The present disclosure relates generally to communications networks, and more particularly, to power, data, and cooling delivery in a communications network.
Network devices such as computer peripherals, network access points, and IoT (Internet of Things) devices may have both their data connectivity and power needs met over a single combined function cable. Examples of technologies that provide this function are USB (Universal Serial Bus) and PoE (Power over Ethernet). In conventional PoE systems, power is delivered over the cables used by the data over a range from a few meters to about one hundred meters. When a greater distance is needed or fiber optic cables are used, power is typically supplied through a local power source such as a wall outlet due to limitations with capacity, reach and cable loss in conventional PoE. Today's PoE systems also have limited power capacity, which may be inadequate for many classes of devices. If the available power over combined function cables is increased, traditional convection cooling methods may be inadequate for high powered devices.
Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.
Overview
In one embodiment, a method generally comprises delivering power, data, and cooling from a central network device to a plurality of remote communications devices over cables connecting the central network device to the remote communications devices, each of the cables carrying said power, data, and cooling, and receiving at the central network device, power and thermal data from the remote communications devices based on monitoring of power and cooling at the remote communications devices. The remote communications devices are powered by the power and cooled by the cooling delivered from the central network device.
In another embodiment, an apparatus generally comprises a connector for connecting the apparatus to a cable delivering power, data, and cooling to the apparatus, the connector comprising an optical interface for receiving optical communications signals, an electrical interface for receiving power for powering the apparatus, and a fluid interface for receiving coolant. The apparatus further comprises a cooling loop for cooling electrical components of the apparatus with the coolant and a monitoring system for monitoring the cooling loop and providing feedback to a central network device delivering the power, data, and cooling to the apparatus over the cable.
In yet another embodiment, an apparatus generally comprises a connector for connecting the apparatus to a cable delivering power, data, and cooling to a plurality of remote communications devices, the connector comprising an optical interface for delivering optical communications signals, an electrical interface for delivering power for powering the remote communications devices, and a fluid interface for delivering cooling to the remote communications devices. The apparatus further comprises a control system for modifying delivery of the cooling to the remote communications devices based on feedback received from the remote communications devices.
Further understanding of the features and advantages of the embodiments described herein may be realized by reference to the remaining portions of the specification and the attached drawings.
Example Embodiments
The following description is presented to enable one of ordinary skill in the art to make and use the embodiments. Descriptions of specific embodiments and applications are provided only as examples, and various modifications will be readily apparent to those skilled in the art. The general principles described herein may be applied to other applications without departing from the scope of the embodiments. Thus, the embodiments are not to be limited to those shown, but are to be accorded the widest scope consistent with the principles and features described herein. For purpose of clarity, details relating to technical material that is known in the technical fields related to the embodiments have not been described in detail.
In conventional Power over Ethernet (PoE) systems used to simultaneously transmit power and data communications, power is delivered over the same twisted pair cable used for data. These systems are limited in range to a few meters to about 100 meters. The maximum power delivery capacity of standard PoE is approximately 100 Watts, but many classes of powered devices would benefit from power delivery of 1000 Watts or more. In conventional systems, when a larger distance is needed fiber optic cabling is used to deliver data and when larger power delivery ratings are needed power is supplied to a remote device through a local power source.
As previously noted, it is desirable to increase the power available over multi-function cables to hundreds and even thousands of watts. This capability may enable many new choices in network deployments where major devices such as workgroup routers, multi-socket servers, large displays, wireless access points, or fog nodes are operated over multi-function cables. This capability would greatly decrease installation complexity and improve the total cost of ownership of a much wider set of devices that have their power and data connectivity needs met from a central hub.
Beyond the data and power supply capabilities noted above, there is also a need for cooling. For high-powered devices, especially those with high thermal density packaging or total dissipation over a few hundred Watts, traditional convection cooling methods may be inadequate. This is particularly apparent where special cooling challenges are present, such as with a device that is sealed and cannot rely on drawing outside air (e.g., all-season outdoor packaging), a hermetically sealed device (e.g., used in food processing or explosive environments), or where fan noise is a problem (e.g., office or residential environments), or any combination of the above along with extreme ambient temperature environments. In these situations, complex and expensive specialized cooling systems are often used.
The embodiments described herein provide cooling capability along with data and power, thereby significantly enhancing the functionality of multi-function cables. In one or more embodiments, a cable system, referred to herein as PoE+Fiber+Cooling (PoE+F+C), provides high power energy delivery, fiber delivered data, and cooling within a single cable. The PoE+F+C system allows high power devices to be located in remote locations, extreme temperature environments, or noise sensitive environments, with their cooling requirements met through the same cable that carries data and power. As described in detail below, coolant flows through the cable carrying the power and data to remote communications devices to provide a single multi-use cable that serves all of the functions that a high power node would need, including cooling. This use of a single cable for all interconnect functions required by a remote device can greatly simplify installation and ongoing operation of the device.
Referring now to the drawings, and first to
The network is configured to provide power (e.g., power greater than 100 Watts), data (e.g., optical data), and cooling from a central network device 10 to a plurality of remote network devices 12 (e.g., switches, routers, servers, access points, computer peripherals, Internet of Things (IoT) devices, fog nodes, or other electronic components and devices). Signals may be exchanged among communications equipment and power transmitted from power sourcing equipment (e.g., central hub 10) to powered devices (e.g., remote communications devices 12). As described in detail below, the PoE+F+C system delivers power, data, and cooling to a network (e.g., switch/router system) configured to receive data, power, and cooling over a cabling system comprising optical fibers, electrical wires (e.g., copper wires), and coolant tubes.
As shown in the example of
One or more network devices may also deliver power to equipment using PoE. For example, one or more of the network devices 12 may deliver power using PoE to electronic components such as IP (Internet Protocol) cameras, VoIP (Voice over IP) phones, video cameras, point-of-sale devices, security access control devices, residential devices, building automation devices, industrial automation, factory equipment, lights (building lights, streetlights), traffic signals, and many other electrical components and devices.
In the example shown in
The central hub 10 may be operable to provide high capacity power from an internal power system (e.g., PSU providing over and including 5 kW (e.g., 10 kW, 12 kW, 14 kW, 16 kW), or PSU providing over and including 100 W (e.g., 500 W, 1 kW) of useable power or any other suitable power capacity). The PSU 15 may provide, for example, PoE, pulsed power, DC power, or AC power. The central hub 10 (PSE (Power Sourcing Equipment)) is operable to receive power external from a communications network and transmit the power, along with data and cooling, over the cables 14 in the communications network to the remote network devices (PDs (Powered Devices)) 12. The central hub 10 may comprise, for example, a router, convergence device, or any other suitable network device operable to deliver power, data, and cooling. Additional components and functions of the central hub 10 are described below with respect to
Cables 14 extending from the central hub 10 to the remote communications devices 12 are configured to transmit power, data, and cooling in a single cable (combined cable, multi-function cable, multi-use cable, hybrid cable). The cables 14 may be formed from any material suitable to carry electrical power, data (copper, fiber), and coolant (liquid, gas, or multi-phase) and may carry any number of electrical wires, optical fibers, and cooling tubes in any arrangement. Examples of cable configurations are shown in
In one embodiment, power and data are received at an optical transceiver (optical module, optical device, optics module, transceiver, silicon photonics optical transceiver) configured to source or receive power, as described in U.S. patent application Ser. No. 15/707,976 (“Power Delivery Through an Optical System”, filed Sep. 18, 2017), incorporated herein by reference in its entirety. The transceiver modules operate as an engine that bidirectionally converts optical signals to electrical signals or in general as an interface to the network element copper wire or optical fiber. In one or more embodiments, the optical transceiver may be a pluggable transceiver module in any form factor (e.g., SFP (Small Form-Factor Pluggable), QSFP (Quad Small Form-Factor Pluggable), CFP (C Form-Factor Pluggable), and the like), and may support data rates up to 400 Gbps, for example. Hosts for these pluggable optical modules include line cards on the central hub 10 or network devices 12. The host may include a printed circuit board (PCB) and electronic components and circuits operable to interface telecommunications lines in a telecommunications network. The host may be configured to perform one or more operations and receive any number or type of pluggable transceiver modules configured for transmitting and receiving signals.
The optical transceiver may also be configured for operation with AOC (Active Optical Cable) and form factors used in UWB (Ultra-Wideband) applications, including for example, Ultra HDMI (High-Definition Multimedia Interface), serial high bandwidth cables (e.g., thunderbolt), and other form factors. Also, it may be noted that the optical transceivers may be configured for operation in point-to-multipoint or multipoint-to-point topology. For example, QFSP may breakout to SFP+. One or more embodiments may be configured to allow for load shifting.
In one embodiment, one or more network devices may comprise dual-role power ports that may be selectively configurable to operate as a PSE (Power Source Equipment) port to provide power to a connected device or as a PD (Powered Device) port to sink power from the connected device, and enable the reversal of energy flow under system control, as described in U.S. Pat. No. 9,531,551 (“Dynamically Configurable Power-Over-Ethernet Apparatus and Method”, issued Dec. 27, 2016), for example. The dual-role power ports may be PoE or PoE+F ports, for example, enabling them to negotiate their selection of, for example, either PoE or higher power POE+F in order to match the configurations of the ports on line cards 16 with the corresponding ports on each remote network device 12.
In addition to the remote communications devices 12 configured to receive power, data, and cooling from the central hub 10, the network may also include one or more network devices comprising conventional network devices that only process and transmit data. These network devices receive electrical power from a local power source such as a wall outlet. Similarly, one or more network devices may eliminate the data interface, and only interconnect power (e.g., moving data interconnection to wireless networks). Also, one or more devices may be configured to receive only power and data, or only power and cooling, for example.
In one embodiment, each heat sink or heat exchanger at the remote device 12 (shown in
The cable's jacket may include two small sense conductors for use in identifying a leak in the cooling system. If a coolant tube develops a leak, the coolant within the jacket causes a signal to be passed between these conductors, and a device such as a TDR (Time-Domain Reflectometer) at the central hub 10a, 10b may be used to locate the exact position of the cable fault, thereby facilitating repair.
In one or more embodiments, the central hubs 10a, 10b may provide additional power, bandwidth, or cooling as needed in the network. Both circuits 14a, 14b may be used simultaneously to provide power to an equipment power circuit to provide higher power capabilities. Similarly, redundant data fibers may provide higher network bandwidth, and redundant coolant loops may provide higher cooling capacity. The control systems (described below) manage failures and revert the data, power, and cooling to lower levels if necessary. In another example, redundant central hubs 10a, 10b may form a dual-star topology.
It is to be understood that the network devices and topologies shown in
In the example shown in
In one or more embodiments, various sensors 28a monitor aggregate and individual branch coolant temperatures, pressures, and flow rate quantities at strategic points around the loop. Other sensors 28b monitor the current and voltage of the power delivery system at either end of power conductors 36. One or more valves may be used to control the amount of cooling delivered to the remote device 12 based upon its instantaneous needs, as described below. The coolant may comprise, for example, water, antifreeze, liquid or gaseous refrigerants, or mixed-phase coolants (partially changing from liquid to gas along the loop).
The central hub 10 maintains a source of low-temperature coolant that is sent through distribution plumbing (such as a manifold), through the connector 39a, and down cable's 14 coolant supply line 38a to the remote device 12. The connector 39b on the remote device 12 is coupled to the cable 14, and the supply coolant is routed through elements inside the device such as heat sinks 35 and heat exchangers that remove heat (described further below with respect to
In an alternate embodiment, only a single coolant tube is provided within the cable 14, and high pressure air (e.g., supplied by a central compressor with an intercooler) is used as the coolant. When the air enters the remote device 12, it is allowed to expand and/or impinge directly on heat dissipating elements inside the device. Cooling may be accomplished by forced convection via the mass flow of the air and additional temperature reduction may be provided via a Joule-Thomson effect as the high pressure air expands to atmospheric pressure. Once the air has completed its cooling tasks, it can be exhausted to the atmosphere outside the remote device 12 via a series of check valves and mufflers (not shown).
In cold environments the coolant may be supplied above ambient temperature to warm the remote device 12. This can be valuable where remote devices 12 are located in cold climates or in cold parts of industrial plants, and the devices have cold-sensitive components such as optics or disk drives. This may be more energy efficient than providing electric heaters at each device, as is used in conventional systems.
The cooling loops from all of the remote devices 12 may be isolated from one another or be intermixed through a manifold and a large central heat exchanger for overall system thermal efficiency. The central hub 10 may also include one or more support systems to filter the coolant, supply fresh coolant, adjust anti-corrosion chemicals, bleed air from the loops, or fill and drain loops as needed for installation and maintenance of cables 14 and remote devices 12.
The connectors 39a and 39b at the central hub 10 and remote device 12 are configured to mate with the cable 14 for transmitting and receiving power, data, and cooling. In one embodiment, the connectors 39a, 39b carry power, fiber, and coolant in the same connector body. The connectors 39a, 39b are preferably configured to mate and de-mate (couple, uncouple) easily by hand or robotic manipulator.
In order to prevent coolant leakage when the cable 14 is uncoupled from the central hub 10 or remote device 12, the coolant lines 38a, 38b and connectors 39a, 39b preferably include valves (not shown) that automatically shut off flow into and out of the cable, and into and out of the device or hub. In one or more embodiments, the connector 39a, 39b may be configured to allow connection sequencing and feedback to occur. For example, electrical connections may not be made until a verified sealed coolant loop is established. The cable connectors 39a, 39b may also include visual or tactile evidence of whether a line is pressurized, thereby reducing the possibility of user installation or maintenance errors.
In one or more embodiments, a distributed control system comprising components located on the central hub's controller and on the remote device's processor may communicate over the fiber links 37 in the combined cable 14. The sensors 28a at the central hub 10 and remote device 12 may be used in the control system to monitor temperature, pressure, or flow. Servo valves or variable speed pumps 29 may be used to insure the rate of coolant flow matches requirements of the remote thermal load. As previously described, temperature, pressure, and flow sensors 28a may be used to measure coolant characteristics at multiple stages of the cooling loop (e.g., at the inlet of the central hub 10 and inlet of the remote device 12) and a subset of these sensors may also be strategically placed at outlets and intermediate points. The remote device 12 may include, for example, temperature sensors to monitor die temperatures of critical semiconductors, temperatures of critical components (e.g., optical modules, disk drives), or the air temperature inside a device's sealed enclosure. The control system may monitor the remote device's internal temperatures and adjust the coolant flow to maintain a set point temperature. This feedback system insures the correct coolant flow is always present. Too much coolant flow will waste energy, while too little coolant flow will cause critical components in the remote device 12 to overheat.
Machine learning may also be used within the control system to compensate for the potentially long response times between when coolant flow rates change and the remote device's temperatures react to the change. The output of a control algorithm may be used to adjust the pumps 29 to move the correct volume of coolant to the device 12, and may also be used to adjust valves within the remote device to direct different portions of the coolant to different internal heat sinks to properly balance the use of coolant among a plurality of thermal loads.
The control system may also include one or more safety features. For example, the control system may instantly stop the coolant flow and begin a purge cycle if the coolant flow leaving the central hub 10 does not closely match the flow received at the remote devices 12, which may indicate a leak in the system. The control system may also shut down a remote device if an internal temperature exceeds a predetermined high limit or open relief valves if pressure limits in the coolant loop are exceeded. The system may also predictively detect problems in the cooling system such as a pressure rise caused by a kink in the cable 14, reduction in thermal transfer caused by corrosion of heat sinks 35, or impending bearing failures in pump 29, before they become serious.
All three utilities (power, data, cooling) provided by the combined cable 14 may interact with the control system to keep the system safe and efficient. For example, sensors 28b may be located in the power distribution module 30 of the central hub and power supply 33 of the remote device 12. Initial system modeling and characterization may be used to provide expected power, flow properties, and thermal performance operating envelopes, which may provide an initial configuration for new devices and a reference for setting system warning and shut-down limits. This initial characteristic envelope may be improved and fine-tuned over time heuristically through machine learning and other techniques. If the system detects additional power flow in power conductors 36 (e.g., due to a sudden load increase in CPU in remote device 12), the control system may proactively increase coolant flow in anticipation of an impending increase in heat sink 35 temperature, even before the temperature sensors register it. This interlock between the various sensors and control systems helps to improve the overall responsivity and stability of the complete system.
The network device 40 may include any number of processors 42 (e.g., single or multi-processor computing device or system), which may communicate with a forwarding engine or packet forwarder operable to process a packet or packet header. The processor 42 may receive instructions from a software application or module, which causes the processor to perform functions of one or more embodiments described herein. The processor 42 may also operate one or more components of the control system 43. The control system (controller) 43 may comprise components (modules, code, software, logic) located at the central hub 10 and remote device 12, and interconnected through the combined cable 14 (
Memory 44 may be a volatile memory or non-volatile storage, which stores various applications, operating systems, modules, and data for execution and use by the processor 42. For example, components of the optical module 48, control logic for cooling components 45, or other parts of the control system 43 (e.g., code, logic, or firmware, etc.) may be stored in the memory 44. The network device 40 may include any number of memory components.
Logic may be encoded in one or more tangible media for execution by the processor 42. For example, the processor 42 may execute codes stored in a computer-readable medium such as memory 44. The computer-readable medium may be, for example, electronic (e.g., RAM (random access memory), ROM (read-only memory), EPROM (erasable programmable read-only memory)), magnetic, optical (e.g., CD, DVD), electromagnetic, semiconductor technology, or any other suitable medium. In one example, the computer-readable medium comprises a non-transitory computer-readable medium. Logic may be used to perform one or more functions described below with respect to the flowchart of
The interfaces 46 may comprise any number of interfaces (e.g., power, data, and fluid connectors, line cards, ports, combined connectors 39a, 39b for connecting to cable 14 in
The optical module 48 may comprise hardware or software for use in power detection, power monitor and control, or power enable/disable, as described below. The optical module 48 may further comprise one or more of the processor or memory components, or interface for receiving power and optical data from the cable at a fiber connector, for delivering power and signal data to the network device, or transmitting control signals to the power source, for example. Power may be supplied to the optical module by the power supply 47 and the optical module (e.g., PoE+F optical module) 48 may provide power to the rest of the components at the network device 40.
It is to be understood that the network device 40 shown in
The power detection module 52 may detect power, energize the optical components 51, and return a status message to the power source. A return message may be provided via state changes on the power wires or over the optical channel. In one embodiment, the power is not enabled by the power enable/disable module 54 until the optical transceiver and the source have determined that the device is properly connected and the network device to be powered is ready to be powered. In one embodiment, the device 50 is configured to calculate available power and prevent the cabling system from being energized when it should not be powered (e.g., during cooling failure). The power detection module 52 may also be operable to detect the type of power applied to the device 50, determine if PoE or pulsed power is a more efficient power delivery method, and then use the selected power delivery mode once the power is enabled. Additional modes may support other power+data standards (e.g., USB (Universal Serial Bus)).
The power monitor and control device 53 continuously monitors power delivery to ensure that the system can support the needed power delivery, and no safety limits (voltage, current) are exceeded. The power monitor and control device 53 may also monitor optical signaling and disable power if there is a lack of optical transitions or communication with the power source. Temperature, pressure, or flow sensors 57, 60 may also provide input to the power monitor and control module 53 so that power may be disabled if the temperature at the device 50 exceeds a specified limit.
Cooling is supplied to the device 50 via cooling (coolant) tubes in a cooling (coolant) loop 58, which provides cooling to the powered equipment through a cooling tap (heat sink, heat exchanger) 56, 59 and returns warm (hot) coolant to the central hub. The network device 50 may also include a number of components for use in managing the cooling. The cooling loop 58 within the network device 50 may include any number of sensors 57, 60 for monitoring aggregate and individual branch temperature, pressure, and flow rate at strategic points around the loop (e.g., entering and leaving the device, at critical component locations). The sensor 57 may be used, for example, to check that the remote device 50 receives approximately the same amount of coolant as supplied by the central hub to help detect leaks or blockage in the cable, and confirm that the temperature and pressure are within specified limits.
Distribution plumbing routes the coolant in the cooling loop 58 to various thermal control elements within the network device 50 to actively regulate cooling through the individual flow paths. For example, a distribution manifold 55 may be included in the network device 50 to route the coolant to the cooling tap 56 and heat exchanger 59. If the manifold has multiple outputs, each may be equipped with a valve 62 (manual or servo controlled) to regulate the individual flow paths. Thermal control elements may include liquid cooled heatsinks, heat pipes, or other devices directly attached to the hottest components (CPUs (Central Processing Units), GPUs (Graphic Processing Units), power supplies, optical components, etc.) to directly remove their heat. The network device 50 may also include channels in cold plates or in walls of the device's enclosure to cool anything they contact. Air to liquid heat exchangers, which may be augmented by a small internal fan, may be provided to cool the air inside a sealed box. Once the coolant passes through these elements and removes the device's heat, it may pass through additional temperature, pressure, or flow sensors, through another manifold, and out to the coolant return tube. In the example shown in
The distribution manifold 55 may comprise any number of individual manifolds (e.g., supply and return manifolds) to provide any number of cooling branches directed to one or more components within the network device 50. Also, the cooling loop 58 may include any number of pumps 61 or valves 62 to control flow in each branch of the cooling loop. This flow may be set by an active feedback loop that senses the temperature of a critical thermal load (e.g., die temperature of a high power semiconductor), and continuously adjusts the flow in the loop that serves the heat sink or heat exchanger 59. The pump 61 and valve 62 may be controlled by the control system and operate based on control logic received from the central hub in response to monitoring at the network device 50.
It is to be understood that the network device 50 shown in
In the examples shown in
The components may have various cross-sectional shapes and arrangements, as shown in
The cable may be configured to prevent heat loss through supply-return tube-tube conduction, external environment conduction, coolant tube-power wire conduction, or any combination of these or other conditions, as described below.
Over a long cable, a type of unwelcome counter flow heat exchange may be created as the coolant supply tube receives heat via internal conduction in the cable from the hotter coolant return tube, which tends to equalize the two temperatures along the length of the cable (referred to as supply-return tube-tube conduction). For example, the supply coolant may be so preheated by the return coolant flowing in the opposite direction that it is much less effective in cooling the remote device. In one embodiment, a thermal isolation material 69 located between the two coolant tubes 67 may be used to prevent undesirable heat conduction, as shown in
External cable temperatures may influence thermal energy flow into and out of the cable, potentially reducing system cooling effectiveness. Placement of the thermal isolator material 69 between the coolant tubes and the outer jacket 64 as shown in
A third mode of heat transfer that may be controlled by the design of the cable is between the power conductors and the coolant tubes. The cross-sectional size of the power conductors is preferably minimized to reduce volume, weight, and cost of copper and improve flexibility of the cable. However, smaller conductors have higher resistance, and I2R losses will heat the length of the cable (potentially hundreds of Watts in systems that deliver kilowatt levels of power over multi-kilometer distances). By providing thermally conductive paths inside the cable between the power conductors 66 and coolant tube 67, as depicted by regions 71 in
In one or more embodiments, in order to reduce fluid frictional effects, tube interiors may be treated with hydrophobic coatings and the coolant may include surfactants. Also, the supply and return coolant tubes 67 may be composed of materials having different conductive properties so that the complete cable assembly may be thermally tuned to enhance system performance.
It is to be understood that the configuration, arrangement, and number and size of power wires, fibers, coolant tubes, and insulation regions, shields, coatings, or layers shown in
It is to be understood that the process shown in
Although the method and apparatus have been described in accordance with the embodiments shown, one of ordinary skill in the art will readily recognize that there could be variations made to the embodiments without departing from the scope of the embodiments. Accordingly, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
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