Cooling Loop Layout
I redesigned and optimized the layout of the liquid cooling loop for the drivetrain system.
Drivetrain, UBC Formula Electric · 2025-10-18 – 2025-11-29
Context
We need to cool four motors (running temp ~80°C) and four inverters (max temp ~40°C). The cooling loop was previously a single series loop with three pumps. This layout was not optimal due to the large difference in required temperatures of components and the very high pressure drop (resulting in the use of three pumps).
Approach
I first collected pressure drop and flow rate data for each component in the loop using an Arduino and sensors. After analyzing the data and comparing options, I found that splitting it into two loops (inverters and motors separately), increasing the size of the tubes, and adding sections of parallel tubes was the best option. This layout would be able to satisfy the temperature requirements, significantly decrease the pressure drop, reduce the system to two pumps, and cool the motors more evenly.
Outcome
Both cooling loops ran easily at both low and high flow rates, validating the pressure drop data and calculations. We are now in the process of collecting temperature data and making small refinements to the loops.
Project Media
