1. Solar Car Design
“Any intelligent fool can make things bigger and more complex... It takes a touch of genius - and a lot of courage to move in the opposite direction.”
-Albert Einstein

2. Keep It Simple!

3. Key Ideas To Focus On Safety Reliable Efficient Execution
Is this safe?
Reliable
Must first finish the race.
Efficient
Performance Considerations.
Execution
Can we do it?

4. Process Learn general solar car concepts
Spends time observing successful executions
Read Event Rules!
Work on design
A lot of design problems and considerations can be solved simply by applying the constraints found in the rules.

5. Overview
Array Position
Wheel Layout
Frame
Suspension
Electrical

6. Array Position A Few Concepts Above Body Body Contour
Below Driver's Head/Canopy

7. Array Position Above Body No Shadows from Driver or other components.
Design Freedom below array

8. Array Position Body Contour Aerodynamic Shaded by General Shape of Car
Many Angles to sun

9. Array Position Below Driver's Head Shaded by any items above array
Can be bright for driver
Driver is exposed to more direct sun without canopy

10. Flat Array vs. Curved Flat Solar Arrays Curved Solar Arrays
Easier to execute
Angle to sun less of a concern
Curved Solar Arrays
Higher the angle the greater chance for breaks without ideal support.
Angle to sun more of a concern
Power Tracker Considerations

11. Hybrid Array
Increase overall array efficiency by placing higher efficient cells in most optimal position.

12. Wheel Layout
3 Wheel
2 in front
1 in front
4 Wheel

13. 3 Wheel Layout 1 in Front Generally less stable
Unstable in most turns at decent speed

14. 3 Wheel Layout
2 in Front
Generally Stable
“Gets it done”
Popular

15. 4 Wheel Possibly heavier than 3 wheels due to extra suspension
Potential to provide better support and ride
Road Debris benefit

16. Frame Space Frame Tub Triangles Usually welded metal Usually composite
Aluminum
Steel
Tub
Usually composite
Carbon Fiber
Fiberglass
Tube-like shapes/sections

17. Frame
Space
Must be designed to support all necessary loads

18. Frame Tub/Composite Lighter Stronger Easier to design
Harder to execute
Higher cost

19. Important Cargo Driver Batteries Suspension mounts Array mounts
Motor/Motor controller

20. Suspension Do you need one? Good idea? Not necessarily.
Solar Cells are fragile
Road Debris
Driver Comfort and ultimately Driver Safety

21. Suspension Types Double Wishbone MacPherson Strut or McPherson strut
Popular
MacPherson Strut or McPherson strut

22. Suspension
Double Wishbone

23. Suspension
MacPherson Strut or McPherson strut

24. Electrical
All solar cars are electric (battery) cars with an added array.
All solar car main electrical systems look schematically the same.
Difference is in the details and execution.

25. Electrical
Solar Cars are cars first, battery powered/electric cars second, and solar cars third.

26. Electrical Power Trackers
Converts and optimizes array power for system.
Not needed, but a good idea.
High cost.
Power Tracker for each array string/angle, or one large Power Tracker for the whole array.

27. Electrical Fuses Switches Specific Fuse Detailed by Event Rules.
Add fuses where it makes sense for added safety.
Switches
Specific Switches Detailed by Event Rules.
Add switches when it makes sense for added safety.

28. Electrical AC vs. DC We're working with DC.
Make sure components are DC rated for your application.
Contact manufacturer or trusted consultant to make sure your components will work reliably with your DC application.

29. Electrical Wire Size wire for worst case scenario.
Temperature
Voltage
Current
Wire should be capable of carrying more current than fuses at operating temperatures.

30. Summary
Keep It Simple
Safe
Reliable
Efficent

31. Questions