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Elma Mektron Systems experience 25% increase in cooling rate using Staubli connectors
Elma Mektron Systems Ltd, a major player in the open bus architecture computer industry, have for some time been creating computer enclosures for use in severe environments, especially for COTS military applications. Recent significant increases in data processing speed in the CPCI,VME,VPX,VXS, and µTCA architecture have created an opportunity for new and innovative high power enclosures.
With high speed, comes high power, increasing junction temperatures and therefore higher cooling requirements. A recent innovative example is the development a dual independent, liquid cooled ATR enclosure, using field replaceable cooling devices. The liquid cooled enclosures needed to allow for a large amount of user serviceability and interchangeability, the connections to the cooling system needed to be able to be disconnected and reconnected easily without any risk of fluid loss.
Elma Mektron Systems Ltd called in Stäubli Connectors to advise on the best type of quick release connectors required for this demanding application. Stäubli recommended lightweight, flush-faced, non-spill connectors with secure bayonet locking. The flush faced design ensures no air ingress into the system on connection as well as eliminating any leakage. The bayonet locking system is quick and easy to connect – just push & twist and is durable and reliable, being designed to withstand high vibration applications. The couplings aluminium construction minimises weight, important for in-flight applications. This type of connector will frequently be seen on many types of high performance cars in motorsport where the leak free, lightweight, high integrity features are equally important.
Stäubli organised the manufacture of the cooling plates at one of their partner companies and supplied the finished ‘cold wall’, complete with transition block containing the connectors and hose assemblies to Elma Mektron Systems Ltd, for fitting to their ATR enclosures. As part of the development Stäubli modelled the thermal pressure and fluid dynamics of the system, to produce a thermal model of the cold wall. 3D models and rapid prototyping of components ensured that the cold wall was a perfect fit during final assembly at Elma Mektron Systems Ltd . The design allows for the use of many different coolant types, from seawater to aviation fuel, in a wide spectrum of environments, from aerospace through marine to tracked vehicles. The entire development programme was fast tracked by all parties and working prototypes were delivered in less than 3 months.
The first fully operational liquid cooled enclosure was exhibited at the DSEi show in September 2007. The thermal performance of the enclosure was quite exceptional giving user friendly, high cooling power in excess of 25% above currently available products. A ‘cold wall’ system enables electronics manufacturers to fluid cool by conduction their range of instrument enclosures. Dual independent cold walls ensure the cooling system operates even if one side is damaged and from the outset the cool wall was designed to permit change in the field. The modular construction provides the ability to change the cooling medium easily in response to the conditions encountered and where there is a need to connect automatically; blind mating, dry break connectors can be specified.
Equipment in the defence sector continues to grow in functionality and complexity. This is leading onto a greater need for cooling of the electronics and demands for improved flexibility and range of deployment. Stäubli quick release, dry break connectors are helping to satisfy these demands by ensuring save, clean, rapid and reliable connection and disconnection of all fluids, gases and electrical circuits to support the requirements of modular design and increased flexibility.