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Designing an Innovative Control Panel for a Liquid-Cooled Rack Manufacturer

E Tech Group engineered a cost-effective, custom control panel for a liquid-cooled rack manufacturer, enabling precise testing at a university R&D lab while meeting strict space, budget, and timeline requirements.

Challenge:

A leading manufacturer of liquid-cooled server racks for data centers sought to develop a test assembly for donation to a University Research and Development Data Center. This facility would use the assembly to test liquid-cooled equipment and refine designs for greater efficiency. Key challenges included:

  • Limited Budget and Aggressive Timeline: The client required a cost-effective solution that could be delivered promptly.
  • Design Constraints: The assembly needed to fit within a server rack with a 3U clearance or less, ensuring portability between racks.

Additionally, the project demanded precise control for testing, which necessitated custom engineering expertise.

Solution:

E Tech Group engineered a cutting-edge server rack tray control panel tailored to the client’s stringent requirements. Key elements of the solution included:

Custom Hardware and Software Development:

  • Control Panel Design: Built to fit the 3U clearance while remaining portable.
  • PLC Programming: Incorporated PID position control for a valve, using pressure sensor feedback for precision testing.
  • Headless HMI Integration: Enabled R&D technicians to adjust PID settings via a web browser, ensuring flexibility and ease of use.

Technology Selection:

  • Deployed Automation Direct PLC and headless HMI to align with the client’s preferred platform and cost constraints.

Overcoming Challenges:

  • Leveraged innovative design strategies to accommodate space and functionality requirements.
  • Delivered a fully operational test assembly on time and within budget.

Results:

The project successfully met all design and operational objectives, earning the client’s trust and opening doors for future collaborations. Notable outcomes included:

  • Cost Efficiency: Delivered a robust solution within the client’s budget.
  • Enhanced R&D Capabilities: The University Data Center gained a versatile, user-friendly test assembly, empowering them to optimize liquid-cooled server designs.
  • Client Relationship: The project’s success led to additional work opportunities with the client, strengthening their partnership with E Tech Group.

This case exemplifies E Tech Group’s ability to deliver high-value engineering solutions under tight constraints, showcasing our expertise in automation and our commitment to client satisfaction.

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