OCP ORv3 Blind Mate Liquid Cooling Component Update

Author: Nick Goenner, Engineering Manager, SafeWay Custom Fluid Transfer (The Specialty Manufacturing Company); Chris SC Lee, Mechanical Engineer, Wiwynn Collection: 2023 Global Summit - Cooling Environments

Summary

Nick Goenner (SafeWay, engineering manager) and Chris SC Lee (Wiwynn, mechanical engineer) present the component-level update for the OCP ORv3 Blind Mate Liquid Cooling project — the companion presentation to the system-level overview by Meta. This presentation covers the valve design iterations, flow performance testing results, manifold updates, chassis mechanism updates, and leak testing approach.

The primary engineering challenge throughout 2023 was reducing mate and demate forces and binding observed in prior rounds of testing while simultaneously standardizing flow performance across all four quick coupling supplier combinations. The team resolved this through a structured brainstorming process: each supplier independently developed proof-of-concept solutions, tested them, and reported back; the group selected leading concepts; all suppliers implemented those concepts; the result was a single unified design that cut peak mate forces by more than 50% compared to the previous revision. The key enabler was increased mechanical leverage on the plug side, allowing the plug to overcome the hose forces acting on it, combined with improved pre-alignment geometry that smoothed out the connection stroke.

128 flow performance data points were collected at the critical flow rate; all but 5 fell within the specified range, and those 5 were attributed to measurement uncertainty. Spillage was found to be in line with similar designs but requires further study — test pressure was identified as having a significant effect on measured spillage volume. A new build was completed in September 2023 to address remaining issues (centering reliability, a few force boundary violations, spillage consistency); that build was just starting testing at the time of the talk. Environmental and transportation testing (temperature/humidity cycling, corrosion resistance, packaging vibration, extreme temperatures) was being added for the first time.

Chris SC Lee covers manifold updates (structural changes to the M interface, top/bottom connection flexibility, hose connection options including OCP LQD), chassis mechanism updates (QC mount location optimized for force and binding, injector mechanical advantage improved, spring-latch hold-open feature added to prevent interference with rack frame during servicing), and a leak test concept using pressure gauge, dummy manifold with QC circuit, and a two-loop verification scheme (bypass loop for plug-to-tubing connections; corporate loop for plug-to-manifold-to-cold-plate).