SWARNANDHRA COLLEGE OF ENGINEERING & TECHNOLOGY
(AUTONOMOUS)
(Approved by A.I.C.T.E, New Delhi,Permanent Affiliation to
J.N.T. University Kakinada.Accredited by NAAC with “A” Grade)
JNT UNIVERSITY KAKINADA, KAKINADA
+
DESIGN,ANALYSIS AND MANUFARTURING OF NEW TECHNOLOGY
SOLAR CAR
ABSTRACT
The main aim of the solar car is to create a eco friendly vehicle with the help of solar energy.
Initially solar panels are used as a source of power to charge the batteries in addition to that SELF
POWER GENERATION SYSTEM and THERMO-ELECTRICAL POWER GENERATION
SYSTEM are also used as an alternate source to charge the batteries. These systems help to run the
vehicle during the absence of solar power. The vehicle is given aero dynamic design which
increases the efficiency of the vehicle to a certain extent. Mechanical Actuation System is provided
in the vehicle which works in a sliding mechanism i.e. the solar panels slides outwards during the
charging period and slides inwards during the driving of the vehicle. This system allows to create
more surface area for charging when the panels slides outwards and when the panels slides inwards
it gets placed in an Aero dynamic position hence increasing the efficiency of the vehicle. A
differential gear box set up is made according to the required power, speed and torque using helical
gears. The Thermo-electric power generation system made up by bismusth telloriode , a semi
conductor generates e.m.f using the temperature difference in the vehicle. A reliable innovative
frame structure is used which can with stand any speed, temperature and weight and doesn’t fail
under any circumstances
INTRODUCTION
These systems help to run the vehicle during the absence of solar power. The vehicle is given Aero
dynamic design which increases the efficiency of the vehicle to a certain extent. Mechanical
Actuation System is provided in the vehicle which works in a sliding mechanism i.e the solar
panels slides outwards during the charging period and slides inwards during the driving of the
vehicle. This system allows to create more surface area for charging when the panels slides
outwards and when the panels slides inwards it gets placed in an Aero dynamic position hence
increasing the efficiency of the vehicle. A differential gear box set up is made according to the
required power , speed and torque using helical gears. The Thermo-electric power generation
system made up by bismusth telloriode , a semi conductor generates e.m.f using the temperature
difference in the vehicle. A reliable innovative frame structure is used which can with stand any
speed, temperature and weight and doesn’t fail under any circumstances
IMPORTANCE OF SOLAR ENERGY
Solar energy is an important part of life and has been since the beginning of time. Increasingly,
man is learning how to harness this important resource and use it to replace traditional energy
sources
SOLAR ENERGY IS VERSATILE
Solar energy cells can be used to produce the power for a calculator or a watch. They can also be
used to produce enough power to run an entire city. With that kind of versatility, it is a great energy
source. Some of the ways solar energy is being used today.
SOLAR ENERGY IS IMPORTANT AS CLEAN ENERGY
Since solar energy is completely natural, it is considered a clean energy source. It does not disrupt
the environment or create a threat to Eco-systems the way oil and some other energy sources
might. It does not cause greenhouse gases, air or water pollution. The small amount of impact it
does have on the environment is usually from the chemicals and solvents that are used during the
manufacture of the photovoltaic cells that are needed to convert the sun's energy into electricity.
This is a small problem compared to the huge impact that one oil spill can have on the environment
NEED FOR SOLAR CARS
A solar vehicle is an electric vehicle powered completely or significantly by direct solar energy.
Usually, photovoltaic (PV) cells contained in solar panels convert the suns energy directly into
electric energy. The term "solar vehicle" usually implies that solar energy is used to power all or
part of a vehicle's propulsion. Solar power may be also used to provide power for communications
or controls or other auxiliary functions.
Solar vehicles are not sold as practical day-to-day transportation devices at present, but are
primarily demonstration vehicles and engineering exercises, often sponsored by government
agencies. However, indirectly solar-charged vehicles are widespread and solar boats are available
commercially.
SOLAR CARS
Solar cars depend on PV cells to convert sunlight into electricity to drive electric motors. Unlike
solar thermal energy which converts solar energy to heat, PV cells directly convert sunlight into
electricity.
Solar cars combine technology typically used in the aerospace, bicycle, alternative energy and
automotive industries. The design of a solar car is severely limited by the amount of energy input
into the car. Solar cars are built for solar car races. Even the best solar cells can only collect limited
power and energy over the area of a car's surface. This limits solar cars to ultra light composite
bodies to save weight. Solar cars lack the safety and convenience features of conventional vehicles.
Solar cars are often fitted with gauges and/or wireless telemetry, to carefully monitor the car's
energy consumption, solar energy capture and other parameters. Wireless telemetry is typically
preferred as it frees the driver to concentrate on driving, which can be dangerous in such a small,
lightweight car. The Solar Electric Vehicle system was designed and engineered as an easy to
install (2 to 3 hours) integrated accessory system with a custom molded low profile solar module,
supplemental battery pack and a proven charge controlling system. As an alternative, a battery-
powered electric vehicle may use a solar array to recharge; the array may be connected to the
general electrical distribution grid.
CHASSIS
A vehicle frame, also historically known as its chassis, is the main supporting structure of a motor
vehicle to which all other components are attached, comparable to the skeleton of an organism.
Until the 1930s, virtually every car had a structural frame separate from its body. This construction
design is known as body-on-frame. By the 1960s, unibody construction in passenger cars had
become common, and the trend to unibody for passenger cars continued over the ensuing decades.
Nearly all trucks, buses, and most pickups continue to use a separate frame as their chassis.
DESIGN FEATURES
While appearing at first glance as a simple form made of metal, frames encounter great amounts of
stress and are built accordingly. The first issue addressed is "beam height", or the height of the
vertical side of a frame. The taller the frame, the better it is able to resist vertical flex when force is
applied to the top of the frame. This is the reason semi-trucks have taller frame rails than other
vehicles instead of just being thicker.
As looks, ride quality, and handling became more important to consumers, new shapes were
incorporated into frames. The most visible of these are arches and kick-ups. Instead of running
straight over both axles, arched frames sit lower—roughly level with their axles—and curve up
over the axles and then back down on the other side for bumper placement. Kick-ups do the same
thing without curving down on the other side and are more common on front ends.
Another feature are tapered rails that narrow vertically or horizontally in front of a vehicle's cabin.
This is done mainly on trucks to save weight and slightly increase room for the engine since the
front of the vehicle does not bear as much of a load as the back. Design developments include
frames that use more than one shape in the same frame rail. For example, some pickup trucks have
a boxed frame in front of the cab, shorter, narrower rails underneath the cab, and regular C-rails
under the bed.
On perimeter frames, the areas where the rails connect from front to center and center to rear are
weak compared to regular frames, so that section is boxed in, creating what are known as "torque
boxes".
SELF POWER GENERATION SYSTEM
The self-power generating system is introduced in the vehicle to produce the power supply for
charging the battery continuously by getting the minimum mechanical energy as an input.
PRIMARY DESIGN
This is achieved by introducing the new system which is named as a self-power generation system
in this system there are three main parts for increasing the efficiency of the unit. The first one is a
step up helical gear box with the speed ratio of 1:10 then the second one is a sprocket arrangement
which is having a transmission ratio of 1:2. Finally the new and hi-tech setup placed as the third
one is called planetary gear box. This was considered as a main system in this design the
transmission ratio of this system is 1:3. Therefore the total speed ratio which is achieved in this
design is about 1:60. Final output is transmitted to the alternator for getting the maximum power
output
SECONDARY DESIGN
The secondary design is nothing but having the similar parts which is available in primary design
except the planetary gear box. Here on considering the drawbacks which was occurred because of
using the planetary gear box is confirmed by doing the test drive on road with the whole setup of
the vehicle. At last the sustainability of the system is not up to the level therefore the primary
design is modified into secondary design.
ELECTRIC VEHICLE RATING CALCULATIONS
INTRODUCTION
Solar cars compared to internal combustion engine vehicles are simpler in that they have few major
components. However, being an electrical system makes precise calculations of the ratings of these
major components of the car imperative at the design stage. The ratings of the 3 major components
of the car that will be determined are
The motor power rating required to achieve the necessary speed and acceleration.
The battery capacity which can support the distance required to be travelled.
The solar panel specifications needed to keep the battery sufficiently charged for the
journey.
The power rating of the motor will determine the battery capacity i.e. Ampere-hour charge and
voltage needed to overcome the maximum distance that the solar car will travel on solar power
alone. Consequently this in turn will determine the panel wattage required to sustain the battery
charge.
MOTOR POWER RATING
The power needed to propel a vehicle can be determined by combining the forces that needs to be
applied to the vehicle to move it with the vehicle speed at which this propelling force must be
sustained. The drive torque generated by the motor for the wheels produces a drive force at the
tire/road contact - it is this drive force that moves the vehicle. At the design stage it's easier to
frame the calculation around this drive force rather than the drive torque. Thus the calculations in
this section start by determining the size of this drive force, and given a set of speed at which the
vehicle should move, the drive power is found
The total drive force that has to act on the vehicle to make it move (or keep it moving) can be
estimated by adding together individual force components that arise from different physical effects.
These are force to overcome the rolling resistance of the wheels on the drive surface, force to
overcome aerodynamic drag and force to accelerate the vehicle's mass. There may be other effects
but these are usually the main ones. These opposing forces are accounted for as follows:
THE ROLLING RESISTANCE
The rolling resistance force is the force resisting the rolling motion of the tires as they roll over the
road surface. Factors that contribute to rolling resistance are the (amount of) deformation of the
wheels, the deformation of the roadbed surface, and movement below the surface. Additional
contributing factors include wheel diameter, speed, load on wheels etc. For example, a rubber tire
will have higher rolling resistance on a paved road than a steel railroad wheel on a steel rail.
Similarly, sand on the ground will give more rolling resistance than concrete. The rolling resistance
force can be expressed as,
FROLLING = µR*W,
Where W is the weight of the car.µRis the coefficient of rolling resistance and is a constant that
depends on the type of tires of the vehicle and the surface on which it will roll. Thicker tires with
wider treads, although good for adhesion, however produce more rolling resistance. To conserve
power solar cars need to use thinner tires. Also harder surfaces offer lower rolling resistance force
than softer ones. Some standard values are follows
µR Description
"Pure rolling resistance" Railroad steel wheel on
0.0003 to 0.0004
steel rail
Railroad steel wheel on steel rail. Passenger rail
0.0010 to 0.0024
car about 0.0020
0.001 to 0.0015 Hardened steel ball bearings on steel
Production bicycle tires at 120 psi (8.3 bar) and
0.0022 to 0.005
50 km/h (31 mph), measured on rollers
0.0045 to 0.008 Large truck (Semi) tires
0.010 to 0.015 Ordinary car tires on concrete
Stage coach (19th century) on dirt road. Soft
0.0385 to 0.073
snow on road for worst case.
0.3 Ordinary car tires on sand
Power vs. acceleration time for 60 km/h
In the busy streets of Dhaka city, especially at rush office hours, it is hardly possible to accelerate
freely without being impeded by traffic.
.
CONCLUSION
In conclusion, the round trip journey can be visualized in the following manner –
With battery fully charged start the journey and arrive to the destination. The battery is at
the same time being discharged by the motor and charge by the solar exposure while
driving. Battery should now be at max 40% depleted.
The car is now left subjected to solar exposure for about 6 hours while the user commits to
his/her business. This will bring the batteries back to full charge.
The return trip is made with batteries still having sufficient charge to overcome the
distance.
It is to be noted that the battery charge will only be depleted when the motor is driving the car.
Thus during the time when the car is halted at traffic (unlike an internal combustion engine which
will waste fuel) the batteries of the car will actually get charged by the solar exposure thus
increasing the cars mileage.
