactingly supports an active element of the enclosure 140 characterized as a control board (PCBA) 208 supporting one or more IC devices 210 .
- the control board 208 can be used to provide control and status functions for the enclosure, such as monitoring, temperature and vibration measurements, output control for LED indicators for the various sleds 146 , etc.
- the outer angled surface of the airfoil (e.g., surface 206 ) can be used as a convenient mounting surface for various elements within the enclosure 140 . It is contemplated that such components (e.g., board 208 ) may generate heat at a rate substantially less than the elements at which the airflow 202 is directed, and therefore may require less airflow to maintain the components at a suitable operational temperature. Some cooling of the components mounted to the airfoil may occur as a result of conductive cooling as heat passes through the airfoil to the airflow 202 , as well as through natural convection and radiation.
- FIG. 9 depicts another storage enclosure 140 A substantially similar to the enclosure 140 discussed above. Similar elements are provided with the same reference numerals.
- the storage enclosure 140 A has a storage enclosure housing 142 A with apertures 211 fluidically coupled to the airfoil entry zone 168 . This allows additional airflow 212 to enter the housing between the midplane 158 and the airfoil 160 , thereby decreasing the temperature of the airflow through the enclosure.
- fans such as 214 can be incorporated into the power supplies 152 to further enhance the airflow through the enclosure.
- adding airflow slots such as 211 will tend to slightly increase the pressure in this section of the housing 142 A.
- this tends to reduce the amount of airflow adjacent the HDDs in zone 164 since some air is drawn in through the apertures 211 rather than through the front of the enclosure.
- This technique can be thought of as “robbing Peter to pay Paul”; greater cooling is provided at the rear of the enclosure as compared to the front of the enclosure in relation to the airflow introduced through the slots.
- FIG. 10 is an elevational representation of aspects of the storage enclosure 140 A.
- An active element in the form of a boot device 216 such as a 2.5 in form factor HDD, is mounted to the outer surface of the airfoil 160 .
- the airfoil flange 176 extends to contactingly engage the lower surface 178 of the housing 142 A, thereby sealing off the entry zone 168 and forcing substantially all of the inlet airflow, apart from the airflow passing through the power supplies 152 , to pass adjacent the airfoil 160 and through the exit zone 170 .
- the directed cooling arrangements as embodied herein can provide a number of benefits through active directed cooling of particular elements within a storage enclosure.
- the use of airfoils as disclosed herein can enhance airflow draw without the need to locate fans in the medial portions of the storage enclosure housing. However, it will be appreciated that one or more fans may be placed between the midplane and the airfoil as desired.
- the airflow as embodied herein has been described as being placed between a plurality of data storage devices (e.g., 144 ) and a control board device (e.g., 156 A), it will be appreciated that the airfoil can be adapted for placement between any suitable first and second active elements to accelerate and direct airflow proximate the second active element.
- airfoil and the like will be understood consistent with the foregoing discussion and as understood by the skilled artisan as a stationary member that reduces an available cross-sectional area available to an airflow, and therefore excludes a fan or elements thereof.
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Abstract
Description
- In accordance with some embodiments, an apparatus includes a housing having opposing first and second ends. A first active element is mounted within the housing adjacent the first end, and a second active element mounted within the housing adjacent the second end. A fan assembly is mounted within the housing adjacent the second end to establish an airflow through the housing adjacent the first and second active elements for cooling thereof. An airfoil is mounted within the housing between the first and second active elements to accelerate and direct the airflow proximate the second active element.
- In further embodiments, an apparatus includes a multi-device storage enclosure housing with a first end configured for placement proximate a cold aisle and an opposing second end configured for placement proximate a warm aisle. A plurality of data storage devices are configured to store and retrieve user data from a host device, with the data storage devices being housed within the housing proximate the first end. A control board supports at least one integrated circuit (IC) device to control said storage and retrieval of the user data. The control board is housed within the housing proximate the second end. A fan assembly is mounted within the housing adjacent the second end and configured to establish an airflow through the housing. An airfoil is mounted within the housing between the data storage devices and the at least one IC device to accelerate and direct the airflow proximate the at least one IC device.
-
FIG. 1 is a functional representation of a networked mass storage system to illustrate a suitable operational environment for various embodiments of the present disclosure. -
FIG. 2 is a top plan representation of a storage enclosure fromFIG. 1 . -
FIG. 3 is a storage enclosure with an airfoil to provide directed cooling in accordance with various embodiments. -
FIG. 4 is an isometric depiction of the storage enclosure ofFIG. 3 . -
FIG. 5 is a side elevational depiction of operation of an airfoil of the storage enclosure in some embodiments. -
FIG. 6 is a schematic representation of the airfoil ofFIG. 5 . -
FIGS. 7A-7C illustrate alternative configurations for a midplane of the storage enclosure in accordance with some embodiments. -
FIGS. 8A-8C provide alternative configurations for the airfoil in accordance with some embodiments. -
FIG. 9 illustrates another configuration of the storage enclosure which uses airflow ingress apertures in the storage enclosure housing. -
FIG. 10 is a side view representation of the storage enclosure configuration ofFIG. 9 . - The present disclosure generally relates to directed cooling of active elements such as in a networked mass storage system.
- Mass storage systems often employ multiple data storage devices which are operationally arranged to provide a relatively high data capacity memory storage space. The devices may be grouped together into a mass storage assembly (MSA) or other module that can be removably installed into a rack system (server cabinet).
- Mass storage systems can take a variety of forms including servers, cloud storage modules, RAID (redundant array of independent discs) systems, extended memory systems (JBODs, or “just a box of drives”), etc. The storage systems can be accessed locally or over a network including a local area network (LAN), a wide area network (WAN), the Internet, etc. A storage enclosure can include various active elements such as storage devices, control boards, power supplies, fans, boot devices, etc.
- While operable to provide highly efficient computer storage, conventional mass storage systems can be subject to a variety of limitations, including the inability to remove and replace individual active elements while maintaining the storage enclosure in a powered, operational condition (“hot swapping”), such as in the context of a service operation to replace a failed component or an upgrade operation where new and different performance elements are installed.
- Accordingly, various embodiments of the present disclosure are generally directed to a directed cooling arrangement for use in a multi-device storage enclosure. As explained below, the storage enclosure may be configured with a housing adapted to be mounted within a rack system between a cold aisle (front) and a warm aisle (rear). The housing supports a number of active elements including multiple storage devices, power supplies, control boards, boot devices, etc. One or more fan assemblies located adjacent the rear of the housing operate to establish a cooling airflow through the storage enclosure housing. As cool air is drawn into the front of the housing from the cold aisle, the airflow passes various storage devices and a midplane. An airfoil downstream from the midplane channels and directs the airflow adjacent an active element, such as one or more integrated circuit (IC) devices on a control board. The airflow then passes to the fan assemblies and is exhausted out the rear of the housing to the warm aisle.
- In this way, effective cooling can be supplied to the intermediate portions of the interior of the housing without the need to locate cooling fans in this area. This can provide a number of operational advantages including reduced vibration and noise, and enhanced serviceability of the storage enclosure.
- These and other features of various embodiments will become apparent beginning with a review of
FIG. 1 which generally depicts a networkedmass storage system 100 in accordance with some embodiments. Thesystem 100 includes astorage assembly 102 coupled to acomputer 104 which in turn is connected to anetwork 106. Thecomputer 104 can take a variety of forms such as a work station, a local personal computer, a server, etc. Thestorage assembly 102 includes a server cabinet (rack) 108 and a plurality ofmodular storage enclosures 110. - In some embodiments, the
storage rack 108 is a 42U server cabinet with 42 units (U) of storage, with each unit comprising about 1.75 inches (in) of height. The width and length dimensions of the cabinet can vary but common values may be on the order of about 24 in.×36 in. Other sizes can be used. Each storage enclosure can be a multiple of the storage units, such as 2U, 3U, 5U, etc. Fully populating therack 108 withstorage enclosures 110 can provide several Petabytes (1015 bytes) of storage or more for thecomputer 104 and/or network applications. An example configuration for aselected storage enclosure 110 is shown inFIG. 2 . - The
storage enclosure 110 takes a 36/2U configuration with 36 (3×4×3)data storage devices 112 in a 2U form factor heightstorage enclosure housing 114. A variety of other configurations can be used including storage enclosures with a total of N drives where N=12, 16, 20, 24, 30, 32, 48, etc. Other heights can be used as well, such as 3U, 4U, 5U, etc. While 1U height storage enclosures are contemplated, it has been found in some cases that a thicker enclosure housing (e.g., 2U or greater) provides improved structural stability and vibration response. - The
storage devices 112 can take a variety of forms, such as hard disc drives (HDDs), solid-state drives (SSDs), hybrid drives, etc. Eachstorage device 112 includes a controller and computer memory to provide storage of user data, such as represented byrotatable disc memory 112A andcontroller 112B. In a cloud computing environment, data may be stored in the form of objects (partitions) of selected size and duplicated a number of times in different zones in different storage devices. It is contemplated that thestorage devices 112 inFIG. 2 are 3.5 inch (in.) form factor HDDs with nominal length and width dimensions of 5.75 in.×4.0 in. Other styles and form factors of storage devices can be used, including but not limited to 2.5 in. form factor devices with nominal dimensions of 4.0 in.×2.88 in. -
Retractable sleds 116 are used to secure multiple sets of thestorage devices 112. The sleds can be individually extended and retracted from thehousing 114, as shown for aselected sled 116A which has been partially extended from thehousing 110. Thesleds 116 may include sled electronics (not separately shown) to provide status indications and other control features during enclosure operation. While thesleds 116 are shown to support thestorage devices 112 in a horizontal orientation (e.g., the length and width dimensions of the storage devices are parallel to the overall length and width dimensions of the storage enclosure housing 114), thesleds 116 can alternatively support thestorage devices 112 in a vertical orientation (e.g., “on edge” so that the length and width dimensions of the storage devices are orthogonal to the length and width dimensions of the storage enclosure). - A
midplane 118 extends in a transverse direction across thehousing 114 to provide electrical interconnection paths for thevarious storage devices 112 and sled electronics. The midplane may take the form of a fixed multi-layer printed circuit board assembly (PCBA) with various electrical connectors, signal traces and vias to establish the necessary electrically conductive signal and power paths. - Alternatively, the midplane may take a flexible configuration in which flex circuits (e.g., cables, etc.) are used to maintain electrical interconnection with the storage devices and sleds. When a rigid midplane is used, extension of a sled (e.g.,
sled 116A) will generally result in the associated storage devices on the extended sled being powered down and disconnected from the system. Extension of a sled using a flexible midplane may allow the associated storage devices in the extended sled to remain powered up and operational. - Other active elements in the
storage enclosure 110 ofFIG. 2 include dualredundant control boards 120. Thecontrol boards 120 can take a variety of forms depending on the configuration of thestorage enclosure 110, such as a server, a network switch, a router, a RAID controller, etc. The multiple control boards can be used in a dual mode operation to support failover and failback operations, or as a master/slave arrangement so that one control board provides control operations and the other board operates in a standby mode ready to take over operation should a fault be detected in the main control board. - Dual redundant power supplies are represented at 122. The power supplies 122 provide electrical power for the
control boards 120 and other active elements of thestorage enclosure 110 such as thestorage devices 112. The electrical power is supplied at suitable voltage levels (e.g., 3V, 5V, 12V, etc.). Redundancy is provided such that eachpower supply 122 is rated to supply power for the entire enclosure, should the remaining power supply or supplies be temporarily taken off line. - The
control boards 120 include one or more integrated circuit (IC)devices 124. TheIC devices 124 generate significant amounts of heat during operation, requiring the use of active cooling to maintain the devices in a suitable temperature range. Similarly, thestorage devices 112 can generate significant amounts of heat during operation depending upon system loading. - Accordingly, the
storage enclosure 110 ofFIG. 2 further incorporates a number of electrical fans. Forward locatedfans 126 are provisioned near themidplane 118 at an intermediate location within thestorage enclosure housing 114, and rearward locatedfans 128 are provisioned at the rear of thestorage enclosure housing 114. Therespective fans - Although not separately denoted in
FIG. 2 , it will be understood that vent apertures are provisioned in respective front andend facing surfaces storage enclosure housing 114. The apertures permit cooling airflow from the cold aisle to be drawn into the front of thehousing 114 so as to flow adjacent thestorage devices 112 andmidplane 118, through thefront fans 126, adjacent thecontrol boards 120 andpower supplies 122, and through therear fans 128 out the rear of the housing to the warm aisle. The power supplies 122 may similarly incorporate fans to direct airflow through the power supply housing. - While such an arrangement can be operable, the location of the
front fans 126 within the intermediate portion of the housing can present challenges from a servicing standpoint should one or more of the fans require replacement. As noted above, the use of theretractable sleds 116 permits relatively easy access to theindividual storage devices 112. Similarly, the other active elements such as thecontrol boards 120, the power supplies 122 and therear fans 128 can be easily accessed through therear side 132 of thehousing 114. - Due to clearance and interconnectivity constraints, however, the
front fans 126 are not easily accessible from either the front orrear sides housing 114. In the event of a failure of one or more of thefront fans 126, one service option is to remove therear fans 128 and one or both of thecontrol boards 120 from the rear of thehousing 114 in order to reach in, remove and replace the failed fan(s) 126. This requires the storage enclosure to be powered down for a significant amount of time and provides a risk that one or more of the active components may be damaged or reinstalled improperly. - Another service option is to mount the
storage enclosure 110 on a set of rails, allowing the storage enclosure to be extended forward from the storage cabinet 108 (seeFIG. 1 ). A service door (such as represented at 134 inFIG. 1 ) in the top cover of thestorage enclosure housing 114 can then be opened to provide access to theforward fans 126. This approach is also associated with a number of difficulties, including the fact that the storage enclosure will likely need to be powered down prior to extension. Depending on the size and number of storage devices within the enclosure, the enclosure can also be unwieldy from a weight standpoint (some storage enclosures can weigh several hundred pounds), making such service operations difficult to carry out in a fast and efficient manner. Accordingly, various embodiments of the present disclosure are directed to an improved storage enclosure that uses a directed cooling arrangement to provide requisite airflow cooling for the enclosure without the need to locate fans in the intermediate portions of the storage enclosure housing.FIG. 3 is a top plan representation of astorage enclosure 140 constructed and operated in accordance with various embodiments. Thestorage enclosure 140 utilizes various active elements such as discussed above, and is configured for mounting in a storage cabinet such as 108 inFIG. 1 . - The
storage enclosure 140 includes anenclosed storage housing 142. In some embodiments, thestorage housing 142 has a 3U height and houses a total of 42 data storage devices 144 (14×3×1). Thedata storage devices 144 are contemplated as comprising 3.5 in form factor HDDs, although other styles, types, sizes, numbers and orientations of storage devices can be used. - The storage devices are arranged in a vertical orientation, with groups of three (3) devices being supported by
individual sleds 146. A total of 14 sleds are provided, with the sleds being configured for sliding retraction from afront surface 148 of the housing to provide access to thedevices 144 during service events as discussed above. Access is provided from arear surface 149 of thehousing 142 to facilitate servicing of other active elements of thestorage enclosure 160, including dualredundant control boards 150,power supplies 152 andfans 154. Thefans 154 are electrically powered fans with rotatable fins configured to establish an airflow at a selected rate, and collectively form a fan assembly. Each of thecontrol boards 150 electrically and mechanically support a number of active elements, such asIC devices storage devices 144 with a host device. - A
midplane 158 extends in a transverse direction across a width direction of thehousing 142 and provides electrical and mechanical interconnection of the various active elements of theenclosure 140. Themidplane 158 is a rigid midplane having a multi-layer printed circuit board assembly (PCBA) which supports various connectors and conductive traces (not separately shown) to interconnect the various active elements. Other configurations, including flexible midplanes, can be used. - It will be appreciated that a number of other elements can be incorporated into the
storage enclosure 140 such as sled electronics, monitoring circuits, LED status indicators, cabling, boot devices, mechanical support structures, etc. Such elements have been omitted fromFIG. 3 for simplicity of illustration. - Of particular interest in
FIG. 3 is anairflow diverter 160. The diverter, also referred to herein as an airfoil, operates to provide directed cooling for thestorage enclosure 140 during operation in a manner discussed below. Theairfoil 160 generally comprises a planar member which extends in a transverse direction across the width of thestorage enclosure housing 142 downstream from themidplane 158. Theairfoil 160 can be formed of any suitable rigid material such as sheet metal, plastic, etc. - As further shown in
FIGS. 4 and 5 , theairfoil 160 extends at a selected skew angle (e.g., an acute angle) with respect to thecontrol boards 150 to accelerate and direct airflow established by thefans 154 proximate the control boards. In one embodiment, the angle of theairfoil 160 is nominally 45 degrees with respect to a length direction of thehousing 142 from thefirst end 148 to thesecond end 149. The forced airflow enhances the cooling of theIC devices -
Arrows 162 inFIG. 5 represent airflow that enters theenclosure housing 142 through apertures (not shown) in thefront facing surface 148 of the housing. Thisairflow 162 passes between theadjacent sleds 146 to provide cooling for the storage devices 144 (FIG. 3 ). Thestorage devices 144 and sleds 146 have been omitted fromFIGS. 4-5 for clarity, but are housed withinstorage device zone 164 in the manner set forth inFIG. 3 . - The
airflow 162 continues past thestorage devices 144 and flows through spaced-apartapertures 166 that extend through the midplane 158 (FIG. 4 ) to pass into an airfoil entry zone 168 (FIG. 5 ). The airflow passes along the length of theairfoil 160 to anairfoil exit zone 170, and accelerates along the way due to the continuous decrease in the cross-sectional area available to the airflow caused by theairfoil 160. At this point, the accelerated airflow (represented by arrows 172) is jetted toward and acrossIC device 156B to provide cooling thereof. - Depending on the configuration of the
storage enclosure 140, someadditional airflow 174 may bypass theairfoil 160 and flow to other areas within thehousing 142 downstream from themidplane 158. Theairflow 174 may pass between atop flange 176 of theairfoil 160 and aninterior surface 178 of thehousing 142 through a gap defined therebetween. Regardless, thefans 154 will pull anexhaust airflow 182 through anannular fan channel 184 established by rotation of fins (not separately shown) of the fan out therear surface 149 of thehousing 149 to the warm aisle. - The number, style and arrangement of fans can be varied as required to establish the desired airflow through the enclosure. In one embodiment, the
fans 154 are dual-fin fans having an overall size of nominally 60 millimeters, mm×60 mm×54 mm and are commercially available from Sanyo Denki Co. LTD, Tokyo, Japan. -
FIG. 6 is a schematic depiction of theairfoil 160 ofFIG. 5 . Theairfoil entry zone 168 upstream of theairfoil 160 has an overall height of distance D1 from a lower base surface 186 (e.g., lower surface of housing 142) to the upperinterior surface 178. Theairfoil entry zone 168 may be a zone of relatively low pressure as airflow is pulled through therespective midplane apertures 166. - A
first end 188 of the airfoil at theentry zone 168 is a second, smaller distance D2 from thebase surface 186. An opposing,second end 190 of the airfoil at theexit zone 170 is a third smaller distance D3, where D3 is significantly smaller than D2 (e.g., D2<<D3). Moreover, the base surface at the exit zone may be a top surface of thecontrol board 150 and/or components disposed thereon, such as theIC device 156B. This substantial narrowing of the clearance distance from D2 to D3 results in the rapid acceleration of the airflow. - Returning again to
FIG. 5 , it will be noted that thecontrol board 150 extends under theairfoil 160 so that theupstream IC device 156A is located between the entry andexit zones downstream IC device 156B is located adjacent theexit zone 170. It is contemplated albeit not necessarily required that thedownstream device 156B dissipates heat at a greater rate than theupstream device 156A, so that the greater airflow velocity proximate thedownstream device 156B can help to dissipate this generated heat. As desired, heatsink devices such as 192 onupstream device 156A can be used to increase the surface area and hence, convective cooling of the devices. - The
airfoil 160 as configured inFIGS. 3-6 is configured to generally direct the flow of theairflow 172 exiting theairfoil 160. However, as desired the airfoil and associated components can be arranged to induce turbulence in the airflow in the vicinity of active elements that generate relatively large amounts of heat. As will be recognized by those skilled in the art, turbulent airflow tends to increase heat transfer between the active element and the airflow. However, such turbulence comes at the price of increasing overall pressure losses within the system and can reduce the volume of airflow passing through the system. Accordingly, the directed cooling arrangements disclosed herein can be readily adapted to a given application to provide proper levels of heat dissipation, pressure loss and volumetric flow as required. -
FIGS. 7A-7C illustrate alternative configurations ofmidplanes storage enclosure 140. Themidplane 166A inFIG. 7A has a “turret” configuration withapertures 194 extending betweenadjacent projections 196 to allow airflow to pass therethrough. The overall height of themidplane 166A can be adjusted to facilitate passage of airflow from the datastorage device zone 164 at the desired rate. Themidplane 166B inFIG. 7B has a “low wall” configuration with a shortenedupper surface 198 established to facilitate passage of airflow from the datastorage device zone 164 at the desired rate.FIG. 7C shows yet anothermidplane 166C with a number of spaced apartapertures 199 extending through a medial extent of the midplane to admit airflow from the storage devices. Other configurations are contemplated and will readily occur to the skilled artisan in view of the present disclosure. For example, as noted above, flexible midplanes formed of various flexible components (e.g. cables, flex circuits, etc.) can be used so that a rigid PCBA is not necessarily required. -
FIGS. 8A-8C show various alternative airfoil configurations that can be used with thestorage enclosure 140 to provide directed cooling as discussed herein.FIG. 8A shows anairfoil 160A adjacent abase surface 200 and having a continuously curvilinearplanar surface 201 to channel anairflow 202 between the airfoil and the base surface.FIG. 8B shows anairfoil 160B with opposing planar surfaces characterized as discrete linear segmented surfaces. -
FIG. 8C shows alinear airfoil 160C generally similar to theairfoil 160 discussed above and having opposing linear planar surfaces surfaces 204, 206. Thesurface 204 contactingly engages theairflow 202 to channel the airflow as discussed above, whilesurface 206 contactingly supports an active element of theenclosure 140 characterized as a control board (PCBA) 208 supporting one ormore IC devices 210. Thecontrol board 208 can be used to provide control and status functions for the enclosure, such as monitoring, temperature and vibration measurements, output control for LED indicators for thevarious sleds 146, etc. - In this way, the outer angled surface of the airfoil (e.g., surface 206) can be used as a convenient mounting surface for various elements within the
enclosure 140. It is contemplated that such components (e.g., board 208) may generate heat at a rate substantially less than the elements at which theairflow 202 is directed, and therefore may require less airflow to maintain the components at a suitable operational temperature. Some cooling of the components mounted to the airfoil may occur as a result of conductive cooling as heat passes through the airfoil to theairflow 202, as well as through natural convection and radiation. -
FIG. 9 depicts anotherstorage enclosure 140A substantially similar to theenclosure 140 discussed above. Similar elements are provided with the same reference numerals. Thestorage enclosure 140A has astorage enclosure housing 142A withapertures 211 fluidically coupled to theairfoil entry zone 168. This allowsadditional airflow 212 to enter the housing between themidplane 158 and theairfoil 160, thereby decreasing the temperature of the airflow through the enclosure. As desired, fans such as 214 can be incorporated into thepower supplies 152 to further enhance the airflow through the enclosure. Generally, it will be recognized that adding airflow slots such as 211 will tend to slightly increase the pressure in this section of thehousing 142A. In turn, this tends to reduce the amount of airflow adjacent the HDDs inzone 164 since some air is drawn in through theapertures 211 rather than through the front of the enclosure. This technique can be thought of as “robbing Peter to pay Paul”; greater cooling is provided at the rear of the enclosure as compared to the front of the enclosure in relation to the airflow introduced through the slots. -
FIG. 10 is an elevational representation of aspects of thestorage enclosure 140A. An active element in the form of aboot device 216, such as a 2.5 in form factor HDD, is mounted to the outer surface of theairfoil 160. It will be noted that theairfoil flange 176 extends to contactingly engage thelower surface 178 of thehousing 142A, thereby sealing off theentry zone 168 and forcing substantially all of the inlet airflow, apart from the airflow passing through the power supplies 152, to pass adjacent theairfoil 160 and through theexit zone 170. - The directed cooling arrangements as embodied herein can provide a number of benefits through active directed cooling of particular elements within a storage enclosure. The use of airfoils as disclosed herein can enhance airflow draw without the need to locate fans in the medial portions of the storage enclosure housing. However, it will be appreciated that one or more fans may be placed between the midplane and the airfoil as desired. Similarly, while the airflow as embodied herein has been described as being placed between a plurality of data storage devices (e.g., 144) and a control board device (e.g., 156A), it will be appreciated that the airfoil can be adapted for placement between any suitable first and second active elements to accelerate and direct airflow proximate the second active element.
- For purposes herein, the term “airfoil” and the like will be understood consistent with the foregoing discussion and as understood by the skilled artisan as a stationary member that reduces an available cross-sectional area available to an airflow, and therefore excludes a fan or elements thereof.
- It is to be understood that even though numerous characteristics of various embodiments of the present disclosure have been set forth in the foregoing description, together with details of the structure and function of various embodiments, this detailed description is illustrative only, and changes may be made in detail, especially in matters of structure and arrangements of parts within the principles of the present disclosure to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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