A Guide to Using Liquid-Cooled Power Solutions for Military Systems

When technology operates, it generates significant heat. Modern technologies, such as artificial intelligence (AI) and advanced graphics processing units (GPUs) have higher heat densities than their previous iterations, putting them and their corresponding systems at a higher risk of overheating during normal operations. Efficient cooling systems are critical for maintaining high function for sufficient periods.

Liquid-cooled power solutions offer significant advantages for various military applications. This guide will explain the basic information any defense contractor should know before investing in a power supply unit (PSU).

Common Power and Cooling Challenges in Military Systems

Military operations often face significant challenges in providing continuous and reliable power to energy-intensive applications. Those challenges include:

Harsh Environmental Conditions

Field deployments and training operations often take place in harsh environments, where exposure to extreme temperatures, chemical damage and physical stressors are common. Standard, consumer-grade power supplies with air cooling systems are often insufficient to maintain safe operating temperatures and remain functional in these challenging environments. 

Rugged Use Cases

Military power supplies are often subject to intense vibrational forces, harsh chemicals and other environmental factors that can damage their performance. Rugged systems developed specifically for harsh environments must follow stringent military guidelines to ensure proper function in any application.

High Power Density Requirements

Military operations require dense power supplies that can fit more capacity into a small footprint, especially with the rise of energy-intensive technologies like AI. Conventional air-cooled power supplies must include fans and other elements that increase their size, which makes them unsuitable for use in environments where smaller is better.

Reliability and Uptime

Reliable thermal management is critical for maintaining the high performance and reliability of electronic components — especially for applications operating at the edge of computer networks.  

Power must be readily available to ensure continuity in military operations, such as an Army Forward Operating Base (FOB) that must spend a large portion of its available power on cooling electronic components. Systems that can convert heat into usable power, such as liquid cooling technologies, are essential for maximizing uptime.

Benefits of Liquid Cooling Technology for Military Power Systems

Some of the most significant advantages of liquid-cooled power systems over air-cooled units include:

• Improved reliability: Liquid-cooled power supplies are more reliable at efficiently converting heat energy into energy for your application, especially if you need an uninterrupted supply.
• Superior heat transfer efficiency: Water and synthetic coolants conduct heat better than air, which makes them more efficient at moving excess heat away from its source.
• Higher power density: Liquid cooling technology packs more power-generating capacity into one unit without increasing the risk of overheating, saving valuable space in military settings.
• Quieter operation: Because liquid cooling systems do not require fans, they produce significantly less noise even when performing at high levels.
• Resistance to shock and vibration: Power supplies in military vehicles must be able to withstand high shock and vibration to operate continuously under harsh conditions.
• Longer system life: An efficient power supply extends the operating life of the attached device or equipment, which enables users to reduce downtime and increase productivity.
• Sealed system: Unlike air cooling, liquid cooling is a completely closed system that seals out external contaminants like dust and corrosive chemicals. This construction reduces the risk of system damage and improves reliability and uptime.

It's important to note that air-cooled systems are better for certain applications, such as those where the power supply is isolated from ambient air movement.

An Overview of Liquid Cooling Technology

Understanding how liquid cooling works in military applications is essential for designing systems that meet your specific requirements.

Liquid-cooled power supplies use thermally conductive fluid to pull heat from a heated component, such as a computer chip. This fluid, which can be made of water or synthetic coolants, transports the heat via heat exchanger to an area where it can be properly dissipated into the surrounding environment. In military applications, this type of cooling is beneficial for challenging operations in especially harsh environments because it is in a closed system that blocks out contaminants. 

Types of Liquid Cooling

There are three types of liquid cooling that your system might use:

1. Liquid cold plate (LCP): Coolant flows through channels in the plate, which attaches directly to the hot component. The flowing liquid absorbs the heat and transfers it to the cooling system, keeping the component at a stable temperature. 
2. Immersion: Also called liquid submersion cooling, immersion cooling works by submerging electrical components in a thermally conductive dielectric liquid such as deionized water or mineral oil. This process transfers heat away from the source through direct contact with the coolant, eliminating the need for bulky fans.
3. Heat exchangers: A heat exchanger transfers heat between two or more fluids in a liquid cooling system to lower the power source's temperature. The fluids can be in direct contact with each other or separated depending on the system's design.

The specific type your PSU uses must be compatible with your unit as well as its outer casing and other components.

5 Military Applications of Liquid Cooling Technology

Some of the most notable military use cases for liquid-cooled power systems include:

1. Vehicle and shipboard systems: Naval vessels and ground vehicles, such as tanks and armored personnel carriers, use liquid-cooled PSUs to power onboard electronics, navigation equipment and weapon systems. The unit's compact footprint enables it to fit easily into these vehicles, even when the design is highly complex.
2. Radar and communications: High-powered radar and satellite communication equipment generate significant heat and must often operate in harsh environments. Liquid cooling helps power supplies for these technologies withstand extreme temperatures and provide consistent power. 
3. Directed energy weapons (DEWs): DEWs use concentrated beams of electromagnetic, atomic or subatomic energy to damage or destroy targets. These weapons require massive amounts of power to produce their beams and can easily overheat, which is why liquid-cooled power supplies are an ideal fit.
4. Autonomous systems: Unmanned systems like drones and robots typically have a limited space and weight capacity, making air-cooled units an unsuitable option. Liquid-cooled power supplies are compact and lightweight, providing continuous power to these systems for long periods.
5. High-performance embedded computing: Energy-intensive computing applications, such as radar processing and AI-enhanced image recognition, generate massive amounts of heat. Installing liquid-cooled power supplies in military data infrastructure can prevent overheating and protect valuable assets from being lost.
   

   Choose High-Quality Liquid Cooling Solutions for Military Systems From Astrodyne TDI

   While air cooling can be beneficial in certain applications, liquid cooling is often the more appropriate choice for military systems. Defense contractors and subcontractors looking for high-quality liquid-cooled power supplies can find what they need from Astrodyne TDI.

   We have more than 60 years of experience developing intricate power solutions for mission-critical military applications, and our equipment meets even the most stringent military standards (MIL-STD). Whether you need a COTS component or a custom power system, our team can help you find the solution that works best for your application.

   Contact us today to discuss your project's specific thermal management requirements or to request a quote.