Design of a cooling system of an electric Formula Student car
Tutor / director / evaluatorGuardo Zabaleta, Alfredo de Jesús
Document typeBachelor thesis
Rights accessOpen Access
The incorporation of an in-wheel motor system to the powertrain of a Formula Student car requires an important previous study for its posterior application. Despite the great advantages that it offers at a dynamical level, the fact of keeping the whole powertrain system at an optimal temperature range is a challenge tackled in this project, being the principal objective to define an adequate liquid cooling system. This is composed by the inverter’s heat exchanger – the electronic device which dissipates more heat inside the vehicle -, another heat exchanger for the motor – called cooling block -, a radiator capable of evacuating all this energy and a water pump capable of providing the needed mass flow rate to the system. In order to do that, it is carried out an analytical study, a numerical and an experimental one. Furthermore, it is proposed 3D printed nylon as the principal material for the motor cooling block, aiming to facilitate the manufacturing process and to dramatically reduce its weight. However, it is concluded that the designed system is unviable for that application due to the high temperatures reached in the motor due to the low thermal conductivity of the nylon.