School of Engineering

ENG 2513
Multidisciplinary Engineering Designs
DESIGN PROPOSAL OF
WORLD SOLAR CHALLENGE

SUPERVISOR
DR. MUSTHAK AL-ATABI
1.
2.
3.
4.
5.
6.
7.
8.

DEON LEE XIANG JEN

CHONG WEI ZHONG
BAAPU SHRRERAJ SELVA RAJOO
GEOFFREY TAN WERN-JYAN
RAEFI AZRANI BIN ROPEE ADMAN
SAREN VARMA CHANDRAN
MOGANESH A/L SANMUGAM
AMIR JAVAD KARIMI

ME
CE
ME
EE
EE
ME
EE
ME

1006Q78302
1006Q79344
1006Q79642
0304374
1006Q78842
1006Q10714
1006Q79062
1007C7983

Contents
INTRODUCTION ....................................................................................................................................... 3
OBJECTIVE ............................................................................................................................................... 4
PROJECT MANAGEMENT ........................................................................................................................ 5
BUDGET ............................................................................................................................................... 5
BILL OF MATERIALS ............................................................................................................................. 6
LINEAR RESPONSIBILITY CHART .............................................................................................................. 7
PROJECT TIMELINE .................................................................................................................................. 8
CONCEPTS ............................................................................................................................................... 9
Space frame ........................................................................................................................................ 9
Triangulation ................................................................................................................................... 9
Suspension system ............................................................................................................................ 10
Double wishbone suspension ....................................................................................................... 10
Electrical System of the Solar Car ..................................................................................................... 11
Conventional Solar Car Power System .......................................................................................... 12
Disadvantage of the system .......................................................................................................... 13
Maximum power point tracker (MPPTs)....................................................................................... 13
APPROACH ............................................................................................................................................ 14
Space Frame ...................................................................................................................................... 14
Theory ........................................................................................................................................... 14
Implementation ............................................................................................................................ 15
Suspension ........................................................................................................................................ 16
Implementation ............................................................................................................................ 16
Theory ........................................................................................................................................... 16
Electrical System of the Solar Car ..................................................................................................... 17
Implementation ............................................................................................................................ 17
Theory ........................................................................................................................................... 17
Bibliography .......................................................................................................................................... 18

Page 2

INTRODUCTION
The World Solar Challenge (WSC) is part of the Global Green Challenge, which is a
series of green-energy competitions held all around the world. WSC has a long history of
being touted to be the most challenging competition in solar car racing. It is a 3 (World Solar
Challenge, 2011) 3,000 km race through the harsh Australian Outback from Darwin to
Adelaide. (World Solar Challenge, 2011)
This event has been attracting the participation of the worlds top universities such
as MIT, Stanford University, University of Michigan, Delft University of Technology, Tokai
University, University of New South Wales and many more. These universities are known to
be sponsored by the likes of Volkswagen Das Auto, Toyota, Honda, General Motors (GM),
Mazda, DSM, Dupont, Mitsuba, Sharp, Intel, Dell, Panasonic and Michelin.
Ultimately, the goal of this competition is to test engineering knowledge and skills in
building the most mechanically reliable and energy efficient solar powered car to compete
in the race.

Page 3

OBJECTIVE
1.
2.
3.
4.

Refine the space frame of the solar car

Design & Refine the electrical system
Build the space frame of solar car
Design and build the suspension of the solar car

Page 4

PROJECT MANAGEMENT
BUDGET
Pipe Dimension
OD 21.4mm x 2mm
OD 26.9mm x 2.3mm

Price
RM 29.00 per 6m
RM 41.50 per 6m

Quantity
4 pipes
4 pipes

Total

RM282

8 pipes

Page 5

BILL OF MATERIALS

Materials
Black Hot rolled
steel, Mild Steel.
1011
Motorcycle shock
absorber

Justification
Easily available, easy to shape, economical
Easily available, reliable, economical
Used as the final wrapping for steering wheel

Page 6

LINEAR RESPONSIBILITY CHART

Name
DEON LEE XIANG JEN (Group
Leader)

Branch
Mechanical Engineering

CHONG WEI ZHONG

Chemical Engineering

Responsibilities
1. Conducts group meetings
and discussions.
2. Overall Design Lead
3. Evaluates all works relating
to mechanical systems
4. Plans and delegates tasks

1.

2.
BAAPU SHRRERAJ SELVA RAJOO

Mechanical Engineering

1.
2.
3.

SAREN VARMA CHANDRAN

Mechanical Engineering

1.
2.

GEOFFREY TAN WERN-JYAN

Electrical &Electronics Engineering

1.
2.
3.
4.

5.

RAEFI AZRANI BIN ROPEE ADMAN

Electrical &Electronics Engineering

1.

2.
MOGANESH A/L SANMUGAM

Electrical &Electronics Engineering

AMIR JAVAD KARIMI

Mechanical Engineering

1.

2.
1.
2.
3.

Conduct and evaluate

research on the suitability of
metals for the space frame
and suspension system,
based on
Strength to weight ratio
Cost effectiveness
Availability
Evaluate and refine
suspension system design
Research on suitability of
metals for the space frame.
Evaluate space frame design,
through finite analysis
Cutting and grinding
Suspension Design Lead
Cutting and grinding Team
lead
Conduct research on MPPT.
Evaluate circuit design
proposed.
Evaluate space frame trough
finite analysis.
Oversees the budget and
monetary funding of the
project
Translate 3D drawings into
engineering plans for
grinding frame into shape.
Oversees and evaluates all
research relating to the
electrical system of the solar
car.
Electrical system design lead
Conduct research into ways
of optimizing power storage
and distribution in solar
vehicle.
Evaluate research on MPPT
Documentation
CAD design
Cutting and grinding

Page 7

PROJECT TIMELINE

Page 8

CONCEPTS
Space frame
A space frame is an internal structure, which is meant to serve as an internal structure for
vehicles. (Ludvigsen & Fittipaldi, 2009)
The space frame has been used in cars with
great success in many cars such as the Aerial
Atom as a way to provide a structure while
keeping the weight to a minimum. (Carroll,
2003)

The space frame would also need to

withstand 5G of impact force from all
directions according to the World Solar
Challenge handbook. (World Solar Challenge,
2011)

Image taken from Wikipedia

Triangulation

A triangle is a very strong structural form. The triangle is used in structural designs to
reinforce and support weight. All structures on this page rely on the strength of the triangle.
In some cases you may not see the triangle shape , but the structure relies on the strength
of the triangle as the forces work in a triangular direction. (Fusy, 2009)

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Suspension system
The suspension system works to maximize friction between the tires and the road surface while
absorbing shock, thus ensuring goof stability and handling.
As the Stuart highway in Australia does not have a consistent flat surface for the solar vehicle to
travel on, the suspension system will be essential to the movement of the vehicle. (Harris, 2010)

The illustration above shows what happens when there is no suspension on a vehicle. The horizontal
vector coupled with the vertical vector produces a diagonal vector. The diagonal path of motion of
the wheel makes the car unstable and harder to handle. Additionally, the body of the car
experiences excess shock, which could damage electrical and mechanical components, not to
mention injures the driver. (Harris, 2010) (NASlR, 2006)
Double wishbone suspension

The double suspension system also known as the A-arm suspension system uses to wishbone or A
shaped arms to guided the wheel in an up and down motion. (Harris, 2010)
The primary benefit of a double-wishbone suspension is control. The
geometry of the arms and the elasticity of the
joints give more control over the vehicle
dynamics, such as castor, camber, and toe.
(Carroll, 2003)
The system allows for a smaller shock absorber
compared to the other types of suspension
systems, such as the Macpherson Strut which requires a large shock absorber.
Thus, the double wishbone suspension saves weight. (Harris, 2010) (NASlR,
2006)

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Electrical System of the Solar Car

Initially, the solar energy from the sun is directly converted into electricity by the
array. Next, the electrical energy is stored into the batteries so that it can provide power to
the motor and also other part of the car such as horn, fan and etc. At the same time, the
solar electricity is also been directly to power up the motor when car is running but this
condition only occurs if and only if the battery is fully charge. After that, the motor
controller will enable the motor to accelerate or decelerated by adjusting the amount
power that can pass through to the motor. (Carroll, 2003)

Page 11

Conventional Solar Car Power System

(DIAGRAM 1.1)
The diagram 1.1 shows a layout of the entire electrical system for typical solar car. The 2guage wires that are from the battery to the motor controller are the main power bus
wires. The two switches in between are the motor switch and the battery switch. Power
from the array comes in between the two switches. The switches are included with safety
reasons. If both of the switches are at open they will be no current and power, the car will
be at the condition of off and vice versa. (Carroll, 2003)

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Disadvantage of the system

In the line of designing a system for the race in which

that it can withstand a tremendous amount of heat
and having the ability to function within a certain
period of time, a conventional solar car electrical
system design will be invalid because of the tendency
for the battery to explode and the component to
malfunction is high if applied in such situation. The
reason is the frequency flow to convert from the sun
to current is unpredictable because of the different
light intensity at different area. Thus, for the system to
work in this condition is in-efficient and making it
dangerous to drive. (Electropedia, 2009)

Maximum power point tracker (MPPTs)

So, in order to optimize performance of the car and lowering the percentage for the battery
to exploded and circuit to be malfunction, MPPTS is
introduce into the system to overcome the problem.

A power source will be at maximum if it has the same

impedance as the internal impedance of the power
source. (Electropedia, 2009)
Assume that the performance is 17 Volt, 4.4 Amp and 75 Watt solar array that is used to
charge 12 Volt batteries. The result is only about 2.5 Amps and the power deliver by the
array is just over 50 Watts rather than 75 Watts, the efficiency is loss of over 30 percent.
Maximum power point tracker is to minimize such problem. (Wind & Sun, 2008)
MPPTs are to modify the electrical system at the operating point to ensure that it can
generate the maximum amount of power to the motor. This is done by finding the voltage
or the current of the solar array at which maximum point can be generated. By installing
these MPPTs into the system it will significantly improve the efficiency of a solar energy
system, thus optimizing the performance. (Electropedia, 2009) (Wind & Sun, 2008)

Page 13

APPROACH
Space Frame
Theory

Triangulation in the space frame

- Triangulation in a frame spreads the force exerted on the frame more evenly
throughout all the bodies in a space frame (Fusy, 2009)
-Using the SolidWorks CAD drawing program, frames with and without triangulation was
tested by performing a stress and force analysis simulation to test the degree of
deformation and displacement of each frame.
-Triangulation is then performed at different areas in the space frame to test the
effectiveness of the placing of the structural supports and to analyze which supports are
actually benefitting the frame. This is done so weight saving can be performed and the
space frame can be thoroughly optimized.
-Triangulated frame is much stronger, deforms less, and has less points of failure than a
non-triangulated frame.

Page 14

Implementation

Below is one of the force analysis tests done onto the space frame in the progress of making
a better and stronger structure. ( Results from Finite analysis in SolidWorks)

Upon closer analysis of the structure, the triangulation caused the force to go around the drivers
cockpit. Thus protecting the driver.

One of the force analysis tests done on a frame developed earlier to analyze the shape of
the frame.
In this previous iteration of the frame. The principle of triangulation was not applied. Thus, a front
collision would cause the frame to collapse into the drivers cockpit.

Page 15

Suspension
Implementation
This is an illustration of the double
wishbone suspension.

The system consists of:

- Knuckle
o Links wishbone to tire
o Attaches to dampener
o Provides attachment
points for steering push rod
- Wishbones
o Guide the motion of
the tires
- Dampener
Ensures that the tire stays in
contact with the ground at
all times
Absorbs socks that the
vehicle might experience
(Harris, 2010) (Carroll, 2003)
Theory
As the tire is accelerating horizontally. The bumps on the road cause the tire to experience a vertical
acceleration. (NASlR, 2006)
The double wishbone system uses the dampener to resist the vertical motion of the tire and uses the
wishbones to guide it in the vertical axis. Thus reducing the shock, or sudden vertical acceleration.
(Carroll, 2003)

Page 16

Electrical System of the Solar Car

Implementation

(DIAGRAM 1.4)
By implementing MPPTs into the system, we are able to control the amount of output that is needed
to distribute to the motor and the battery. Through this concept, we can manage a more efficient
synchronous between the electrical component and the energy that the solar array gained from the
sun. As a result, the tendency for the electrical component to spoil is less and the car is more insure
in term of safety to drive. Plus, the car can move further and faster. (Carroll, 2003)
Theory
The Power point tracker is a high frequency DC to DC converter. They take the DC input from the
solar panels, change it to high frequency AC, and convert it back down to a different DC voltage and
current to exactly match the panels to the batteries. MPPT's operate at very high audio frequencies,
usually in the 20-80 kHz range. The advantage of high frequency circuits is that they can be designed
with very high efficiency transformers and small components. (Electropedia, 2009)

Page 17

Bibliography
Carroll, D. R., 2003. The Winning Solar Car. Warrendale: SAE International.
Electropedia, 2009. Solar Power. [Online]
Available at: http://www.mpoweruk.com/solar_power.htm
[Accessed September 2012].
Fusy, ., 2009. Transversal structures on triangulations, with application to straight-line drawing,
Paris: cole Polytechnique.
Harris, W., 2010. How Car Suspensions Work. [Online]
Available at: http://auto.howstuffworks.com/car-suspension9.htm
[Accessed September 2012].
Ludvigsen, K. & Fittipaldi, E., 2009. Space Fame. In: Colin Chapman: Innovation unlimited. South
Bend, IL: Haynes Pubns, pp. 150-164.
NASlR, M. Z. M., 2006. ANALYSIS OF DOUBLE WISHBONE, Coventry: Coventry University.
Wind & Sun, 2008. What is MPPT. [Online]
Available at: http://www.windsun.com/ChargeControls/MPPT.htm
[Accessed October 2012].
World Solar Challenge, 2011. About Us. [Online]
Available at: http://www.worldsolarchallenge.org/about_the_event
[Accessed April 2012].

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