As the cooling lead, my responsibility is to design and manufacture both air-cooling and water-cooling systems that effectively dissipate heat from various sources, ensuring the car operates at peak performance without overheating. Too much heat can cause multitudes of problems with the inner machinery of the car, so it’s my job to make sure these problems are prevented.

 

Electrical systems are never 100% efficient, and all the energy that is lost due to inefficiencies is lost in the form of heat. The main sources of this heat on our EV are the accumulator, motor, and motor controller. The accumulator is air-cooled, while the motor and motor controller are water cooled.

 

Both systems are designed by working backward from the constraints set by FSAE regulations and the specifications of the individual components. The motor has a defined maximum coolant temperature at its inlet, so the water-cooling system is engineered to ensure the coolant remains below this threshold. Similarly, the accumulator cells must not exceed 60°C; if any cell reaches this temperature, the car will automatically shut down. To prevent this, the air-cooling system is designed to provide sufficient airflow, keeping the cells well below the critical temperature.