Customer Objective
A leading manufacturer of industrial components and systems joined forces with a thermal management innovator to develop a line of two-phase refrigerant-based cooling products for the power electronics and high-density computing markets. The concept – if successful – promised steep cooling capacity improvements over existing technologies, but required a variable flow, positive displacement pump capable of operating with low viscosity refrigerants. The design requirements included:
- Operation with refrigerant R134a
- 24 volt electrical power
- Long operational life
- Variable flow capacity
- Integrated electronic control
- Leak-free operation
- Space-efficient integration within the customer system
- Ability to withstand safety pressure of up to 1,500 psig
Cascon Solution
There was little direct industry experience pumping liquid refrigerant, no comparable products on the market, and no published literature for consultation. Adding to the challenge, deadlines were already tight. In order to meet project objectives, component and system development would take place concurrently. To balance risk against a rapid deployment cycle, we elected to address the development challenges in phases.
During Phase I, the Cascon team worked to demonstrate basic performance capabilities and durability, providing support as necessary for the customer’s overall system development process. Cascon tapped its long history of integrating electric drives and its knowledge of wear-resistance pump rotors to quickly design a cost-efficient pump. In order to speed the development cycle, a separate, off-the-shelf motor control was incorporated.
Following on the success of Phase I, Phase II began with a limited pump production run. The prototypes integrated the off-the-shelf control, and significantly improved hermeticity. The customer was able to beta test their system – with Phase II pumps – in field cooling applications. The results demonstrated both reliability and efficacy, but revealed the need for additional fluid flow for optimum system performance.
Armed with knowledge from Phases I and II, the production-ready Phase III design incorporated increased fluid flow, and integrated an application-specific pump control developed by Cascon.
The cooling system design then entered production, and continues to build its record for durability and reliability in a variety of applications including wind turbine power conversions, industrial battery systems and large electric motor drives.
Pump Features
- 24-volt brushless DC motor: Proven over years of use, this motor combines cost efficiency and reliability.
- Integrated electronic control: Preserves space and ensures reliable performance.
- Ultra-wear resistant pump element: Built for longevity under continued use.
- Light weight, compact design. Integration optimizes system design and frees valuable space for other key components.
