Cleaning System for Danfoss Cool Train ™

Development of an innovative system for ensuring the technical cleanliness of components for data center cooling. The Laboratory for Fluid Power and Controls, in collaboration with Danfoss, developed a research methodology, a dedicated cleaning system, and a validation procedure to ensure the required level of technical cleanliness of CoolTrain™ products. 

 

The Challenge

The CoolTrain™ system uses liquid cooling for data centers, where even very small particles can clog cooling channels and reduce system reliability. The required level of cleanliness was defined according to the ISO 4406 standard, for which the company had no established procedure or dedicated equipment. 

From Challenge to Solution

Development Process

1. Requirements Analysis: Determining the required cleanliness level, analyzing the ISO 4406 and ISO 4407 standards, and identifying key influencing parameters.

 

2.Test Rig Development: Development and construction of an innovative device for cleaning and measuring the cleanliness of CoolTrain™ pipe assemblies of various lengths.

 

3. Numerical Simulations:1D simulations of the hydraulic circuit were performed to verify flow rates, pressure losses, and system operation.

 

4. Development of Measurement Methodology: A procedure for sampling, filtration, and particle analysis was developed to determine the cleanliness level in accordance with the standards.

 

 

5. Results Validation: Filter analysis, particle microscopy, automatic particle counting, and determination of fluid and component cleanliness.

6.Industrial Implementation: Based on the working prototype (pictured) and the developed procedures, an automated production line was established for industrial manufacturing.

 

What We Developed

🧪 Cleanliness Analysis Methodology

Measurements according to the ISO 4406 and ISO 4407 standards.

⚙️ Dedicated Cleaning System

Development and construction of the experimental system.

💻 Simulation Model

 Support for system sizing and optimization.

🔬 Validation Procedure

 Reliable determination of the technical cleanliness of components.

🏭 Industrial Solution

 Basis for an automated production line.

Key Results

✅ Developed a new cleaning system.

✅ Developed a measurement methodology according to ISO standards.

✅ Validated the production process.

✅ Completed the industrial implementation.

✅ Received the TARAS award for industry collaboration.

 

The award-winning project is the result of collaboration between Danfoss and the Laboratory for Fluid Power and Controls (LFT) at the Faculty of Mechanical Engineering, University of Ljubljana, led by Assoc. Prof. Dr. Franc Majdič. The partners jointly developed solutions to ensure an exceptionally high level of cleanliness for the CoolTrain™ system, intended for next-generation liquid cooling of data centers.

 

TARAS AWARD

Added Value for the Partner

According to Danfoss, the collaboration enabled the development of a cleaning and validation procedure that was crucial for establishing production and securing an important order on the US market.

 

Technologies and Competencies

  • Fluid Power Technology
  • Technical Cleanliness of Components
  • Particle Analysis
  • Industrial Validation
  • Simulation of Hydraulic Systems
  • Development of Dedicated Devices
  • Process Automation