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BY
CERTIFICATE OF RECOMMENDATION
I/We hereby recommend that the report prepared under my/our supervision is prepared
by Tathagata Pachal entitled Electric Solar Vehicle - RAYRACER be accepted in partial
fulfillment of the requirements for the B. Tech degree in Mechanical Engineering.
________________ _________________
Co-Supervisor Supervisor
Countersigned by:
ACKNOWLEDGEMENT
Firstly I would like to thank KIIT University for letting me learn and portray my knowledge
through the project and also for accepting this project in partial fulfillment of the requirements
I would like to express my sincere gratitude to my Tutor Mentor Prof. (Dr.) Isham Panigrahi
for his immense help and support. I would like to express my gratitude towards my Dean Prof.
(Dr.) Ashok Kumar Sahoo and Project Coordinator Prof. (Dr.) Akshaya Kumar Rout for
their help in completing the project. I would also like to thank Er. Akhilesh Kumar Dewangan
and Mr. V V S Adityam for their endless effort and help for the successful design and
fabrication of the project. Without their invaluable guidance it would not have been possible for
me to complete this project. Also I would like to thank KIIT School of Mechanical Engineering
Lastly we would like to thank everyone who have directly or indirectly helped me in the
Date:
Group No. M5
3
ABSTRACT
The Electric Solar Vehicle is a single-seated vehicle powered by 750 W BLDC hub motor.
Undergraduate students of KIIT UNIVERSITY from multiple academic fields collaborated to
design and fabricate a safe, high performance, cost-efficient electric solar vehicle. Now a days,
dealers of natural resources like fuel, coal etc. are facing a hard time to keep pace with the
increasing demand. Therefore, to carry out this demand it is quite necessary to make a new
exploration of natural resource of energy and power. Therefore sunlight is now a days considered
to be a source of energy which is implemented in various day to day applications. Solar energy is
being used to produce electricity through sunlight. With the help of this technology we aim to
make solar energy powered car in our project. The main component to build a solar car is the
solar panel. The solar cells collect a portion of the suns energy and store it into the batteries of
the solar car. Before that happens, power trackers converts the energy collected from the solar
array to the proper system voltage, so that the batteries and the motor can use it. After the energy
is stored in the batteries, it is available for use by the motor & motor controller to drive the car.
We are going to use two set of batteries; one of which will get the electrical energy from the
panel to drive the motor and another will be used as auxiliary power source which will provide
required power to other electrical devices being used in the vehicle. A microcontroller can be
used in this purpose which can switch to the fully recharged battery when it senses that another
battery is empty or not providing enough power to drive the motor. Again, we used a complete
circuitry to solve the problem of voltage fluctuation due to movement of the sun, earth or cloud
etc. We used a voltage comparator, a relay circuit for and a transistor along with a diode for this
purpose. Comparator compares the voltage of solar panel and the battery and then it provides the
higher voltage to the transistor to activate the relay which provides the required and stable
voltage to the car. However, after all these being proceeded, the motor controller adjusts the
amount of energy that flows to the motor to correspond to the throttle. The motor uses that
energy to drive the wheels. Preliminarily our objective would be to implement our idea on a
basic prototype and afterwards with help of this prototype we can extend our future work on
building a real time electric solar powered vehicle.
4
CONTENTS
Certificate of Recommendation 1
Acknowledgement 2
Abstract 3
Contents 4
List of Tables 5
List of Figures 6
Introduction 7
History & Development of Solar Vehicle 9
Innovation 32
B-Plan & Sustainability 36
Colclusion 42
Biblography 44
5
LIST OF TABLES
LIST OF FIGURES
Figure 1 Sun-mobile 9
Figure 2 vintage model 1912 Baker electric car 9
Figure 3 Bluebird solar car 10
Figure 4 Freeman solar car 10
Figure 5 Citicar 10
Figure 6 Solar powered race car 11
Figure 7 Sunrunner solar race car 11
Figure 8 The GM Sunraycer 12
Figure 9 Venturi Astrolab 12
Figure 10 Body Forces on a trike 15
Figure 11 Trike stability diagram 15
Figure 12 Free body diagram for C.G Half-width 15
Figure 13 ANTI-ACKERMAN GEOMETRY 17
Figure 14 Ergo-Body Posture 18
Figure 15 Front View; Isometric View; Back View 20
Figure 16 Side View 20
Figure 17 Front Impact; Figure 18 Rear Impact 21
Figure 19 Side Impact; Figure 20 Torsional Analysis 21
Figure 21 Side view of the fabricated vehicle; Figure 22 Rear view of the fabricated vehicle 30
Figure 23 Block Diagram of working of Buck Boost Converter 31
Figure 24 Infrared Transceiver 32
Figure 25 Arduino Uno Microcontroller Interface 32
Figure 26 Arduino Sketch Block Diagram 33
Figure 27 A relay for main motor supply Circuit Diagram 34
Figure 28 Team Shauridut represented at the dynamic round of Electric Vehicle Championship
2015 at Ambala 43
7
CHAPTER I
1. INTRODUCTION
transition to this energy based economy capable of sustaining the anticipated growth in the
world economy is possible. This effective source is Solar Energy.
CHAPTER II
In 1955, William G. Cobb of the General Motors Corp. (GM) demonstrates his 15 inch long
"Sun-mobile", worlds first ever solar-powered automobile at the General Motors Powerama
Auto show held in Chicago, Illinois. Cobb's Sunmobile introduced the field of Photovoltaics -
the process by which the sun's rays are converted into electricity when exposed to certain
surfaces. When sunlight hit 12 photoelectric cells made of selenium (a non-metal substance with
conducting properties) built into the Sunmobile, an electric current was produced which in turn
powered an electric motor. The motor turned the vehicle's driveshaft which was connected to its
rear axle by a pulley.
Figure 1Sun-mobile
In 1962, the first solar car that a person could drive was demonstrated to the public. The
International Rectifier Company converted a vintage model 1912 Baker electric car to run on
photovoltaic energy in 1958, but they didn't show it until 4 years later. Around 10,640
individual solar cells were mounted to the rooftop of the Baker to help propel it.
In 1977, Prof. Ed Passereni of Alabama University built the Bluebird solar car, which was a
prototype full scale vehicle. The Bluebird was supposed to move from power created by the
photovoltaic cells only without the use of a battery. The Bluebird was exhibited in the
Knoxville, TN 1982 World's Fair.
In 1979, Englishman Alain Freeman invented a solar car. His road registered the same vehicle
in 1980. The Freeman solar car was a 3-wheeler with a solar panel on the roof.
At Tel Aviv University in Israel, Arye Braunstein and his colleagues created a solar car in 1980.
The solar car had a solar panel on the hood and on the roof. The Citicar comprised of 432 cells
creating 400 watts of peak power. The solar car used 8 batteries of 6 volts each to store the
photovoltaic energy. The 1320 pounds solar Citicar is said by the engineering department to
have been able to reach up to 40 mph with a maximum range of 50 miles.
Figure 5Citicar
11
In 1981, Hans Tholstrup and Larry Perkins built a solar powered race car. In 1982, the pair
became the first to cross a continent in a solar car, from Perth to Sydney, Australia. It was
powered by 8 square metres of solar cells and could store surplus solar energy in two 12V
lead-acid batteries for later use. The electric motor could be fed either 12V or 24V, giving some
measure of speed control. The car had four gear ratios which could only be changed when the
vehicle had stopped. Thirty years ago, things like high -efficiency solar cells, MPPTs, in-wheel-
motors, PWM speed controllers and wireless telemetry were still very much in the future but
even with this basic setup they made it. The suspension less vehicle bumped its way across the
Australian continent on bicycle tyres in twenty days which was ten days faster than the first
fossil-powered vehicle to travel that same route.
In 1984, Greg Johanson and Joel Davidson invented the Sunrunner solar race car. The
Sunrunner set the official Guinness world record in Bellflower, California of 24.7 mph. In the
Mojave Desert of California and final top speed of 41 mph was officially recorded for a "Solely
Solar Powered Vehicle" (did not use a battery). The 1986 Guinness Book of World Records
publicized these official records.
The GM Sunraycer in 1987 completed a 1,866 mile trip with an average speed of 42 mph. Since
this time there have been many solar cars invented at universities for competitions such as the
Shell Eco Marathon. GM Sunraycer was 19.7 feet long, 6.6 feet wide and 3.3 feet high. It
weighs 390 pounds and had gross weight of 573 pounds with driver. Average speed of 41.6
mph during 44.9 driving hours over 1950-miles race. It's was made of aluminium tube space-
frame chassis with body of composite sandwich material. It contains solar array of about 90
square-feet to power 3 KW, 4 HP magnequench brushless DC-Motor.
There is also a commercially available solar car called the Venturi Astrolab. Time will only tell
how far the solar car makes it with today's and tomorrow's technology.
Today, more than a half-century after Cobb debuted the Sun-mobile, a mass-produced solar car
has yet to hit the market anywhere in the world. Solar-car competitions are held worldwide;
however, in which design teams pit their sun-powered creations (also known as photovoltaic or
PV cars) against each other in road races such as the 2008 North American Solar Challenge, a
2,400-mile drive from Dallas, Texas, to Calgary, Alberta, Canada, ISIE ESVC India etc.
13
CHAPTER III
In Accordance to the Golden rule of TRIKE DESIGN, it appears to stem from HGJ's calculations
on lateral stability. To ensure lateral stability for the situation of constant speed straight line
motion, it is recommended that the three wheeled vehicle with two wheels on the front axle be
designed so that its mass centre is located in the front third of the vehicle. The centre of gravity
should be mounted as close to the two-wheel axle as possible to maximise rollover stability. The
height of the centre of gravity should be less than half the track measurement and less than the
distance to the front axle. If the centre of gravity is in the front half of the vehicle, the vehicle
will be stable at all speeds, otherwise further calculation is necessary to determine the speed limit
of lateral stability.
Lateral Stability: Depending on the value of the under steer coincident a vehicle may be either
directionally stable at all speeds, or become unstable above a threshold speed (known as the
critical speed).
Rollover Stability: A measure of a vehicle's tendency to tip over sideways when a lateral body
force is applied (e.g. during cornering). Engineering design is all about compromise, and
deciding on track, wheelbase and weight distribution is one big set of interrelated effects.
3.1 FOR A TADPOLE LAYOUT (2 WHEELS ON THE FRONT AXLE, 1 ON THE REAR)
Track: Wide track gives good lateral stability, though being wider than a bike; it limits the places
that it can get through without being disassembled. On the road however, that extra width means
passing vehicles are further away from the rider. A narrow track can allow a trike to ride through
doorways, but makes it easier to tip over in the corners.
Wheelbase: A longer wheelbase gives a smoother ride with less pitching and allows greater
braking performance, but gives a proportionally thinner trike, thus lowering the roll-over
threshold. Shortening the wheelbase gives better lateral stability, but could pitch forward under
heavy braking.
Centre of Gravity (CG): A rearward weight distribution improves directional stability under
braking, but reduces lateral stability Having the weight distribution forward improves lateral
stability, but reduces directional stability under braking (as load on the rear gets less) and at the
extreme, lifting the rear wheel and tipping the nose to the floor.
up more space on the road. Its still important to have a stable trike and this is how Ive gone
about sizing it.
Stability: This isnt a lesson and theres no quiz at the end, this is a reference. Normally when I
read technical papers, I skip over the equations first time through. I begin stability calculations
with an approximate wheelbase, track and centre of gravity position and then iterate through the
calculations to refine them from there. Because the all three values have interrelated effects,
theres no clear reference value, so I prefer to work from a rough idea, check if its feasible and
then refine it from there.
The width of half the stability area at the position of the centre of gravity (v) is:
V = u tan
= tan1 (t/w)
V = ut/w
The resultant force on the C.G (FR) is the vector addition of the two orthogonal forces and the
projected length of it at the ground (l) are:
For the limit conditions,
When l < vl\lt the vehicle is stable,
When l = vl roll-over point,
When l > vl \gt vehicle has rolled over.
So to calculate the lateral acceleration limit (in multiples of g):
hamax = ut/w
amax = ut /wh
16
This means, with track of 1.56 m (t = 0.78) that the maximum lateral acceleration occurs at
0.78g (7.651 m/s2).
Weight Distribution: Ive heard that the weight distribution for a trike is best with a third on
each tyre, but this represents a situation where maximum deceleration during braking will be
slightly less than cornering performance, and reduced load on the rear tyre under heavy braking
could allow directional instability, depending on the centre of gravity height. It is normally
better to think about front/rear weight distribution in terms of axles. You dont get any more
grip just by adding extra wheels to an axle in the same way you dont get extra grip just by
adding wider wheels. All things being equal, as the load on each tyre reduces, the amount of
grip for each tyre reduces proportionally (Its a generality, there are effects by changing the
number of wheels and size of the contact patches, but friction doesnt care about contact area).
Front axle load can be calculated from equilibrium of moments about the rear contact patch:
Ffront= mgu/w + mah/w
At static loading:
Force {front} = 40 mg
Force {rear} = 60 mg
At 1g braking:
Force {front} = 56 mg
Force {rear} = 44 mg
40/60 at static laden is not the ideal 50/50, but its not far enough away to cause any drastic
handling problems; its quite normal to see a modern forward car around 63/37.
17
CHAPTER IV
Treats more gently with inner wheel during lateral load transferring situation & involve outer
wheel to get proper cornering due more grip.
CHAPTER V
The Drivers must wear a certified driver suit during the dynamic rounds of the event.
The drivers must also use a certified helmet, gloves and shoes during the dynamics rounds.
Each team must be having two drivers and they both must have a valid medical insurance
and driving license which must be presented on the event site when asked by the officials.
There must be a firewall between the driver and Drive train so as to protect him from the health
hazards that can happen. Fire wall should be a thermal and electrical insulator and rigid.
There should be two kill switches the vehicle. They should be placed in such a way that it can
be easily accessed by driver and other outside the vehicle for organizers. Kill switch be clearly
visible from a long distance with a bright red colour.
The Drivers seat should be properly fixed and rigid. There must be a set of seat belts in the
seat. Use of seat belt is mandatory in the event.
The teams must use fire extinguishers of 2.0 kg during the event and that has to be rigidly fixed
to the vehicle.
No wires must go under the base frame of the vehicle or the lowest point of the vehicle.
Motor, suspension, steering, braking and transmission should be fastened by lock nut.
19
CHAPTER VI
Length: 5060 mm
Width: 1340 mm
Height: 1234 mm
Ground Clearance: 152.4 mm
Wheel Base: 1980 mm
21
Using formula,
Rolling Resistance = 0.092 x mass of vehicle x average speed
= 0.092 x 130 x 35
= 418.6 Watt
Motor Specification
Power 750W
Operating Voltage 48V
Battery Specification
Voltage 12V
25
Capacity 20 AH
Quantity 4
Energy Calculation
Energy consumed by motor in 3 hrs. = Power x Time
= 500 x 3
= 1500 WH
Charging time (from 0 to 100% without considering power loss) = Energy Stored in Battery/Power of
panel
= 720/400
= 1.8 hours
Charging time (from 0 to 100% considering power loss factor as 2.5) = 4.5 hours
26
Leverage 3
6.7.13 CALCULATION FOR INERTIAL TORQUE (TJ) FOR DYNAMIC BRAKING ONLY
CHAPTER VII
Figure 21 Side view of the fabricated vehicle Figure 22 Rear view of the fabricated vehicle
It is basically a dc transformer which can step up or step down the voltage on the basis of
chopper circuit.
We can increase the output voltage by increasing the duty cycle of semiconductor switch.
We can directly charge the battery through an inductor to prevent the sudden change in current.
We can, as well as connect the Dc motor directly to the circuit.
CHAPTER VIII
8. INNOVATION
Arduino Sketch (program for the ABA): This helps to have an external programmer (e.g.
an AVR-ISP, STK500, or parallel programmer), you can burn sketches to the Arduino
board without using the bootloader. This allows you to use the full program space (flash)
of the chip on the Arduino board. So with an ATmega168, you'll get 16 KB instead of 14
33
(on an ATmega8 you'll get 8 KB instead of 7). It also avoids the boot loader delay when
you power or reset your board.
Objectives of ABA:
The objective of this device is to alert the driver to apply brakes in situations where the velocity
of the vehicle is high enough to not allow the vehicle to stop within a distance which is necessary
to avoid collision. The device will determine the relative velocity between the vehicle and the
object in front of it (which may be another vehicle). It will sound an alert if this relative velocity
suddenly increases. It will be triggered at a distance that is sufficient for the vehicle to stop to
prevent collision.
Program Logic:
The instantaneous relative velocity of the vehicles will be calculated by time averaging the
difference of two consecutive readings of distance. This velocity will be compared with a table
of Minimum real velocities and corresponding Braking distances. The alarm will be triggered
if this relative velocity exceeds the velocity corresponding to the current distance between the
vehicle and the object.
34
Safe-speed setting (SSS) is an electronic device to have a proper control on vehicle propulsion
and also helps the vehicle for better performance. It controls the performance of motor under
every possible condition. Major components of SSS:
Digital speedometer
A feedback control circuit (on-off control or proportional control)
A comparator
Functioning of SSS:
The speed setting in terms of voltage is input to the comparator
An output from the digital speedometer will be fed to the comparator
The comparator decides if the vehicle velocity exceeds or is below the set velocity
The comparator output controls: a relay that will switch the motor - or - a potentiometer
that will control the speed of the motor
35
It is a simple circuit for protecting and monitoring the health of the electrical system of the
vehicle (electric drive and auxiliaries). Monitored aspects:-
Battery health indication (Percentage charge)
Motor protection (overload tripping and Low voltage cut-off) with by-pass option.
Live-body detection and warning.
Electric throttle malfunction and auxiliary electric throttle.
Components
For battery health indicator: a 5-LED indication via analogue circuit
For motor protection: an MCB of appropriate rating
For Live-body: a sensitive LED indication via appropriate circuit
For electronic throttle malfunction: LED indication for loose connection
Advantages
Quick localization of fault in the vehicle
Decreases potential of damage to equipment
Cost effective as it cuts expenditure on spare parts
Physical safety of personnel
Easy to repair the vehicle as exact cause is made known
36
CHAPTER IX
Team Shauridut has designed and manufactured a single seated three wheeler electric solar
vehicle which has a unique concept of directly running on solar power without the use of any
external batteries. This vehicle is very effective in running directly on solar power with an
approx. speed of 20-30 kmph. This vehicle goes to a top speed of approx. 50-60 kmph. The
Vehicle has a powerful 500W, 36V motor and 6X100W solar panels. It has many innovative
systems attached to the vehicle like KERS, brake alerts, distance measuring system, advanced
panel cooling system, etc.
9.2.1 STRENGTH
which are ultra-light weight. But this doesnt reflects on the strength of the vehicle nor on its
dynamic stability and vehicle is durable at any extreme conditions.
Run directly on Solar Energy
We have specially concentrated on the fact to run the vehicle directly on solar power on full load
with best performance and speed of the vehicle. We have been successful in designing and
manufacturing such vehicle which is capable of running directly on solar power. We have 6 solar
panels which is sufficient to drive a powerful electric hub motor to take a average load on 50-80
kg mass. This is a great achievement from the future point of prospective.
9.2.2 WEAKNESS
9.2.3 OPPORTUNITIES
9.2.4 THREATS
9.3 S T P ANALYSIS
9.3.1 SEGMENTATION
Geographic
We are focusing in both urban and rural parts of India but to have our manufacturing hub and
initial launch in Orissa since Orissa is the only area/state in India to receive highest intensity of
solar rays.
Demographic
India is the world largest country with youngsters (below 30) having formal technical
knowledge.
We plan to develop the service sector of India by using the labour force available in India for
expanding from Light Motor Vehicle to Heavy Duty Vehicle.
Psychographic
People of India are very concerned regarding the cost factor.
Inspiring the labour force to go for non-conventional sources of energy because its a necessity
right now as we are reaching the point when we will be out of petroleum products.
Societys style statement is going to get affected too. In other words, when the neighbour is
going to have a solar car, its natural in India that people will get curious and they would want to
have one such type of car as well.
9.3.2 TARGET
Target audience comprises everybody who are eligible to drive, that is, youth, elders,
Male/female
39
9.3.3 POSITIONING
Using the unique concept of running the vehicle only with solar energy but not batteries
It is a burning topic of todays debate on fuel scarcity.
Inspiring the youth for sustainability of conventional resources
Expanding from Light Motor Vehicle to Heavy Duty Vehicles and we initiate it from
Orissa.
We collaborate with TATA Powers who is going to help us get promoted in the market
through channels like print media, online media, social media and conducting workshops
as well.
We are collaborating with TATA Powers because of and solar car will be used for the
TATA Powers industry tour too.
We also collaborate with profitable government funded NGOs (e.g.: CREDA) which
basically promotes eco-friendly environment and let them use our vehicle as their official
transport facility.
Collaborations with mini cities/ townships (e.g.: Renaissance Housing Society, Burdwan,
West Bengal) and every property buyer of the township will be getting a solar vehicle
along with their property and the township will be promoted as an eco-friendly township.
Replacing auto rickshaws with solar car. CNG running rickshaws wont sustain for long
as CNG is one of the conventional source of energy which will surely get extinct at some
point of time
Using solar car for college/university campus tours.
Replacing petrol/diesel running golf cart with solar golf cart
We also collaborate with Uber Cab Service, which basically gives their car on rent basis
and, let the customer be the driver.
In rural areas, if one of the resident buys the solar car, the mentality of the people living
over there becomes more curious about the same and it turns out to be a big deal for the
people who doesnt own it. This is not only because of the features or specialty of the
technology involved behind but its about reputation factor too in the rural India.
40
9.5 BUDGET
9.6 SUSTAINABILITY
Limited Conventional resource and will get extinct in the near future.
Expensive
Hazardous
Not eco friendly
High maintenance and running cost
CHAPTER X
10. COLCLUSION
The above results, discussions as well as mechatronic design for an electric solar vehicle
concludes the followings:
i. A three-wheeled low-cost electric solar vehicle (ESV) for lower income strata of
developing countries is feasible and practicable.
ii. Our ESV, a single-seated vehicle powered by 750 W BLDC hub motor can be a good
choice for Indian market.
iii. A multivariate technical group has enriched the design and fabrication of our EVS, for
which it stands with higher safety, high performance as well as cost-efficient electric
solar vehicle.
iv. The dynamic stability of our ESV has been successfully done through maintaining the
CG in the front half of the vehicle which in turn taking care for lateral and rollover
stability as well.
v. Our design for wide track, longer wheel base and forward weight distribution system
improves lateral stability of the ESV, which also reduces directional stability under
braking (as load on the rear gets less) and at the extreme, lifting the rear wheel and
tipping the nose to the floor.
vi. During fabrication a special attention was given to reduced cornering stability with
acceleration of a tadpole which becomes reduced cornering stability with braking.
vii. Use of Buck Boost Converter in the EVS improve the efficacy of its power system
including effective recharging facilities.
viii. Safety and Ergonomics consideration in design as well as in fabrication including drivers
seat design, incorporation of lock nut for motor, suspension, steering, braking and
transmission etc. strengthen the acceptability of consumers in Indian road ways.
ix. Application of Automatic Brake Alert in our design strengthens the safety aspects of the
ESV which will reduce the severity of any accident. This is our special innovation in this
project.
43
x. The attempt in using a Safe-speed setting (SSS), an electronic device to have a proper
control on vehicle propulsion, was also successful for the ESV.
xi. Use of aluminum alloy pipes for light weighted chassis with durable strength, use of
Ergonomically designed vehicle interior, running on direct solar power without battery
source, use of several advanced electronic devices like kinetic Energy Recovery System,
Automatic Brake Alert system, Distance measuring system, Solar panel Heat sensors,
Advanced Cooling system etc. have strengthen the vehicle as an advanced ESV in global
market.
xii. It is an economically viable, low budgeted ESV costing only within INR 80,000,
xiii. The present eco-friendly ESV, RayRacer can be a choice for future generation
consumers.
Figure 28 Team Shauridut represented at the dynamic round of Electric Vehicle Championship 2015 at Ambala
44
CHAPTER XI
11. BIBLIOGRAPHY