www.a4.frTECHNOLOGIE AU COLLEGE

September 2011

Solar-powered dragster

D-SLD

CONTENT OF THE CDROMThis project’s CDRom is available in the Company catalogue (ref “CD-BE1”).It contains:- The FreeHand version file - The Illustrator version file- The PDF version file (readable and printable with AcrobatReader software).- Photos of the product, perspectives in .DXF format- The full 3D modeling in the different versions of SolidWorks, Parasolid and eDrawings format.

This booklet and CDRom may be copied for students for internal school use*

September 2011Etienne Bernot - Jean Luc Mathey - Nicolas Devaine

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02 - 03

04

05

06 - 10

11

12 -13

14 - 15

16

17 - 18

8 rue du FromenteauZ.A. Les Hauts des Vignes - 91940 Gometz le Châtel

Tél. : 01 64 86 41 00 - Fax. : 01 64 46 31 19www.a4.fr

Edité par la Sté A4

Product presentation

Nomenclature and exploded of assembly

Exploded view and motor unit nomenclature

Drawings of two perspectives

Definition drawings of parts to be made

Shaping the aluminium wire

Electric circuit and wiring diagram

Vehicle assembly sheet

Nomenclature of kit

Option of electrical energy storage capacitor

* This booklet may be copied as many times as necessary within school establishments for educational use only, on thecondition that the publisher’s name is included: A4. Copying or distribution for commercial use is not permitted withoutagreement from A4. Any copying or distribution of all or part of this booklet outside of school use is not permitted withoutagreement from A4.

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Product Presentation

Soldrag vehicle photovoltaic cell:

Function

Manufacturing

Kit

Cell support

Photovoltaic cell

Gear motor

Chassis

Driving wheel

Flexible aluminium wire

Bonnet

On/Off command

Technology Efficiency Cost Use

Monocristalline cells 24% High

Polycristalline cells 18.6%

12.7%

Average

Amorphous cells Low

Aerospace

Home

Consumer products

Electric vehicle powered by solar energy.Only operates in direct sunlight (unless using the super capacity capacitor) or an incandescent lamp. Under tungsten or halogen lighting, a minimum of 300 W at 20 cm from the photovoltaic cell is required for an equivalent efficiency. A fluorescent tube lighting (neon) does not allow the photovoltaic cell to power the motor.The photovoltaic cell assembled on a flexible wire is adaptable to capture the light more easily.There is the option of a 10 F super capacity capacitor which can be assembled to store energy, thus allowing a few minutes of operation without direct lighting.

- Chassis: made of expanded PVC 3 x 40 x 127 mm (supplied in the kit): angles cutting + screws pointing- Photovoltaic cell support: made of 6 x 20 x 40 mm expanded PVC: cutting + drilling.- Cover: made of HIPS (High Impact Polystyrene) 1 x 40 x 127 mm (correct dimensions provided in the kit): angles cutting + drilling.- Cell support aluminium wire to be shaped- Angles to be cut again + small diameters drilling + hot bending on thermo-bender with resistant wire or cold bending.- PropulsO gear motor: provided in separate parts to be assembled.- Ø 3 steel axles: to be cut again with ends chamfered.- Wiring: wires to be soldered for to connect photovoltaic cell, motor and switch.

All parts and materials are available in full. The 560-757 reference kit contains the plastic parts ready to be assembled as well as all other parts and components (see page 16).

A cell converts lighting energy into electric energy. There are several technologies for photovoltaic cells, with different properties and efficiencies:

The photovoltaic cell of the SolDrag vehicle is amorphous; it is the best in terms of cost, but it is only efficient in a limited wave length range, near infrared.

A4

01 0102

0103

0104

02

05

02

02

07

13

A 01

01

0208

01

091011

01

1716 02

01

181920

02

03

01

222324

01010125

02

Rear wheel Injected ABS (on PropulsO set), Ø 48 mm

Countersunk head screws Ø 2.2 x 4.5 Nickel-plated steel, metal sheet, countersunk head, Ø 2,2 x L 4,5 mm

Aluminium wire Aluminium wire Ø 3 x L 110 mm1

Chassis Expanded PVC, thickness 3 x 40 x 127 mmHood HIPS thickness 1 x 40 x 127 mm

Cap screws Ø 2 x 6 Nickel-plated steel, metal sheet, cylindrical head, Ø 2 x L 6 mm

Photovoltaic cell 3 x 60 x 60 mm, 100 mAh under sunlight

Expanded PVC, thickness 6 x 20 x 40 mmSpacer plate

Washer 3 x 9 Injected ABS

Front wheel Injected ABS (on PropulsO set), Ø 28 mm

Cap screws Ø 3 x 6.5 Nickel-plated steel, metal sheet, cylindrical head, Ø 3 x L 6,5 mm

Double-sided tape Double-sided tape 20 x 20 mm

Cable wiring Red flexible wire, 1 conductor, length 140 mmCable wiring Red flexible wire, 1 conductor, length 15 mmCable wiring Red flexible wire, 1 conductor, length 125 mmMotor unit See detailed nomenclature of assembly on page 4

Student Worksheet

Staples Injected ABS

Change over slide switchSwitch

Front wheel axle Nickel-plated steel, Ø 3 x L 55 mmPhotovoltaic cell support plate Expanded PVC, thickness 6 x 20 x 40 mm

PROJECT PART

DOCUMENT TITLE

Name

ClassCollege

Date NOMENCLATURE

ASSEMBLY

MARK PART PROPERTIESNUMBER

TECHNOLOGYCOLLEGE

A4

03

18

02

20

07

10

11

A

03

04

19

17

01

0817

16

Unmarked screws are 18

Student Worksheet

ExerciseColour in the movable parts

05

09

22

16

A 01

PROJECT PART

DOCUMENT TITLE

Name

ClassCollege

Date EXPLODED VIEW

ASSEMBLY

TECHNOLOGYCOLLEGE

A4

04

01 Motor Ø 21 - Output axle Ø 2 - 2300 tr/min at 1.5 V.21

Rear driving wheels axle Nickel-plated steel, Ø 3 x L 60 mm06 01

02 Cap screw Ø 3 x 6.5 Nickel-plated steel, metal sheet, cylindrical head, Ø 3 x L 6.5 mm18

01

Screw without head

01Right flank

Injected ABS (on PropulsO set)01

Left flankInjected ABS (on PropulsO set)

12

01Gear

Injected ABS (on PropulsO set)

1314

Injected ABS (on PropulsO set)

15

21

15

13

12

18

06

A

14

Student Worksheet

Exploded view of motor unit APropulsO gear motor equipped with a motorspecially adapted to the photovoltaic cell used.

Important tips for the gear motor operation:

The axle mustn’t be distorted. This is likely to happenwhen 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 ends destroysthe pinion hub, removing a chip during the process.The pinion risks being unbalanced and free ofrotation on its axle.

An oil drop on the endless screw can improve thegear’s operation.

PROJECT PART

DOCUMENT TITLE

Name

ClassCollege

Date EXPLODED VIEW and NOMENCLATURE

MOTOR UNIT

MARK PART PROPERTIESNUMBER

TECHNOLOGYCOLLEGE

A4

05

Scale 1 : 1

Student Worksheet

ExerciseMeasure the three dimensions and pencil them onto the drawing

PROJECT PART

DOCUMENT TITLE

Name

ClassCollege

Date PERSPECTIVES

DRAWINGS OF TWO

TECHNOLOGYCOLLEGE

A4

06

01 01 Chassis Expanded PVC, thickness 3 x 40 x 127mm

Drilling spots are used to position and hold screws They are made with a needle or a 1.5 mm diameter drill.

Scale 1 : 1

15 x

45°

127

40

3 3.5

1122

.514

10

27

Student Worksheet

PROJECT PART

DOCUMENT TITLE

Name

ClassCollege

Date DEFINITION DRAWING

CHASSIS

MARK PART PROPERTIESNUMBER

TECHNOLOGYCOLLEGE

Drilling Spot

A4

07

02 01

Scale 1 : 1

Fo

ld li

ne

Fo

ld li

ne

10

2015 x 45°

127

10

4030°

10

30°

Hole Ø 3

Student Worksheet

PROJECT PART

DOCUMENT TITLE

Name

ClassCollege

Date DEFINITION DRAWING

BONNET

MARK PART PROPERTIESNUMBER

TECHNOLOGYCOLLEGE

Bonnet HIPS 1 x 40 x 127 mm

Cutting and drilling drawing (before bending)

Bending drawing

Hot bending on thermo-bender with resistantwire or cold bending after grooving.

The three drilling spots are 3 mm diameter and open.

A4

08

010304

01Photovoltaic cell support plate

Expanded PVC 6 x 20 x 40Expanded PVC 6 x 20 x 40

Spacer plate

Drilling spots are used to position and hold screws.They are made with a needle or a 1.5 mm diameter drill.

Scale 1 : 1

Ø 3.5

6

20

4010

17

5

Drilling spot

Student Worksheet

Cell support plate (4)

Spacer plate (3)20

10

10

Drilling spot

5

20

10

3.517

Drilling spot

Ø 3.2 x 10

6

40

17

PROJECT PART

DOCUMENT TITLE

Name

ClassCollege

Date DEFINITION DRAWING

CELL SUPPORTPLATE AND SPACER

MARK PART PROPERTIESNUMBER

TECHNOLOGYCOLLEGE

Drilling spot

A4

09

Front wheel axle Nickel-plated steel, Ø 3 x L 55 mm 0105

01 Gear 14Rear driving wheel axle Nickel-plated steel, Ø 3 x L 60 mm06 01

Injected ABS (on PropulsO set), 48 teeth

A 29 mm length tube will be usedas a template to fit the axle.

Functional tolerance is 1.5mm

Fitting

31,75

Scale 1 : 1

Chamfer0.5 X 45°

Chamfer0.5 X 45°

29.25

55

60

1.5

29

(29.25)

Assembling the rear wheel axle with the cogwheel

Front wheel axle (5)

Rear wheel axle (6)

PROJECT PART

DOCUMENT TITLE

Name

ClassCollege

Date DEFINITION DRAWING

WHEEL AXLES

MARK PART PROPERTIESNUMBER

TECHNOLOGYCOLLEGE

Student Worksheet

A4

10

01 Aluminium wire Aluminium wire Ø 3 x L 110 mm07

Scale 1 : 1

Chamfer0.5 X 45°

110

Ø 3

Ø 7 to 9mm

Aluminium wire before bending

Bended aluminium wire (7)

PROJECT PART

DOCUMENT TITLE

Name

ClassCollege

Date DEFINITION DRAWING

ALUMINIUM WIRE

MARK PART PROPERTIESNUMBER

TECHNOLOGYCOLLEGE

Student Worksheet

A4

11

010304

01Photovoltaic cell support plate

Expanded PVC 6 x 20 x 40 mm thicknessExpanded PVC 6 x 20 x 40 mm thickness

Spacer plate

01 Aluminium wire Aluminium wire Ø 3 x L 110 mm0717 02 Countersunk head screws Ø 2.2 x 4.5 Nickel steel, metal sheet, countersunk head, screws Ø 2.2 xL 4.5

02 Double-sided tape 20 x 20 mm double-sided tape19

Scale 1 : 1

07

07

1703

04

19

17

Pencil or pen Ø 7 to 9 mm

Shaping the aluminium wire

Assembling the plates and aluminium wire

PROJECT PART

DOCUMENT TITLE

Name

ClassCollege

Date SHAPING AND ASSEMBLY INSTRUCTIONS

ALUMINIUM WIRE

MARK PART PROPERTIESNUMBER

TECHNOLOGYCOLLEGE

Student Worksheet

Important tips for shaping the aluminium wire:- You will need a template to make it easier to shape it, for example a pen or pencil with a diameter between 7 and 9 mm,- Make a full turn with the aluminium wire around the template

Important tips for assembling the aluminium wire on the various plates:- The wire ends must be chamfered,- Screws (17) are used to fix the wire (7) onto the plates (3 and 4)

Photovoltaic cell 1.5 V

Motor

A4

12

Switch

Converting lightenergy into

electrical energyOn/Off Command

Converting lightenergy into

mechanical energy

Photovoltaic cell 1.5 V (20)

Switch (22) Motor (21)

Function Function Function

M

Structural diagram

Functional diagram

Part: Part: Part:

DRD de l'arrière 01 +DRD de l'arrière 01

-

PROJECT PART

DOCUMENT TITLE

Name

ClassCollege

Date FUNCTIONAL DIAGRAMSTRUCTURAL DIAGRAM

CIRCUIT

TECHNOLOGYCOLLEGE

Student Worksheet

A4

13

Wiring the electrical components

Wire routing

Motor polarity

Scale 1 : 1

22

20

21

24

25

23

03

A

As shown on the drawing, wires pass between thespacer plate (3) and the gear motor (A).

PROJECT PART

DOCUMENT TITLE

Name

ClassCollege

Date WIRING DIAGRAM

ELECTRIC CIRCUIT

TECHNOLOGYCOLLEGE

Student Worksheet

- Photovoltaic cell (20)- Motor (21)- Switch (22)- Black wire (23), length 140 mm- Red wire (24), length 15 mm- Red wire (25), length 125 mm

We use wires provided with the photovoltaic cell

The motors used are reversible; they can rotate in both directions.A test must be done on the first of a serial to determine which motor terminal you must connect the + of the photovoltaic cell so that the vehicle moves in the right direction. In fact, from one series to another, marks on motor terminals can be different.

Test to be done on the first of a series:- Identify how one you can distinguish between both motor terminals.- Conduct an operation test to identify on which terminal you must connect the + of the photovoltaic cell, for the whole series to be manufactured.

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ASSEMBLY GUIDEStage Activity

100

140

150

120

130

Motor unit assemblyPlan: gear motor assembly plan on page 04.Parts: PropulsO set, 2 screws TC Ø 3 x 6.5 mm, motor, steel axle Ø 3 x L 60 mm.Tools: Phillips screwdriver, cutter plier.Control : function test with a power supply (battery) 1.5 to 3 V.

Aluminium wire and plate assemblyPlan : assembly plan of aluminium wire and plates on page 11.Part : spacer plate, cell support plate, aluminium wire Ø 3 x L 110 mm,2 countersunk head screws Ø 2.2 x L 4.5 mm.Tools : Phillips screwdriverControl : one can bend the aluminium wire without it moving (rotating)in the plates.

Fixing the spacer plate onto the motor unitParts : 2 cap screws Ø 3 x 6.5 mm, motor unit, aluminium wire and assembled platesToolsl : Phillips screwdriver.Control : good support : no gap in the assembly.

Fixing the motor unit on the chassisParts : motor unit, 4 cap screws Ø 3 x 6.5 mm, chassis.Tools : Phillips screwdriver.Control : good support : no gap in the assembly.

Fixing the double-sided tape onto the cell support plateParts: cell support plate and double-sided adhesive pellets.Control: positioning ; the double-sides pellets must not exceed the plate sides.

Student Worksheet

– Using the parts supplied in kit K-SLD

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160

170

180

190

200

Fixing the front axle on the chassis and rear wheels on the gear motorParts : 2 wheels Ø 28, 2 wheels Ø 48, 2 treads,4 screws CH Ø 3 x 6.5 mm, chassis, axle Ø 3 x L 55.Tools : Phillips screwdriver, cutter plier (removing plastic parts).Control: good support: no gap in the screwed assemblies but the front axlemust stay free of rotation.

Attaching the switch on the motor unitParts : motor unit, switch, 2 screws Ø 2 x 6 mm.Tools : Phillips screwdriver.Control: good support : no gap in the assembly.

WiringPlan: wiring diagram of various electrical elements on page 13.Parts: motor unit, switch, connecting wires (23, 24 and 25).Tools: soldering iron, cutter plier.Control : function test under sunlight or incandescent light.

Fixing the photovoltaic cell on the cell support plateParts: photovoltaic cell, cell support plate equipped with 2 double-sidedadhesive pads.Control : good support : no gap in the assembly.

Fixing the hood on the chassisParts: 3 washers Ø 3x9, 3 cap screws Ø 3 x 6.5 mm, cover, vehicle.Tool: Phillips screwdriver, cutter plier.Control: good support : no gap in the assembly.

Student Worksheet

ASSEMBLY GUIDEStage Activity

- Using the parts supplied in kit K-SLD

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Kit Nomenclature

Red PropulsORef. : PO-GRAP-01-R

01

01

01

01

01

02

02

15

01

01

Photovoltaic cell 4.5 V - 100 mAh under sunlight.Dimensions 60 x 60 x thickness 3 mm. Ref. : CEL-2V6-160MA

Grey expanded PVC plate 127 x 40 x thickness 3 mm (chassis).

HIPS yellow plate 127 x 40 x thickness 1 mm (cover).

Grey expanded PVC plate 20 x 90 (85 mini) x thickness 6 mm

Double-sided adhesive pads 20 x 20 mm. Ref AD-D08

Sheet metal screws: cylindrical head Ø 2 x L 6.5.Ref. : VT-TC-2X6

Sheet metal screws: cylindrical head Ø 3 x L 6.5.Ref. : VT-TC-3X6

Electric motor specially adapted to the solar cell.2300 tr/min under 1.5 V - Ø 21 - Axle 2 mm. Ref MOT-D21-SOL-A

Steel axle Ø 3 x length 120 mm minimum.

Micro-inverter with slider.Ref INV-GLI

01

01Aluminium wire Ø 3 x length 110 mm minimum.

Sheet metal screws: countersunk head Ø 2.2 x L 4.5.Ref. : VIS-TF-2M2X4M5

02

01Super capacity chemical capacitor 2.3 V - 10 F. 01 Ref : CDC-10F

The kit described here corresponds to the individual one (to make an object):The kit for 10 manufacturing differs by the quantity of each part (x 10) and the packaging; partsare grouped by type.In the kits, plastic parts have correct dimensions.Important tips: to avoid losing parts, do not detach them from the PropulsO injection bunchbefore use.

Part Quantity Diagram

Option of electrical energy storage capacitor

Student Worksheet

17 www.a4.fr

Electric energy storage capacitor optionThe super capacity capacitor is directly soldered to photovoltaic cell terminals.As soon as the cell is lit, even under a diffuse light, the capacitor begins to load.Upon starting the vehicle, the capacitor is unloading in the motor; that allows autonomy for up to8 minutes, depending on its load.

Comment :To simplify, there is no serial diode with the capacitor. Consequently, in the absence of light, thecapacitor unloads through the photovoltaic cell. Therefore, for the vehicle to work, it must havealready been exposed to light.

Without the capacitor

With the capacitor

Student Worksheet

A4

18

MotorPhotovoltaic cell1.5V

Switch

Capacitor

Wiring plan

Location of the capacitor

Scale 1 : 1

Structural drawing

M

22

20

21

24

25

2326

26

+

-+

-

+ -Brazing

PROJECT PART

DOCUMENT TITLE

Name

ClassCollege

Date ASSEMBLING THE SUPER CAPACITY CAPACITOR

CAPACITOR OPTION

TECHNOLOGYCOLLEGE

Student Worksheet

- Capacitor (26)- Photovoltaic cell (20)- Motor (21) - Switch (22)- Black wire (23), length 140 mm- Red wire (24), length 15 mm- Red wire (25), length 125 mm