Infrared Thermometers and IR Camera Optimize Race Cars

Challenges in Measuring Brake and Tire Temperatures

Formula Student is one of the most demanding student engineering competitions worldwide. Teams around the globe develop new race cars each year to test them at national or international events. FaSTTUBe, the Formula Student team of TU Berlin, utilizes modern technologies for their vehicle optimization, including Optris infrared pyrometers for monitoring brake and tire temperatures. One of the biggest challenges for them is to control the temperature of sensitive components such as the brakes and nearby parts. Excessive temperature exposure can lead to severe issues, from material fatigue to safety risks. Without continuous temperature measurement, a targeted analysis of temperature trends and performance optimization would be nearly impossible.

The challenge with brakes is that high temperatures arise quickly and are difficult to track manually. In past test runs, overheating has repeatedly caused material damage. Without precise temperature data, causes such as excessive friction or design flaws cannot be identified in time. Placing contact thermometers on moving parts is impractical.

Tire temperature is also a critical performance factor. The optimal operating temperature must be consistently maintained to ensure maximum grip and even tire wear. Uneven temperature distributions can indicate problems in the suspension setup and must be detected early.

Placing contact thermometers on moving parts is impractical. Mounting the contact temperature sensors not on the parts prone to overheating but just near them results in inadequate temperature signals or delayed or no temperature response.

Contactfree Temperature Measurement as a Key to Vehicle Optimization in Motorsport

Implementing Optris infrared technology has significantly improved FaSTTUBe’s race car performance. Moreover, FaSTTUBe’s experience shows that measurement during driving is often complicated by external factors such as dirt and air turbulence. Sensor positioning is, therefore, crucial for data quality. Accurate temperature control enables the early detection of overheating issues and ensures better suspension tuning. Critical temperatures, especially in the braking sector, could be detected, and appropriate countermeasures taken to prevent material damage.

By continuously monitoring and recording temperature data, FaSTTUBe engineers can compare past and present test results to track long-term improvements. The pyrometer data is used for in-the-moment analysis and stored for future reference, allowing engineers to optimize vehicle setups across multiple seasons. This ensures that each new car iteration benefits from prior testing and avoids repeating known overheating issues.

A key advantage of Optris CSmicro pyrometers is their compactness and robustness. The sensors can be seamlessly integrated into tight spaces, which is crucial in motorsport. Furthermore, they feature high accuracy of ±(0.3% of the measured value + 1°C) and rapid response times, enabling precise data analysis. Their ability to function reliably in harsh conditions has been essential in capturing reliable data under varying track and weather conditions.

Additionally, FaSTTUBe has successfully used the Optris sensors to optimize tire performance. Since tire temperature directly affects grip and wear, the team utilizes real-time thermal readings to adjust suspension setups dynamically. During endurance runs, engineers can analyze temperature distributions across different tire zones, ensuring each tire reaches its optimal working condition. This has significantly improved handling and overall lap times in competitions.

Temperature data is processed using proprietary software and external analysis tools, allowing the team to fine-tune their car based on detailed heat maps and gradient trends. Engineers at FaSTTUBe compare data across different test sessions, identifying anomalies that could indicate design weaknesses. This level of detailed analysis ensures that any potential issues are addressed before competitive racing events.

The use of Optris thermal cameras in battery development has proven to be a valuable addition. Capturing thermal developments within the battery helps maximize the safety and efficiency of the energy system. The collected data directly contributes to the further development of the vehicles, ensuring that FaSTTUBe remains competitive in international competitions.

With its infrared sensors and thermal cameras, Optris provides a reliable and precise solution for temperature measurement in motorsport. The high measurement frequency, compact design, and excellent accuracy make Optris the ideal partner for demanding race car applications. FaSTTUBe continues to refine its setup, leveraging the long-term reliability of Optris sensors to push the boundaries of electric race car performance.