The Design of Integrated Thermal Management System Aimed for Overall Monocoque Structure in FSAE Race Car

This article is focused on the potential problem of inadequate heat dissipation performance in the powertrain system of FSAE race cars which adopt an overall monocoque structure. It aims to design an integrated thermal management system with slanted dual radiators that match the aerodynamic design and incorporates an oil cooler, to achieve better thermal reliability and stability under high load conditions. During the development process, various studies were conducted to coordinate and unify the thermal management system and the side aerodynamic devices, including the correlation between different radiator layouts, geometric parameters, and heat dissipation performance, the gain in heat dissipation performance by the structural design of the side aerodynamic devices, the design and simulation of the engine thermal management system pipelines, and the performance verification of the thermal management system during engine bench tests and road tests.