Design and Development of a Test Bench for Header Tanks Validation in a Formula 1 Team

This thesis presents the design and development of a dedicated test bench for validating the header tanks of a Formula 1 car, carried out within the Gearbox and Systems Department at Visa Cash App Racing Bulls F1 Team. The project was initiated to address the need for a safer, more repeatable, and standardized testing procedure, replacing the temporary setups previously employed. The new bench adopts a modular and compact architecture, enabling rapid adaptation to evolving component specifications while maintaining a permanent core structure. This approach minimizes redesign efforts during the winter development phase, when resources are particularly constrained. All testing equipment was integrated into a single and electrically safe assembly that ensures controlled operating conditions. In addition, specific design measures were implemented to eliminate dimensional deviations and alignment errors observed in the previous configuration. The main section of the bench was developed within a short development window to meet the team’s demanding schedule. The resulting system improves testing accuracy and ease of use, delivering reliable validation results while simplifying operator workflows. The outcomes achieved fully satisfy the initial requirements, ensuring accurate volumetric capacity measurements for each header tank unit at its different fill levels. In conclusion, this work provides a modular testing platform that enhances operational efficiency and testing accuracy, thereby contributing to the continuous advancement of the team’s engineering processes.