Clean manifold assembly made to measure

Engineering, sourcing and assembly of a UHP cooling distribution system

VDL Klima and Teesing have worked together for many years, including on components for liquid based temperature controlling systems. This involved design, assembly and delivery. This story is about how in that collaboration you sometimes take a trip: the starting point is the first idea and together you eventually arrive at a modified design.

This project started with a simple request for hose for a UHP cooling system. We know a lot about liquid cooling systems, so when we get a request like this we keep asking. We always look at the specific application with the mechanical, thermal and chemical requirements.

Co-engineering with customer

VDL klima engineers had devised a solution for a cooling unit for an optical system based on PFA hoses and couplings. Because the available space was very limited this turned out not to be a practical feasible solution.
With that challenge as the starting point, a process began in which VDL and Teesing jointly designed the solution.

Galvanic corrosion

A typical problem in cooling systems is galvanic corrosion. And more specifically the corrosion between the metals aluminum and stainless steel. Stainless steel is often used because of cleanliness requirements and chemical resistance. Aluminum is exceptionally good at transferring heat energy and is usually a part of the primary heat transfer system. Energy is transferred from electronics or optics to the cooling medium. But because the combination of aluminum and stainless steel is just about the worst possible combination in terms of galvanic corrosion, there can be no direct contact. This is usually solved by plastic hoses. There are aluminum alloys that have less of a problem, but these have other disadvantages, such as limited machining possibilities. Therefore, the use of insulating materials remains inevitable.

Synthetic couplings in PVDF?

In a case like this we always investigate the possibility of using plastic couplings. For example, from PFA or from PVDF. But for this lens cooler in a machine with many moving parts, vibrations were the reason why plastic would not be strong enough.

PVDF can be an excellent solution, which we often recommend. But if mechanical reliability is a requirement, then aluminum is superior. Tests have been done where 100 PVDF couplings were tested simultaneously. In the process, 1 clutch was rotated when assembled (according to regulations, of course). So what should work in theory turns out to be different in practice.

If you are going for the maximum achievable, then a aluminium coupling is preferred anyway, but made from that hard-to-machine alloy. It took until 2018 for a manufacturer to rise to the challenge. Serto has been supplying couplings for about 30 years and has a very nice system of radial mounting, which means couplings take up less space and can be dismounted without taking the piping loose. They use a metal crimp ring which allows the coupling to be mounted multiple times and can be used on either pipe or hose (using a support sleeve in the hose).

Cleanroom assembly lens cooling production manifolds

Photo: manufactured manifolds are ready for assembly with hoses.

Set of manifolds with hoses cooling water application cleanroom

Photo: for optimal thermal properties, a set of 4 manifolds was chosen.

Productie verdeelblok assemblages cleanroom

Photo: hoses are ready for assembly. They are pre-assembled with Serto aluminum couplings.

Application specific manifold in stainless steel proved better

The engineering team soon abandoned the idea of loose couplings because that is sensitive to mechanical interference in a high-vibration environment. They switched to a manifold block, which was also the most complicated part of this assembly. The consequence of the very limited space is that the heat distribution in the manifold causes small temperature differences. In the end, the engineers decided on 2 separate distribution blocks so that the heat would not be transferred. In this application with little space, the couplings also had to be small. Because the parts to which the manifold was connected were stainless steel, the manifold and the couplings had to be stainless steel as well.
Serto's standard stainless steel couplers are already very compact and can be mounted radially, which is ideal in situations with limited space. But for this particular case they were not yet compact enough, so Serto was involved in the project to produce couplings specifically for this application.

From the manifold, we went through hoses to aluminum couplers that are screwed into the aluminum cooling element. Thus, no different metals come into contact and for galvanic corrosion the best starting point has been created.

The process of co-engineering

After initial exploratory discussions, a project team was formed from both companies, which discussed progress on a regular basis. The engineering issues led to custom made manifolds and the request to Serto to supply a special design coupling.

After our 3D drawings were fitted into the 3D drawings of the machine and the expectation arose that the design would not cause any assembly and fitting problems, we produced and delivered a prototype.

After the prototype, we moved on to the final design, where the flow restrictors that we had included in the prototype in the support sleeve of the connector on the manifold, have now become part of the manifold itself.

The process of co-engineering is something that Teesing feels very comfortable with. With final responsibility for a subsystem and as central director of engineering - mechanical production - suppliers - customer - cleanroom assembly.

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