One More Reason Turbochargers Rule [ November 19th, 2008 ] By: Charles Smith Posted in » Ramblings

It has been getting cold around here and sitting still in a car does nothing to help keep warm. Luckily I drive a WRX and that means it is turbocharged. Besides the added torque/power it makes, one really nice thing in the winter is that my car heats up faster.

Turbos spin really effing fast, and most turbos are cooled and lubed by the engine oil. The turbocharger is transferring heat from the exhaust gasses and its own spinning into the oil. This beautiful heat transfer results in warmer overall oil and so your cabin heaters work that much faster.

Oh how I do love my turbocharged car. There is one caveat, with the turbocharged car you have to be much more careful about running the engine hard (especially when it is cold) and shutting off the engine too soon after running hard. If the turbo gets very hot from running hard, shutting off the engine shuts off oil flow to the turbocharger. The oil left in it can burn off/cake in the turbo (BAD!!!).

Keeping Drivers Cool [ July 30th, 2008 ] By:Charles Smith

The whole point of keeping a racecar cool is so you can keep the driver(s) cool. There are lots of neat ways that race teams around the globe do it. Here are a few of them:

Cut Back On Layers

This may sound obvious but most racing suits have three or more layers of material to them. Keeping the layers down to a minimum (safety still matters) will allow the air you bring into the car to do its job and cool the driver down. The Subaru World Rally Team cuts that down to 2 layers of outerwear for the really hot rallies. The neoprene underwear still restricts breathability but keeps the drivers safe from fire.

One of the neat things about Rally Racing is that short sleeved suits are allowed in the extremely hot rallies. Many famous world champs have rocked the short sleeves or rolled up sleeves during desert rallies. See Colin McRae and Richard Burns for prime examples.

Drink Lots of Water

Being properly hydrated keeps drivers cool for a few reasons. First of all they can sweat, and if the car is breathing right that sweat can evaporate and will take a large amount of heat away from the driver(s). You will also lose a large amount of water through sweating, especially in the heat of a cockpit.

Your body is mostly water, so any heat your body generates related to general metabolism gets dumped into that mostly water body of yours. Less water means higher temps for the same metabolism (when controlling for the effect of sweat).

Your blood volume is also 80-90% water and so losing water means your blood volume will go down. This makes your heart work harder (oh look more energy release) and you feel hotter for the same temperature. Petter Solberg has said that he and Phil Mills will drink 10 liters of hydration fluid (mostly water and some electrolytes) in a day. That works out to over 1 gallon per person on that day not including the water that is in the food they eat. So drink up before and on race days.

Put Things In Freezers

Put everything you wear in a freezer (except maybe the neoprene) as it will make it a little nicer for that much longer. Your clothes will absorb that much more heat before letting you heat up.

Throw in some towels sprayed with water. Freeze those puppies so when at service, or pre and post race, you can wrap one around your neck and keep cool.

Mix Alcohol and Water

I am not saying drink alcohol, but add water and rubbing alcohol together and keep that chilled in a spray bottle. When you can, spray some on your skin and lots of heat will be pulled away with the alcohol and water (so will the oils in your skin). This works so well that some racecars will put this mix in intercooler spray reservoirs. It really will make that much of a difference.

Drinking alcohol will actually hurt your ability to cool off as it is a diuretic. So that is just one more reason not to drink when racing (besides the many obvious ones).

Neat Technologies Help

A loyal reader Dustin Tarditi reminded me about things like UnderArmor (loved it for lacrosse) and their high tech cousins deemed Cool Suits. Under armor is great for wicking away sweat (and with that heat) from the body and allowing air to do its job.

Cool Suits are even cooler as they will run coolant (water or what have you) from a cooler that is in the racecar (or in the pits) through tubes and across your body. The tubes are zig zagged across your chest and they pull heat away from your body into the coolant (which goes into the cooler).

Newer styles of Cool Suits are focusing on the wrists and palms. Why? Because “in order to cool the body you must cool the blood”, and the blood is a lot closer to the skin around the hands. This is the same reason you treat heat stroke/exhaustion by cooling the hands and feet rather than the whole body (the latter is dangerous as it may make it harder for the body to cool itself as it will bring the blood into the core due to shock). The trick to the new technologies is making them lightweight and not interfere with the driver(s) control of the car.

July 30th, 2008 | 4 Comments

Keeping Racecars Cool [ July 22nd, 2008 ] By:Charles Smith

While racecars are usually most definitely awesome, today’s weather reminded me they are pretty effing hot inside them. In the quest to save weight (translation: saving time on your laps/stages) common things are kept off the car. Air conditioning is gone, underbody/frame insulation is gone and the lexan windows usually dont roll down. Combine that with the fact that a racecar’s engine runs quite a bit hotter and cars with antilag systems (ALS) have exhaust temperatures above 1000 ºC the car’s interior will be hotter when running. However there are a few tricks to keeping the cabin temperatures survivable:

Air Vents

Racecars have a love hate relationship with air. At really high speeds it slows them down and sometimes even makes them crash, but it also cools their engines. In a similar fashion, it can help cool the cabin and driver(s). Keeping your drivers alive means getting them nice cool air to breath. Good helmets allow the driver to breath and it lets sweat do its work at cooling the driver(s) down. NASCAR likes to use forced air helmets that push air through the helmet, while Rally tends to use open face helmets (very breathable and you can yell at your driver in them).

In order to let a helmet do its job air needs to be getting to the driver(s) from outside. Vents to the cabin are nice for this. Rally cars often have a vent on the top center of the car to let air in through a diffuser so the drivers can breath and cool off. Air also has to exit the cabin, but if your windows are closed how can it do that? Closable vents in the back windows help with getting air out of the car, however in a Rally application I would suggest a filter on them (dust likes to come into the car otherwise). Andrew Comrie-Picard’s Mitsubishi is a shining example of common air ducting.

Window Tint

Sunlight heats up the cabin majorly. Ever been burned by a seatbelt buckle that was left in sunlight on a hot day? I know I have. Tinting a racecar’s windows with reflective tint can reduce any sunlight that is causing the cabin to get real hot. While black tint works to combat cabin temperatures, mirror tint works better (more reflection, less absorption) as it will not radiate as much heat through the glass into the cabin.

Roof Paint

Another way to keep the cabin temperatures from skyrocketing due to sunlight is to paint the roof of the car. The roof of the car is often not seen by spectators, so diverting from your colorscheme is not as big a deal. Painting the roof white will keep it from absorbing as much heat from the sun and further lowering the temperatures in the cabin.

Interior Paint

The interior is exposed to light too! Roll cages and the inside of the car frame make up a large surface that can absorb even more heat. Painting them white keeps them from absorbing as much heat. Plus a consistent interior color makes the car look neater and better organized. Also white shows everything wrong(great trait in a racecar) like: all sorts of leaks including exhaust, cracks and where you dropped your notes pen.

Insulate Exhaust Pipes

Exhaust pipes in racecars get extremely hot. They get way hotter than the exhaust on a street car so there is a lot more heat that comes off of them and into the cabin. Wrapping the exhaust in heat insulation might add a couple pounds, but it might give you a better performing engine. Higher exhaust gas temperatures means higher exhaust gas velocity, and if you’re running a turbo this means a faster spooling turbo. Not only will you get a possible gain in your engine, the cabin temps will drop. A normal exhaust will radiate heat into the metal on the underside of the cabin (a good amount of it too) which will transfer into the cabin. 1000ºC exhaust gas will conduct massive amounts of heat through a thin piece of metal(exhaust piping).

Regardless of what you’re racing doing everything you can to combat high cabin temperature will make your racedays more enjoyable and more consistent. Heat fatigues people, and tired drivers are dangerous drivers. That one, came straight out of a DMV Manual.

July 22nd, 2008 | 4 Comments

Gas Saving Tip #1 [ June 25th, 2008 ] By:Charles Smith

With people so concerned over the price of gasoline I will post gas saving tips, no matter how strange and minute they may be. Today’s gas saving tip is Fill Up When It Is Colder.

That means, since it is summer now, fill up late at night or on cooler days. Why? Because a gallon of gasoline is a volume not a mass. Higher temperatures of gasoline means less mass per dollar when compared to the same price at a lower temperature. While the effect of this is small, it could make a difference in the long term.

The effect of temperature is not minute enough to scrape by the law books. Most states (probably all) have laws related to the sale of bulk volumes of liquid, especially gasoline. They have to be sold as the volume they would fill at a defined temperature. For example, in Arizona all bulk sales have to be sold as the volume they would be at 60ºF. So, during the summer, a gasoline truck actually carries less gasoline than it does during the winter even though they are carrying the same volume. By the way, Arizona is WAYYYYYYYYYYY hotter than 60ºF during the summer, so people at the pump are losing a good amount of mass per gallon.

Also, when it is hot out, gasoline likes to evaporate faster. So you could be losing some mass to evaporation before it even gets into your gas tank.

Recap: Fill up when it is coldest (at night).

June 25th, 2008 | 4 Comments

How Engines Respond to Air Temperature [ April 24th, 2008 ] By:Mark Ozimek

I’m sure that everyone has heard or experienced first hand how cars have more power when it is colder outside. This may strike some of you as being counter-intuitive, but from a technical standpoint, it makes a lot of sense. Let’s break it down to see what is happening when it gets cold out.

The engines in cars burn gasoline (or diesel) and oxygen to create energy. The heat created by this explosion causes the air inside the cylinder to expand, pressing down on the piston, which creates a torque in the crankshaft. There is a very specific ratio between the amount of gasoline and air that provides peak power. This ratio is called the Air/Fuel Ratio or AFR, for obvious reasons. Get too far away from this ratio, and the gasoline won’t even ignite! As a general rule of thumb, engines run with around 12 to 16 pounds of air per pound of gasoline. Below 14.7:1 is called “rich”, while above that is “lean”, while 14.7:1 is “stoichiometric” for normal gasoline. Typically cars run lean for better economy when subjected to low load conditions, and rich when the pedal is to the floor, to help prevent overheating of the engine. Getting into optimal AFRs will be an article for another day though.

Why does all that matter? Well, notice that it is pounds of air and fuel. Engines have a constant volumetric displacement, but it’s possible to vary the mass of air flowing into the engine by changing the density of the air flowing into the engine. In fact, this is exactly how a throttle valve works. When the throttle is partially open, the air flow is restricted such that the density of air in the cylinders is very low, so there is very little mass. The ECU is aware of how much air is in there and injects an amount of fuel to match to get close to the AFR that it wants. A turbocharger or supercharger takes this in the opposite direction and increases the density of air by compressing it.

All of this has a point, don’t worry! Many of you have surely taken some sort of chemistry class, either in high school or college. To make things simple, air can be modeled as an “ideal gas”, which means we can easily say how four very important things relate as you change one of them: Density, Volume, Temperature and Pressure. The density and temperature terms are the critical ones for explaining why engines have more power when it is cold out. As temperature decreases, the density increases. That means when it is cold out, the engine will be able to contain a higher mass of air than at a higher ambient temperature, assuming the same throttle position and engine speed. When there is more air, there is more force from it’s expansion when the gasoline burns, which translates to more torque and power.

We can take this a bit further though. Notice the pressure term. At sea level, the air pressure is much higher than it will be somewhere like Independence Pass, Colorado, at 12,095ft. At this point, the pressure is down to about 60% of the pressure at sea level. Pressure and density have a direct relationship, so at 60% of sea level pressure, the engine is flowing 40% less mass, which will then correspond to a loss of about 40% of the engine’s power that it had at sea level (This is a rough approximation and it will be more or less depending on load and engine design. Having a turbocharger is a good way to get around this loss in pressure, but a significant power reduction will still be there). Pretty substantial, isn’t it? Now you know why the WRC racers were complaining about how slow the cars felt in Mexico, as they were racing at around 6,000ft for much of the course.

Another thing to note: With lower air temperatures, while the engine power increases due to the increased density, the drag from air resistance increases as well. The body of the car has to push more dense air out of the way as it is moving forward. This will negate a lot of the benefits of the extra power at higher speeds, but drag is a very minor part of the forces a car must overcome when accelerating at low speed. A similar effect is going on at high altitudes.

April 24th, 2008 | 3 Comments

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