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Mini-Course in Electrical Engineering Chris Jones, Intern

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1 Mini-Course in Electrical Engineering Chris Jones, Intern

2 Working Safely with Electrical Components Working with High Voltages –It is a good idea to work around the car without power connected to the system –Always be aware of when the car is live –When working on electrical systems, use single hand or latex protection –Walkthrough the entire system and watch for exposed wires or connectors often

3 Working Safely with Electrical Components Minimizing Risks –Minimize number of people around/or with access to the car –Put physical protection between the driver and any electrical circuits –Properly insulate all connectors –Make sure that no connectors are grounded to frame –Store car with battery disconnected –Be neat in arranging your circuit Loose wiring may snag and be difficult to work with Planning your conduit will save you time during the race

4 Tools of the Trade Soldering Iron/Gun Wire Strippers/Cutters Wire Crimpers Needle-nose Pliers Diagonal Cutters Multimeter Heat Gun

5 Schematics Plan your circuit on paper before wiring your car Example: Northview Race Team 97 schematics

6 Connectors Deciding when to use crimp connectors Types of connectors that work well Problems with crimp connectors

7 Wiring Selecting wire type and size Wiring strategies and planning –Planning how to route your wires –Running wires between components –Being neat in placing your wires How to work with battery cables

8 Soldering – The Easy Way Tools you need to get started –Soldering Irons / Guns –Solder –Heat Shrink Recommendations for effective soldering

9 Batteries Explaining Winston Solar Challenge rules Different types of lead acid batteries –Automotive –Deep Cycle (Marine) –Sealed How to care for your battery –Cycling and Voltage limits Recommendations for the auxiliary system Replacement batteries

10 Drive System Motors –The different types Brush Brush less Hub –Selecting what is right for you Controllers –Why they are needed –How to decide on the right controller

11 Solar Cells Types of Solar Cells –Terrestrial Grade –Space Grade General Information How to wire your solar cells –Series –Parallel Explaining Winston Solar Challenge rules

12 Solar Arrays Advantages of prefabricated vs. custom-built arrays How to build your own solar array –What do you look for in a base material? –How do you insulate your array? –How do you solder solar cells together? –What do you mount your solar cells to? –What is encapsulation and how do you do it? Power Trackers General care for a solar array

13 Instrumentation Meters for the modern solar car –Voltmeters –Ammeters –Amp-hour counters –Temperature sensors and gauges The E-Meter

14 Summary Be safe around your vehicle. Be aware of when your car is live. Minimize risks. Have the proper tools to work on your car. It makes your work much faster. Plan your circuit before putting it together. Size your battery system, solar array, and wires and select your connectors according to your needs. Ask others for help when you dont understand how to do something.

15 Q&A Do you have any questions?

16 Where can you purchase parts? General Solar Supplies –KTA Services Ken Koch 944 W. 21st St. Upland, CA 91784 909-949-7914 909-949-7916 (Fax) Power Trackers –Australian Energy Research Laboratories (AERL) Stuart Watkinson M.S. 660 Proston, Queensland 4613, AUSTRALIA 011-6171-689308 011-6171-689197 (Fax) Solar Cells –ASE Americas, Inc. Ms. Evelyn Bennett 4 Suburban Park Drive Billerica, MA 01821 508-667-5900 x266 508-663-2868 (Fax) –Photon Technologies Robert Mulligan P.O. Box 790 Severna Park, MD 21146 410-544-0911 410-544-4075 (Fax) –Siemens Solar Camarillo, CA 805-482-6800 805-388-6395 (fax)

17 Where can you purchase parts? Motors –Advanced D.C. Motors, Inc. 219 Lamson Street Syracuse, NY 13206 315-434-9303 315-432-9290 (Fax) –Solectria 27 Jason St. Arlington, MA 02174 508-658-2231 508-658-3224 (Fax) Motor Controllers –Curtis PMC 6591 Sierra Lane Dublin, CA 94568 510-828-5001 510-833-8777 (Fax) Solder for Solar Cells –@ONCE Attn: Catalog Sales 4 Sunset Way, Bldg. C Henderson, NV 89014 888-428-6623 800-950-5679 (fax) For more information, go to: –

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