2007 Solar Powered Car TECHNOLOGIE AU www.a4.fr
September 2007 Etienne Bernot - Jean Luc Mathey - Nicolas Devaine Edité par la Sté 8 rue du Fromenteau Z.A. Les Hauts des Vignes - 91940 Gometz le Châtel Tél. : 01 64 86 41 00 - Fax. : 01 64 46 31 19 www.a4.fr Product Presentation 01 Exploded View And Nomenclature 02-03 Drawing Of Two Perspectives 04 Chassis Definition Drawing 05 Solar Cell Support Definition Drawing 06 Wheel Axle Definition Drawing 07 Structural Diagram And Wiring 08 General Manufacturing Flowchart 09 Kit Nomenclature 10 CDROM This project s CDRom is available in the Company catalogue (ref CD-BE1 ). It contains: - The FreeHand version file (editable with this software - Evaluation version included). - The PDF version file (readable and printable with AcrobatReader software). - CharlyGraal format machining files. - The full 3D modeling of SolidWorks, Parasolid and edrawings format This booklet and CDRom may be copied for students for internal school use* * This booklet may be copied as many times as necessary within school establishments for educational use only, on the condition that the publisher s name is included:. Copying or distribution for commercial use is not permitted without agreement from. Any copying or distribution of all or part of this booklet outside of school use is not permitted without agreement from.
Product Presentation Function Electric car experiment, running off solar energy. The cell is rotatable, to allow it to better capture the light. Manufacturing - Chassis is made from expanded PVC, 6mm. - The solar cell support is made of 2 mm HIPS (High Impact Polystyrene). Rectangular shape, supplied in the kit with correct dimensions. Angles to be cut again + small drill diameters made + hot folding using a thermobender with resistive wire. - The PropulsO gear motor is provided with injected parts to assemble. - The Ø 3 steel axles are to be cut again and chamfered at the ends. - The solar cell is supplied with its wires that must be soldered to the motor terminals. Solar cell Cell support Rotatable cell Chassis Wheel Ø48 Gear Motor The solar cell of the Soltec car Solar or photovoltaic cells are comparable to photodiodes. They convert light energy into electrical energy. They are made of a silicon base. There are different technologies for these cells, with different efficiencies: Technology Efficiency Cost Properties Monocristalline cell 24% High Reacts with light frequencies close to UV Polycristalline cell 18.6% Medium Reacts with light frequencies close to UV Amorphous cell 12.7% Low Reacts with light frequencies close Infrared The solar cell in the Soltec car is amorphous. It has the advantage in terms of cost but is only efficient in a limited range of light. The Soltec vehicle runs very well in the sun, even if it is slightly cloudy. Under tungsten or halogen light, a minimum of 300 W is needed at 20 cm for an equivalent efficiency. Fluorescent tube lighting (neon) does not allow the solar cell to power the motor. 01 www.a4.fr
03 04 02 06 01 05 A B B 01 Wheel unit See detailed nomenclature of this assembly on page 03 A 01 Motor unit See detailed nomenclature of this assembly on page 03 06 10 Cap screws Ø 3 x 6.5 Nickel-plated steel, sheet metal, cylindrical head Ø 3 x 6.5 05 04 Wheel Injected ABS, PropulsO, Ø 48 04 01 Double-sided tape 20 x 20 mm double-sided tape, to support the solar cell 03 01 Solar cell 3 x 60 x 60 mm 100m Ah in the sun 02 01 Solar cell support HIPS, thickness 2 x 40 x 120 mm, cut, drilled, folded 01 01 Chassis Expanded PVC, Thickness 6 x 40 x 100 mm, drilled MARK NUMBER PROPERTIES Date ASSEMBLY EXPLODED VIEW AND NOMENCLATURE 02
Exploded view of the motor unit (A) PropulsO gear motor equipped with a motor specially adapted for the solar cell used. Important tips for the geared motor: 08 06 12 10 07 The axle mustn t be distorted. This is likely to happen when it s cut with a saw and badly held in a vice. Don t forget to chamfer the axle ends (see page 09). The fitting of a non-chamfered axle at the ends destroys the pinion hub, removing a gear during the process. The pinion risks being unbalanced and free of rotation on its axle. An oil drop on the headless screw can improve the gear s operation. 11 09 Exploded view of the wheel unit (B) Is only used to support and guide the assembled rear axle free wheel. No motor is assembled. The only function of the cogwheel is stoppage, using the axle. 08 07 06 11 09 12 01 Motor Ø 21 - Output shaft Ø 2-2300 tr/min at 1.5 V 11 02 Wheel axle Nickel-plated steel, Ø 3 x 6.5 10 01 Headless screw Injected ABS (on PropulsO set) 09 02 Cogwheel Injected ABS (on PropulsO set), 48 teeth 08 02 Left flank Injected ABS (on PropulsO set) 07 02 Right flank Injected ABS (on PropulsO set) 06 04 Cap screw Ø 3 x 6.5 Nickel-plated steel, cylindrical head, Ø 3 x 6.5 MARK NUMBER PROPERTIES Date MOTOR UNIT A WHEEL UNIT B EXPLODED VIEWS AND NOMENCLATURE 03
Exercise 1 - Measure the three dimensions and pencil them onto the drawing 2 - Colour in the movable parts Scale 1: 1 ASSEMBLY Date DRAWINGS OF TWO PERSPECTIVES 04
Ø 5 Ø 2 100 Ø 2 17 6 3.5 40 The 2mm diameter holes are drilling spots, or deeper ones are 3mm. They are used to position and hold screws. The 5mm diameter hole is through bore. Its function is to let the solar cell s wires reach the motor. 01 01 Chassis Expanded PVC, Thickness 6 x 40 x 100 mm, drilled MARK NUMBER PROPERTIES Scale 1: 1 Date CHASSIS DEFINITION DRAWING 05
40 (40) Ø 3 5 2 40 Cut 0 x 45 120 Both holes are 3mm diameter and open. 90 Hot bending on thermo-bender with resistant. wire 02 01 Solar cell support HIPS, thickness 2 x 40 x 120 mm, cut, drilled, bended MARK NUMBER PROPERTIES Scale 1: 1 Date SOLAR CELL SUPPORT DEFINITION DRAWING 06
Single wheel axle (x 2 identical parts) Chamfer 0.5 X 45 65 Chamfer the ends of the axles with a file or grindstone attached to a mini drill. Wheel axle with the assembled cogwheel (x 2 identical assemblies) Fitting 31.75 (31.75) 1.5 You can use a 31.75 mm long tube as a template for the fitting of the axle. Functional tolerance is more than 2mm. 31.75 09 02 11 02 Cogwheel Injected ABS, PropulsO, 48 teeth Wheel axle Nickel-plated steel, Ø 3 x 65 MARK NUMBER PROPERTIES Scale 1: 1 Date WHEEL AXLE DEFINITION DRAWING 07
Structural diagram Solar cell 4.5V M Motor Wiring Polarity: The motor is reversible and does not have intrinsic polarity. The vehicle s operating direction depends on the motor s wiring. The only object which can determine the vehicle s operating direction is the powertrain, which can either be placed at the front or back. Therefore, it is up to the individual to decide, and to wire the motor. MOTORISATION Date ELECTRICAL DIAGRAM AND WIRING 08
General manufacturing flowchart Student Worksheet 20 x 20 mm double sided tape 4.5 V Solar cell Cap screws Ø 3 x 6.5 Motor PropulsO set of pieces Sort out pieces Assemble motor gear and wheel unit A & B Assemble on chassis Assemble solar cell support on the chassis Stick the solar cell on support Wiring Original Ø 3 nickelplated steel Cut and chamfer 2 axles L = 65 mm Original Chassis Drilling Support for the original solar cell Drilling Chamfering 10 x 45 Thermobending 09 www.a4.fr
Kit Nomenclature Student Worksheet To make a Soltec vehicle, use the kit consisting of 17 parts, including a plastic bunch of 40 parts. The plastic for the chassis and solar cell support are supplied in the correct size, ready to use. The nomenclature below corresponds to the individual kit : Reference K-SLT-01 (to make one object only). The kit for 10 manufacturing reference K-SLT-10 differs by the quantity of each part ( x 10 ) and packaging of parts. Important tips: Chamfering axles is necessary to ensure good operation of the gear motor. To avoid losing parts, do not detach parts of the injection bunch before use. A drop of lubricant on the headless screw may improve the gear motor s operation. Individual kit (ref. K-SLT-01) Part Quantity Design PropulsO: red plastic bunch of parts 1 Steel axle diameter 3 x length 135 minimum. 1 Electic motor specially adapted to the solar cell. 2300 tr/min under 1.5 V - Ø 21-2 mm output shaft. 1 4.5 V solar cell - 100 mah in the sun. Dimensions 60 x 60 x thickness 3 mm. 1 Double-sided tape, 20 x 20 mm. 1 Sheet metal screw, cylindrical head Ø 3 x L 6.5. 10 Expanded PVC plaque 100 x 40 x thickness 6 mm. 1 HIPS plaque x 40 x thickness 2 mm. 1 10 www.a4.fr