3D Printed Cold Plate Heat Exchanger for an Electric Race Car | The Cool Parts Show #51
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- čas přidán 16. 08. 2022
- Electrification of vehicles can bring new manufacturing challenges, as the Dynamis PRC student team at the University of Milan discovered when transitioning its Formula SAE race car from internal combustion to battery power. The inverter that converts the DC power from the battery to AC to drive the motors must be kept within a specific temperature range; to maintain this range, the electric race car incorporates a fluid-cooled heat exchanger called a cold plate. The 3D printed device produced by M4P was designed by Puntozero using nTopology software. Regular and irregular lattice structures as well as biomimicry helped reduce the size and weight of the cold plate from an earlier machined design while increasing surface area, saving energy in directing the flow of coolant, and improving cooling performance.
This episode brought to you by Carpenter Additive. www.carpenteradditive.com/
CORRECTION: Text embedded in this video has an incomplete name for our nTopology expert. His full name is Alkaios Bournias Varotsis.
LEARN MORE ABOUT:
The creation of this cold plate
ntopology.com/case-studies/co...
The Dynamis PRC student racing team at the University of Milan
www.dynamisprc.com/
Formula SAE racing competition for college students
www.fsaeonline.com/
Design firm Puntozero
www.puntozero3d.com/en/home-2/
Materials supplier and additive manufacturer M4P
www.metals4printing.com/home-en/
nTopology design software
www.additivemanufacturing.med...
What is laser powder bed fusion?
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Another episode where 3D printing reduced weight for an electric vehicle
• Generative Design Impr...
Another use of nTopology for an unconventional lattice
• What Does a Topology O...
Another cool part using shark skin-inspired features
• 3D Printing for Better...
Our Shark Week coverage of ongoing biomimicry research and applications
• 3D Printing Is Enablin...
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you say electric cars im thinking pc cooling
This approach is proof that over engineering can be a problem. Traditional copper heatsinks have way more surface area than this part would ever be able to accomplish. This cold plate also affects pressure and flow both of which are not as relevant in a PC application. Also, computer parts don't generally have weight constraints.
Im thinking grow lights
@@TheRealWinser the 3d design absolutely allows for better flow/surface area. When manufacturing and shipping parts weight is a big factor. A pc version of this would almost never be for home though. Too expensive. Yes copper performs better.
@@carrionpvp PC components don't require high flow rates to operate and certainly don't require pressure optimization either. Engineering is about doing the least amount of work to reach a specific goal. Anything more than that is over engineering.
Im thinking colander 🤣
Absolutely one of the coolest freakin' 3D printed parts I've ever seen, and objectively it is technically, probably, the coolest..
Hi guys! As a former member of team Dynamis PRC, I am extremely proud to see our content featured on your channel. If you don't mind a correction, though: the university's name is actually "Politecnico di Milano", which stands for Polytechnic of Milan, but it's usually called with its Italian name internationally. The difference isn't subtle because there are actually plenty of other universities in Milan, including a couple called University of Milan, which might generate confusion!
One thing I didn't find an answer to in the video (and I hope it's not in the video, because otherwise I'm clearly not paying attention), is why is this thing open at the top? Is it just to show off the internals?
@@MrMartinSchou It's because the channels are closed, you could fill it flush, but it would be additional material and mass for no reason.
@@ajwright5512 It has only two fluid ports (in/out), and the heat enters through conduction on one surface? Which surface? Or is air forced through the exterior lattice? Wouldn't having a full plane on one of the two largest surfaces be needed for highest heat flow?
@@MrMartinSchou at 15:50 you can see the additional parts in the assembly that enclose the fluid channel.
@@ajwright5512 Looking at it frame by frame the channels are not closed on top
I love this approach! Not only it optimised tapering for heat transfer in the material, increased surface area, optimised flow, but it also seemed to me that they have more turbulent flow than traditional water blocks for even more heat transfer.
And since this is a race car, you are optimising for weight so I can see why aluminium was chosen over copper (I usually use copper because weight/mass is less of a concern for the types of projects I work on, and it is more about decreasing the volume which is why vapour-chambers and heat-pipes are something I use more frequently.
Really cool project!
Adds new meaning to the concept of the "cool parts" show.
Thank you 🙏🏻
Great content
Y the lattices occupy 70% of block? Y not use the entire block for 400% improvement ?
Potentially useful for computer cooling aswell.
very interesting project. It's very pretty, -almost art. But the important thing; How does it measure? What is the efficiency compared to a more conventional heat exchanger?
Would this perform better or worse than an equally-sized enterprise CPU waterblock / GPU waterblock with skived copper microfins? Because the heat exchange area is a more 3D structure, but the surface area in a given volume seems lower, I genuinely can't guess which would perform better. Not knowing the curve of the pump being used or the scale of their heat load and cooling and radiating surface area doesn't help either
My life goals include have numerous machines worth millions of dollars allowing me to precisely create the countless ideas I have, too bad working class stays working class
It's still quite expensive, but if you have an idea and you can create a 3D model of it you can send it to an online 3D printing service to have them print the part for you. Might be several hundred $$$ to print a metal part like this (or more), but it's not millions of dollars.
Why not using a single piece construction, since in this design also we have to put a plate on top, fasten in, put a gasket and then hope that it won't leak.
So.... What pressure drop between inlet and outlet ?
Does it also workaround the fact that 3D Printed Metals are less dense and have alot worse thermal conductivity and a higher thermal resistance? For example with Copper the Thermal conductivity goes down from 405w/m*k to 350w/m*k or even 300w/m*k.
what's the fouling rate like?
Pretty cool. Pun that. It looks just like you might expect a computer AI to recursively create the highest (surface area) to (flow rate) structure it can compute. Compare this snake channel to equally sized plate heat exchangers or typical radiator pipe-in-fins designs. Size for size, weight for weight, it's very tempting to want to know the exact advantages. I'd use these all over on a car or truck for minimizing cooling systems. Or on service truck applications where hot water is needed on demand or hot fluid of any kind, or where massive cooling is needed in industrial uses. Fascinating stuff. At the moment I think these have to beat the efficiency of a good plate heat ex to gain any traction.
Okay, so the theory is maximizing surface area of aluminum-to-water to optimize aluminum's superior coefficient of thermal transfer, but instead of doing it in a way that makes sense, they used an iterative design that will likely allow a thin film of water to insulate the plate and potentially boil the coolant if it gets hot enough.
Why was it not a single-piece part that you could have machined the mating surface into it?
Will the rough surface finish in the flow path cause turbulence or friction issues?
I expect it will increase thermal transfer, due to increased surface area and friction. I suspect they can design for that in mind. i.e. knowing the surface properties of the printed material.
you want some turbulence for cooling efficiency, otherwise you have some kinda skin effect where the water on the circumference is hot while the inside is cold, and acting as an insulator. manufacturers purposefully add turbulence in waterblocks so that it doesn't happen.
can you explain more in detail
@@satibel
not surprised 0 temp result was shown.
This is five years behind the AMHX curve... Can you show some cutting edge stuff?
I am curious. Can you give me some keywords to find info on cutting edge additively manufactured heat exchangers?
@Alter Ego This isn’t related to racing, but you might enjoy our episode on this heat exchanger developed for a helicopter:
czcams.com/video/1qifd3yn9S0/video.html
We also have some other interesting stories about 3D printed heat exchangers on our website:
www.additivemanufacturing.media/articles/the-case-for-tackling-the-toughest-material-first
www.additivemanufacturing.media/articles/how-thin-can-i-make-it
How tf is it posible to clean such sls parts
This will need distilled water or fluids free of impurities to avoid blockage.
hey guys iam currently doing my postgraduate in automobile technology and iam doing some research on a topic improvement on heat dissipation in inverter in EV. can i know more about this project and what can be the future works done in this topic. Also what is the weight reduction on the cool plate.
The complete case study from nTopology is available here: www.ntop.com/resources/case-studies/cold-plate-automotive-power-electronics/
(Near the bottom, there are a few comments on additional optimizations Dynamis and Puntozero have planned for this component.)
We don’t have the exact weights for the part, but can say the 3D printed version is 25% lighter.
Cool, cool... but such extreme "channeling" is not necessarily good. Since 3D printed surface is quite rough, and that induced a lots of friction thus slowing a fluid-flow thus decreasing cooling...
No. This surface finish promotes turbulence and you ABSOLUTELY want turbulence when convective heat transfer is concerned. Yes you pay the price of increased friction but the tradeoff is absolutely convenient in the end.
So a radiator?....
8.30 not true, this wont reduce pressure drop. It will increase boundary layer friction and therefore pressure drop.
101 fluid dynamic
The part is awsome by the way.
Actually it's been demonstrated that internal vanes to guide the flow around elbows (>= 90° turns) reduce the concentrated pressure drop due to the turn. Yes, that many tiny little channels do increase the skin friction, but this effect is non negligible and helps mitigate the issue. Plus, the net increase in heat transfer coefficient is so positive that nothing else matters as much.
Won't the increase in friction increase the contact time of the fluid with the heat exchanger thereby improving it's cooling efficiency? Plus, seems like the 90 degree turns might be worse for flow than the guides.
> saves grams of weight
> negates weight savings by making it EV
Should have made it a hybrid combustion electric powertrain just as the Porsche 919 EVO hybrid has beaten all records on tracks it's raced. On the Nürburgring with budgets taken out of the equation the Porsche 919 EVO beat the Volkswagen ID.R by around 45.9 seconds. Amusingly enough, every Nürburgring (excluding Tesla Plaid) lap time record set by Tesla has been beaten by various years of Honda Civic Type R. Which the Plaid get's beaten by an Audi RS4 all being a fraction of the cost of the full EV counterparts.
This is great, untill the car is older than like a yr and crud has started to collect in all these "ports"
it's a race car, it won't drive for long. also, you can add chemicals to prevent "crud"from forming
The car's operating lifespan is way shorter than a year. 2-3 months of testing in late spring, 3-4 races in summer, 1-2 months of further testing for the new car in autumn. Then it stays quiet and warm in museums, fairs and expos.
they got the idea from human guts ah
Another hype 3d print that wont be put into use.
Definently giving me some tryphobia vibes here
This doesn't make any sense. How is this designed in Italy, produced in Italy, by Italian companies, and still doesn't resemble a pizza?
why u have helmets when there is no overhead loads or risks
The helmets aren’t the most fashionable, but we were required to wear them for safety reasons. Those charges that you see at 18:30 get hoisted up from the ground floor, all the way over the top of where we were standing, to get loaded into the atomizer. This didn’t occur while we were filming, but safety is imperative.
@@AdditiveManufacturing got it.
@@AdditiveManufacturing 17:28 top left
too expensive and production is too slow.
Background music is very annoying. 🙈🙈🙈🙉👎
The heat sink will be covered with scale and all sorts of oxides inside, which will reduce its service life by 3-5 times and it will be almost impossible to clean it, and thin walls also reduce the resource. Another case when designers and not an engineer make details.
The application is for a racing EV with an annual run time measured in hours. The suggestion that they didn't think about fouling factors or service life is just risible.
In racing vehicles, only purified water with thermal absorption assistance is added. No one uses water from a tap or antifreeze. Water is replaced regularly to look for any engine contaminants. Also, most racing vehicles are replaced after one year of usage. As this is a learning project, the best way for them to learn is to try.
This activates my trypophobia. Ew.