Battery electric vehicles fitted with solar cells would extend their range and allow recharging while

parked anywhere in the sun.

Solar array
The solar array consists of hundreds of photovoltaic solar cells converting sunlight into electricity Often made of gallium arsenide.

Batteries
Solar cars use a range of batteries including lead-acid batteries, nickel-metal hydride batteries (NiMH), NickelCadmium batteries (NiCd) and Lithium ion batteries.

Challenges

The design of a solar vehicle is severely limited by the energy input into the car (batteries and power from the sun).

solar cells generally used on the roofs of buildings where they are always exposed to the sky and weight is largely irrelevant rather than on vehicle roofs where size is limited.

Limitations

Electrical and mechanical systems

The electrical system controls all the power that comes into and leaves the system. Solar panels converts the solar energy into electrical energy which is stored in batteries. Hence batteries act as fuel tank in solar car.

Mechanical systems
The mechanical systems of a solar car are designed to keep friction and weight to a minimum while maintaining strength. composites ensure a good strength-to-weight ratio.

Solar cars usually have three wheels, two front wheels and one rear wheel: the front wheels steer and the rear wheel follows. Generally a Solar car has room for one person.

DESIGN of solar car

It includes chassis & framework of the car. No. of solar cells to be placed. Suspension used. Type of steering used. Type of braking used
Size and dimensions of batteries and motor used.

Classification

Designing of solar car can be divided into following parts : chassis & framework. braking. suspension, wheel & wheel hub. steering.

CHASSIS & FRAMEWORK

Chassis
Chassis is classified on basis of: a) No. of wheels & no. of driving wheels, b) On basis of wheel base size

Frame

Frame is the main part of chassis on which automobile components are attached. It should be rigid and strong enough to support the weight of vehicle including the driver and to withstand stresses, shocks and vibrations encountered on the road.

Type of tube and its material to be used

There

are two types of tubes used 1) rectangular or square , 2) round cross section tubes We will use round tubes as they stronger by unit weight than rectangular and lighter than rect. one. Size & strength of tube is specified by its O.D and its wall thickness .

Material used
The material to be used to const. the frame work and body should be light in weight & strong and within the budget. Some of the alloys are: Chromoly (s.a.e j404 chromium-molybdenum alloy steel) i.e. 4130 steel Alloy of aluminum like 6061 and 7075 Titanium Carbon fiber tubes. Out of all the alloy CHROMOLY is best suited since it can be easily welded and is easily available.

BRAKING SYSTEM

Apart from the mechanisms for starting, accelerating and running a vehicle on the road, an additional system for stopping the vehicle is also required Known as braking system.

FUNCTIONS OF A BRAKE The brakes of a vehicle have to absorb all the energy given to the vehicle by the engine plus that due to the momentum of the vehicle.

CLASSIFICATION OF BRAKING SYSTEMS

1.HAND BRAKES 2.MECHANICAL BRAKE SYSTEM 3.HYDRAULIC BRAKE SYSTEM

HAND BRAKE SYSTEM

The hand brake is used: (1)when stopping and starting a car on a slope (2)when parking

MECHANICAL BRAKE SYSTEM

Mechanical brake system is used to apply brakes to all four wheels of vehicle. There are cams and brake shoes on the four wheels. Cams are connected to the brake pedal by means of levers and flexible cables.

HYDRAULIC BRAKE SYSTEM

Complete compensation is achieved by using a fluid to operate the brakes. This is because a fluid in a closed circuit exerts an equal pressure in all directions and further advantage is that as no mechanical linkage is necessary and therefore frictional losses are considerably reduced.

CLASSIFICATION OF BRAKES

1.DRUM BRAKES 2.DISC BRAKES

ADVANTAGES OF DISC BRAKES:

(1)Disc brakes are lighter than drum brakes. (2)Better cooling effect. (3)Pressure distribution is uniform in distribution. (4)Brake pads can be easily removed.

DISADVANTAGES OF DISC BRAKES:

(1)Cost is higher. (2)Higher pedal pressure is required for stopping vehicles.

SUSPENSION SYSTEM
THE SUSPENSION SYSTEM OF AN AUTOMOBILE SEPERATES WHEEL/AXLE FROM BODY.
THE PRIMRY FUNCTION OF SUSPENSION SYSTEM IS TO ISOLATE THE VEHICLE STRUCTURE FROM SHOCKS AND VIBRATIONS.

NEED FOR A GOOD SUSPENSION SYSTEM

A GOOD SUSPENSION SYSTEM MUST HAVE FOLLOWING TWO QUALITIES:

1. SPRINGINESS:IT IS THE ELASTIC RESISTANCE TO THE LOAD. 2. DAMPING:TO ABSORB THE WORK ENERGY AS HEAT ENERGY AND THE CONTINUOUS OSCILLATIONS OF SPRING.

ELEMENTS OF SUSPENSION SYSTEM

IMPORTANT ELEMENS OF SUSPENSION SYSTEM ARE: 1. SPRINGS. 2. DAMPERS. SPRINGS ACTS AS A RESERVOIR OF ENERGY. THEY STORE ENERGY DUE TO SUDDEN FORCE WHICH COMES WHEN THE VEHICLE ENCOUNTERS A BUMP. DAMPERS REDUCE THE TENDENCY OF THE CARRIAGE TO CONTINUE TO BOUNCE UP AND DOWN ON ITS SPRING AFTER THE DISTURBANCE.ALSO PREVENTS EXCESSIVE BUILD UP OF AMPLITUDE AT NATURAL FREQUENCY.

INDEPENDENT SUSPENSION
INDEPENDENT SUSPENSION IS A TERM USED TO DESCRIBE ANY ARRANGEMENT BY WHICH THE WHEEL HAS NO EFFECT ON OTHERS. INDEPENDENT SUSPENSION SYSTEM USES COIL SPRINGS. USUALLY FRONT AXLE IS DEAD AXLE AND REAR AXLE IS THE LIVE AXLE.

TYPES OF INDEPENDENT FRONT SUSPENSION SYSTEM: 1. DOUBLE WISE BONE SUSPENSION SYSTEM. 2. SINGLE WISE BONE i.e. MACPHERSON STRUT ASSEMBLY.

REAR WHEEL SUSPENSION SYSTEM

THE REAR AXLE IS THE LIVE AXLE AS IT IS RESPONSIBLE FOR TRANSMITING POWER TO THE WHEEL EXCEPT IN THE FOUR WHEEL DRIVES. LOAD VARIATIONS IN CAR AFFECTS THE REAR SUSPENSION THEREFORE REAR SUSPENSION HAS TO BE DESIGNED KEEPING IN MIND THAT THE DRIVE REMAINS COMFORTABLE WHEN THE CAR IS EMPTY OR CARRIES PASSENGERS

Steering system
Function of steering system is to enable the driver to control accurately the direction of the automobile by the means of Steering gears and Steering linkage. Good steering system provides directional stability, ease of steering through corners and reduces tyre wear.

Two major components of steering system:

1) Steering gears: It multiply the drivers effort at the steering wheel. It changes rotary motion of the steering wheel into straight line motion that will move the steering linkage. It provides a gear reduction that will make the automobile easier to steer. Steering ratio: A typical ratio of 16:1 means that in order to turn the front wheels by one degree, the steering wheel has to be rotated 16 degrees.

2) Steering linkage:
Steering linkage system connects the gear box to the front wheels. The steering linkage transfer the side-to-side movement of the pitman arm into the left-to-right movement of wheels.

ELEMENTS OF STEERING SYSTEM:

Tie rod ends allows the linkage to move back and forth freely so that steering effort will not interfere with vehicles up & down motion on the road. Relay rod attached to steering gears moves when the steering wheel is turned. Idler arm moves back & forth with the relay rod, connected at each end to a tie rod. The tie rods are attached to each wheels spindle assembly so that movement of steering wheel results in movement of front wheels.

Steering geometry:
Caster angle: is the tilt or inclination of the top axle towards the front or rear of car. Camber angle: is the outward or inward tilt of wheel at the top. Outward tilt is assumed as(+ve) & inward tilt as (-ve) camber angle. Kingpin inclination: is tilted in at the top towards the vehicle so that weight of the load will be thrown towards the tyre centre. Toe in: the wheels are closer together at the front than at the back. Toe out: spreading apart of front wheels on turns to give correct turning alignment.

Ackerman linkage for turning the vehicle:

The Wheels should move about a common centre to roll freely without sideslip. The centre will be on a line drawn through the rear axle, where lines drawn through the centre of the front wheels intersect. The inner wheel must turn through a greater angle than the outer. This difference in movement of the inner and outer wheels is obtained by inclining the track rod arms. The angular difference between tyres is about three degrees.

The inclination of the track rod arm is such that lines drawn through them will intersect theoretically at the centre of rear axle. This arrangement , usually known as Ackerman principle or linkage.

Practical applications

Electro-solar hybrid car which uses Solar energy as well as runs on conventional Fuel.