 Chapter 5

Engineering Design Process

Introduction to Engineering Course

International University for

Science & Technology
The Engineering Design Process

Step1 Step4
Customer need Development of
alternative
or opportunity designs

Step5
Step2 Evaluation of designs
Problem definition & Selection of optimal
& Specifications design

Step3 Step6
Data and information Implementation of
collection optimal design
Case Study:
Solar-Powered Electric Vehicle
Step 1: Customer Need or Opportunity
 write a proposal explaining how to design and build a solar-
electric vehicle to compete in a 1000 km cross-country race.

Step 2: Problem Definition and Specifications

 Maximum vehicle size: Length = 6 meters; Width = 2 meters;
Height = 1.6 meters
 Minimum height: 1 meter

 Maximum solar panel size: 8 square meters

 Battery type: Commercially available lead-acid batteries

 Maximum battery weight: 308 pounds

 Solar cells: Terrestrial cells costing less than $10/watt

Step 3: Data and Information Collection

you have to collect extensive data and information about:

 Technologies associated with electric motor systems,

batteries,
 Solar power systems
 Vehicle aerodynamics
 The design and construction of light-weight structures
 Mechanical drive systems, and wheels
 The topography of the race route, expected weather
conditions
Step 3: Data and Information Collection

High performance solar vehicle could be obtained by

achieving the following:

 High solar panel power

 Low aerodynamic drag
 Low vehicle weight
 High electrical power system efficiency
 High mechanical drive system efficiency
 Good battery performance
 High overall reliability
Step 4: Development of Alternative Designs

Design tradeoffs??

 High solar panel power requires large solar

panel surface area. However, large surface
area would result in high drag and high vehicle
weight.
Step 4: Development of Alternative Designs

Design tradeoffs??

 Low vehicle weight was imperative, but at some

point would contribute to poor structural integrity
and low overall reliability. One way to solve the
weight problem, at least partially, would be to
carry less battery capacity than the maximum
allowed. So you have to decide whether an
extra battery capacity is worth carrying an extra
weight.
Step 4: Development of Alternative Designs

An important step in this stage of the engineering design

process is to select performance specifications or design
targets for the key design parameters.
For example you can decide the following specifications:
 Solar panel power (peak) - 1,000 watts
 Aerodynamic drag - 0.13
 Vehicle weight - 300 pounds
 Electric power system efficiency - 92%
 Mechanical drive system efficiency - 98%
 Battery capacity - 5 kw-hr
Step 5: Evaluation of Designs and Selection of
Optimal Design
This is one of the most difficult and challenging part!.
You now need answers to such questions as:
 What should the external shape of the vehicle be?

 Should the structure be made from aluminum

tubing, composite materials, or a combination of
both?
 Should the vehicle have three or four wheels?
Step 5: Evaluation of Designs and Selection of
Optimal Design
 What solar cells should be selected?
 What motor and motor controller should be used?
 What type of drive train (chain, belt, or gear) should be
used?
 What type of tires should be used?
 What type and how many batteries should be used?

After answering these and other questions, you can choose

the optimal design. A series of drawings of all the parts
followed, and then you can advance to the final step of
the engineering design process.
Step 6:
Implementation of Optimal Design

Now began the "real" work, This part of the project

can be divided into three stages.
 The first stage consisted of building the
mechanical system, including the overall
structure, wheels, steering, and brakes.

 Stage two is the installation of the power

electronic system including the motor, motor
controls, batteries, and drive system.
Step 6:
Implementation of Optimal Design

 Third stage consists of the fabrication of the

external body, using composite materials to meet
weight requirements and then assembling the
solar cells and complete the solar panel.
Finally! A Beautiful Solar Vehicle