Written By Connor Harvey
Track Day 5th of May 2023
We are relentless in our pursuit of engineering excellence. In our quest to optimise our racing car’s performance, we recognise the critical role played by the cooling system. With that in mind, we embarked on an exhilarating day of radiator testing.
Our journey began by establishing a baseline. We fired up Annie, our 2022 FSAE EV, with an unobstructed radiator, allowing it to operate without any modifications. This initial run provided us with a benchmark to compare against as we explored different radiator configurations.
Armed with curiosity and a roll of tape, we set out to investigate the impact of radiator size on cooling efficiency. We started by taping the radiators to half their original size. To our surprise, the temperature remained within an acceptable range, consistently below our maximum limit of 55 degrees. Encouraged by this result, we pushed further, taping the radiators down to a quarter of their original size. This reduction in surface area allowed us to gather valuable data and insights into the performance of significantly smaller radiators.
Throughout the testing process, we closely monitored the temperature changes. It was crucial to ensure that the engine remained within safe operating limits. We discovered that while the quarter-sized radiator showed promise, it fell slightly short of meeting our car’s cooling requirements. Furthermore, we conducted an extreme test where we fully taped one radiator, rendering it completely ineffective. As expected, the temperature began to climb steadily. This experiment reinforced the critical importance of an efficiently functioning cooling system to prevent overheating and protect vital components. Our motor controllers began derating at the temperature threshold of 55 degrees, further emphasizing the need for optimal cooling to ensure consistent performance.
Analysing the comprehensive data collected throughout our testing, we gained valuable insights that would guide our future decisions. We concluded that the quarter-sized radiator was slightly too small for our car’s cooling needs. Additionally, the test with no radiator at all highlighted the severe consequences of inadequate cooling. Armed with this knowledge, we embarked on our next steps towards optimization.
Looking ahead, we recognised the need for further testing under demanding conditions. To simulate the rigorous and everchaing environment of the FSAE-A competition, we planned to run another track day in warmer temperatures. This would provide us with valuable insights into the performance of our cooling system under extreme heat. By continually fine-tuning our approach, we aimed to achieve optimal cooling performance, ensuring peak efficiency and reliability on the race track.
In conclusion, the radiator testing adventures opened new doors of understanding in our cooling performance. Armed with valuable insights, we remain committed to continuous improvement, eagerly anticipating further testing under challenging conditions.
We would like to thank our friends at Sydney Motorsport Park and the Australian Racing Drivers’ Club, as well as the University of Wollongong for their continued support of the team.
