On June 4, DEKRA iST was invited to participate in the “Smart eMobility Taipei”organized by EETimes at the HNBK International Convention Center. WangChu Chen, Director of High Power Engineering Department, delivered a talk titled “New Insight for AI Technology - Leverage Automotive Experience to Reinforce Reliability of Liquid Cooling Solution” He highlighted the rising importance of reliability engineering, explored cutting-edge trends in liquid cooling solutions, and shared how lessons can be applied to help clients stay ahead of the novel challenges brought by AI technologies.
“Why do we focus on reliability?” WangChu Chen opened his talk with this key question, he emphasized that reliability validation goes far beyond ensuring product quality; it's a critical factor in product mission profile, cost control, risk management, and overall market competitiveness. Most importantly, he stressed that the true core value of reliability lies in earning client trust and building brand credibility.
Evolution of liquid cooling technology
Liquid cooling technology can be dated back to the 1920s, when it was first used in automotive engine cooling systems. DEKRA iST began providing validation and testing services for liquid cooling products in Kunshan of mainland China as early as 2012. In 2018, the company launched a dedicated liquid cooling validation program in Hsinchu Taiwan, building over a decade of hands-on experience in ensuring the reliability validation of liquid cooling solutions.
The turning point that truly pushed liquid cooling technology into the industry spotlight came in 2023, when NVIDIA’s breakthrough in AI server performance drove a major leap in computing capabilities. As TDP (Thermal Design Power) levels surged, traditional air cooling solutions tended to fall short in managing high-density heat sources. In response, liquid cooling, known for its superior heat exchange efficiency and stability, quickly emerged as the go-to thermal solution for AI servers and data centers.
Inside liquid cooling system of AI server
With years of practical experience, DEKRA iST supports clients from the product design phase by integrating reliability assessment and validation testing for key parts and components in their liquid cooling systems. This ensures greater stability across the entire cooling setup. Below are the common categories of parts and component:
- Cold Plate：Positioned at the front line of the thermal module, it directly transfers heat away from the chip。
- Liquid Cooling Module,LCM：It functions like a closed-loop automotive system, and includes circulating coolant through internal channels to dissipate heat.
- Ultra Quick Disconnect,UQD：It is a connector designed for fast assembly or dissembly, widely used in AI server.
- Manifold：It includes the building manifold and in-rack manifold. Together with hose kits, they connect to CDU/ RPU, completing the full cooling circuit.
In the automotive industry, reliability validation has always been held to the strictest standards. WangChu Chen shared examples from the automotive standard VW80000 M-07 adopted by Volkswagen, which outlines several key tests:
- Pressure Cycling Test: Simulating 100,000 on-off cycles to evaluate reliability and predict system lifespan.
- Overpressure Test: Assessing the system capacity for surge resistance.
- Negative Pressure Test: Simulating vacuum conditions to check for structural deformation.
Another critical challenge is the “water hammer test”, which occurs when a valve shuts rapidly, creating a pressure surge. This test evaluates the resistance of pipeline and connectors against rupture. To meet these challenges, DEKRA iST has developed a high-pressure shock simulation system based on client needs. This system helps identify structural weaknesses in components like Y cables, offering strong support for AI clients looking to validate reliability under high-intensity operating scenarios.
Once pressure testing is complete, the next step is to verify whether any part or component, particularly the cold plate, has undergone deformation. Even subtle surface deformation can compromise the overall cooling efficiency. DEKRA iST currently employs two non-destructive analysis techniques:
- CMM(Coordinate Measuring Machine)It provides 3D flatness measurement to detect any warpage or deviations from planarity caused by pressure.
- X-ray：It enables examination of Ultra Quick Disconnect (UQD) assemblies, ensuring secure locking to prevent potential leaks or rupture.
WangChu Chen put a special focus on the UQD as a critical node within the entire liquid cooling system. One key parameter is the Cv value, which quantifies the relationship between pressure and flow rate, and that essentially determines how efficiently fluid passes through the connector. Given the stringent demand for performance from clients, DEKRA iST has developed a comprehensive testing framework to ensure that products are aligned with both real-world application requirements and quality standards.
Conclusion
Starting with liquid cooling validation for electric vehicles, DEKRA iST has steadily expanded its expertise to cover emerging automotive applications such as ADAS, autonomous driving systems, and charging infrastructure. As liquid cooling becomes increasingly popularized in managing the intense thermal load of AI servers, DEKRA iST has built a comprehensive set of testing methodologies and validation capabilities. (Read more: Liquid Cooling Total Solution for AI Server Applications)
In an era defined by high power consumption and high thermal loads, DEKRA iST stands ready with expert consulting and extensive validation capacity. True to its mission of “Problem Solved”, the company is committed to joining hand with clients to address the heat challenges of the AI age.
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