Structural Design and Manufacturing of a Cruiser Class Solar Vehicle

Abstract

Cruisers are multi-occupant solar vehicles that are conceived to compete in long-range (over 3,000 km) solar races based on the best compromise between the energy consumption and the payload. They must comply to the race's rules regarding the overall dimensions, the solar panel size, functionality, and safety and structural requirements, while the shape, the materials, the powertrain, and the mechanics are considered at the discretion of the designer. In this work, the most relevant aspects of the structural design process of a full-carbon fiberreinforced plastic solar vehicle are detailed. In particular, the protocols used for the design of the lamination sequence of the chassis, the leaf springs structural analysis, and the crash test numerical simulation of the vehicle, including the safety cage, are described. The complexity of the design methodology of fiber-reinforced composite structures is compensated by the possibility of tailoring their mechanical characteristics and optimizing the overall weight of the car. Video LinkThe video component of this article can be found at https://www.jove.com/video/58525/ A new design philosophy must be approached, including a different vision of material use and manufacturing. First, materials must be selected based on the highest strength-to-weight ratio and, as a direct consequence, carbon-reinforced fiber plastics represent an optimal solution. Furthermore, specific stratagems in the design must be implemented.In the present article, the procedures employed to design some of the most important structural parts of the solar vehicle, such as its monocoque chassis, the suspension, and even a computational crash test are depicted. The final scope is to obtain rapidly a solar vehicle with the least possible weight, in a trade-off with aerodynamics and race rules.

Effect of the Stacking Sequence on the Impact Response of Carbon-Glass/Epoxy Hybrid Composites

“…Glass or carbon fiber reinforced polymer composites have been conveniently used in a large selection of industrial products and applications [1], as aerospace and aircrafts [2,3], automotive [4][5][6], ships and sailing [7,8], biomedicine and sports [9,10]. This is especially due to their high strength to weight ratio and non-corrosive properties.…”

Effect of ply thickness on damage mechanisms of composite laminates under repeated loading

“…Due to the excellent properties of composites, such as light-weight, high-strength and corrosion resistance [1], the use of these materials has increased drastically in a large assortment of multi-faced applications and market products [2], involving different industrial sectors and market segments such as aerospace and aircrafts [3,4], automotive and motorbikes [5,6] or their parts [7], sport equipment, architecture and interiors, energy and windfarms, oil and gas, sailing and boat building [8,9] or many others (Figure 1).…”

Static stress analysis of suspension systems for a solar-powered car

“…It is equipped with a solar-electric powertrain developed for efficiently transporting four passengers weighing 80 kg each. With a monocoque, structural and non-stuctural parts in carbon fiber reinforced polymer (CFRP), a roll-cage in titanium alloy, and some other distinct technical features, it represens one of the lightest multi-occupant solar cars ever built [16]: a vehicle with total mass of 300 kg allows to transport 320 kg due to four occupants. Using 5 m 2 of monocrystalline silicon photovoltaic panel on the roof, 64 kg of lithium-ion batteries, two electric engines coupled directly to the rear wheels and further solutions for optimal energy control, either a range of 600 km at cruising speed, or velocitiy peaks of 120 km/h can be achieved [16].…”

“…With a monocoque, structural and non-stuctural parts in carbon fiber reinforced polymer (CFRP), a roll-cage in titanium alloy, and some other distinct technical features, it represens one of the lightest multi-occupant solar cars ever built [16]: a vehicle with total mass of 300 kg allows to transport 320 kg due to four occupants. Using 5 m 2 of monocrystalline silicon photovoltaic panel on the roof, 64 kg of lithium-ion batteries, two electric engines coupled directly to the rear wheels and further solutions for optimal energy control, either a range of 600 km at cruising speed, or velocitiy peaks of 120 km/h can be achieved [16]. During its first contest (American Solar Challenge 2018) this vehicle travelled 1.762 miles (2835 km) in the Unites States with four passengers, without other energy sources than the sun, winning at a cruising speed of about 55 km/h [6].…”

“…Currently, the suspension system is based on a novel design consisting of longitudinal arms with leaf springs ( Figure 2) in which arms, springs and wheels are made in CFRP [16]. Figure 3 shows how the transversal leaf spring is mounted.…”