Defining the problem
My job as the Head of Cooling Systems was to analyze each area of the vehicle that required cooling as well as the processes and methods to achieve the desired temperature. Not only that, I had the opportunity of managing a team of 4 great engineers.
Mainly, the areas that required cooling were: electronics and powertrain. Moreover, we had the amazing task of letting our creativity flow as the Formula Student Competition is very strict with the Rules.
Not only that, also, our main job was to design the accumulator structure (with all the cooling processes) and do the accommodation inside the car.
The Solution
For the powertrain we decided to creating a liquid cooling loop, that involved: motor, pump, catch cans, and radiator. However, for the electronic components we decided to use an active cooling system by making use of fans, especially for the battery accumulator; not only that, as a heat sink within, we designed our own cooling fins to fit the shape of the batteries.
Moreover, we also had into consideration the weight distribution of the car and how this can affect greatly to the dynamics of the vehicle. Therefore we made an innovative design by creating a space in the middle so the motor could fit perfectly and, by this, we achieved an almost perfect weight distribution of the whole car.
Finally, to secure safety, the materials used for this main component were: plastic ABS, glass fiber, and rubber.
Reflection
Definitely, being in charge of people change your perspective as an engineer, you realize all the parts that are involved in the creation of a craft and you have to develop yourself in order to help your people to be better.
Without any doubt, this has been one of my biggest projects as an engineer.