Custom EV Water Cooling Circuit

Another task I got to lead while developing this electrified McLaren MP4-12C was designing an active water cooling system for a trial of new motors. The need for active water cooling was informed largely by dynamometer testing, and the primary goal of the system was to maximize the time a motor could perform at peak torque before limiting its output.

While circulating coolant, there needed to be a configurable temperature monitor to automatically toggle a cooling fan on the radiator based on the driving conditions, much like an internal combustion engine. For testing purposes, there needed to be an additional temperature display on the cold side of the circuit.

Secondary design requirements for this system involved a high level of modularity. The parts and routing schemes needed to be applicable to other projects, so most of the materials were sourced OTS from racing supply vendors. I chose to pursue sheet aluminum as the primary material for custom mounting fixtures due it's low cost and potential for rapid iteration.

Continuing to build a cohesive design language on the vehicle was also important, so the construction of these cooling system panels, down to the radii of their curves and spacing of vents, was informed by the lighting panels I had previously installed.

As usual the design started out with some preliminary sketches shown above to determine basic shapes, placement, and mounting solutions. Once the CAD was in good shape, I photoshopped some renders as a final documentations step before seeking approval to order the parts.

When all the parts were approved and ordered, assembly and installation involved a very rewarding combination of tactile metal work, hose routing, and electronics management.

The final validation of this system took place after I had left California, but it was confirmed to be circulating coolant at a suitable rate as specified by the motor manufacturer, with all the control systems functioning properly.