Solar Car Shell Design Allison Bedwinek, Douglas Simmons, Sheldon Low, and Laura Sullivan ME 43A Fall 2004

Project Goals Design a shell for solar car –Overall aerodynamically superior car Low rolling resistance Low coefficient of drag –Incorporate solar panels Meets voltage/current requirements from Electrical Engineering team –Lightweight, yet strong Material selection –Compete in the North American Solar Challenge July 2005 race from Austin, TX to Calgary, AB, Canada

Major Specifications Rayce Regulations –Overall dimensions –Safety Cockpit ventilation Driver Egress –Visibility Nerd Girls –Frame –Solar panels –Drive train

Carbon Fiber Composites Carbon Fiber is a form of graphite in long thin ribbons. The fibers are used to reinforce polymers. Carbon fiber composites are used for everything

Carbon Fiber Construction A plug is made of the desired car shape, and a mold is then built off of that. Carbon Fiber Tissue is placed in the molds while still flexible. These molds are then pressurized and heated. The Resin in the Tissue then adheres to the carbon fiber ribbons to form one solid composite in the desired shape.

Research University of Missouri- Rolla –2003 winning solar car Common Solar Car Features –Thin and streamline –Low to the ground –Unobtrusive windshield and canopy –Wheel fairings solar42.umr.edu

Aerodynamics Drag –Total area –Sharp Corners –Turbulent Flow –Curve Discontinuities Conservation of Momentum

Aerodynamics External Force: Pressure –Cross Sectional Area –Upward and Downward Pressure

Preliminary Considerations Car Frame Wheel Fairings –Turning radius of car –Only on back wheels Solar Panels –1.038 m x.527 m (2) –1.559 m x.798 m (4)

Design of Shell Flat Surface Area for Cells Flat Sides with Fillets Leading and Trailing Edges Curved Underbelly

Flow Analysis With Canopy Dynamic Viscosity: μ=1.5 X 10^-5 N*s/m^2 P max = PaU max = m/s Air Velocity: U = 20 m/s Air Density: ρ=1.29 kg/m^3 Pressure Streamlines Velocity

Flow Analysis of Sides Dynamic Viscosity: μ=1.5 X 10^-5 N*s/m^2 P max = PaU max = m/s Air Velocity: U= 20 m/s Air Density: ρ=1.29 kg/m^3 Pressure Streamlines Velocity

Updates New solar panel layout –Customized modules of SunPower Corp cells built by SunWize –Significantly lighter and thinner F16 windshield canopy More aerodynamic design

Updates Working with Secart LLC of Bethel, CT, a carbon composites engineering firm Mold construction is the most labor intensive step Plugs will be created from 3D models Next month, begin construction of molds Two versions of shell –1 st version – create door, add brackets

Acknowledgements American Solar Challenge Nerd Girls James Seeley, Secart LLC Prof Karen Panetta, Electrical Engineering Prof James OLeary, Mechanical Engineering Matthew Heller and Rick Colombo, EE consultants for Nerd Girls