Solar Car.pdf

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Background

Solar cells are often used in locations where there

isn’t any electricity and where electricity is needed

in small amounts. In such cases, solar cells are

usually connected to batteries, allowing electricity

to be stored for use during times when the sun

isn’t shining.

Not only is the sun a source of heat and light, it’s a

source of electricity too! Solar cells, also called

photovoltaic cells, are used to convert sunlight to

electricity. Solar cells are used to provide

electricity all kinds of equipment, from calculators

and watches to roadside emergency phones and

recreational vehicles.

A single solar cell is able to produce only a small

amount of electricity. But solar cells can be

connected together on a multi-cell panel to

produce larger amounts of electricity. As with

batteries, the more cells that are connected to one

another, the greater the current of electricity that

can be produced. 1 Solar panels can produce

enough electricity to power satellites, recreational

vehicles, and equipment for other applications

where electricity is used in large amounts.

Solar panels are becoming common on many homes.

For this project, you will be using the electricity

from solar panels to power a small car. Your

challenge will be to build a solar car that travels as

fast and straight as possible.

Solar cells are most commonly made from silicon,

the same material used to make computer chips.

Silicon is one of the Earth’s most common

elements, and is a major component of sand and

many kinds of rocks. A solar cell is built like a

sandwich, with two layers of silicon separated by a

thin layer of insulating material. All three layers

work together to convert sunlight into electricity.

When sunlight falls onto the solar cell, it produces

a small electric charge. Like a battery, the charge

is positive on one side of the cell, and negative on

the other. A wire connects the two sides of the

cell, allowing electricity to flow. This flow, or

current, of electricity can be used to power a small

light bulb, turn an electric motor, or recharge a

battery.

A completed solar car.

Build It!

These step-by-step instructions provide you with a

plan for making a basic solar car. If you can think

of ways to improve the design of your car, try

them out. Experiment with the materials.

Solar cells connected in series (in a long chain, positive to

negative, etc.) will increase the voltage of the panel. Solar

cells connected in parallel (all their positive terminals to one

wire, and all their negative terminals to another wire) will

increase the current, or amperage of the panel. In most large

commercial panels, the individual cells are connected both

ways, with rows of cells in series to raise the voltage of the

panel, and then those rows connected to each other in

parallel, to raise the amperage.

Solar Car

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Substitute parts to try to make the car lighter and

faster. Keep a record of your design improvements

as you go.

Tools and Other Materials

Gather together the following tools and materials:

• Hot glue gun with glue sticks

• Scissors

• Retractable utility knife

• Metal ruler

• Pliers

• Roll of clear tape

Materials

A. Construct the Body

1. Using the utility knife, cut the foam board

into three pieces — one measuring 20 cm

by 7 cm, and two measuring 2 cm by 7 cm.

Use the metal ruler to guide your cuts.

The tools and materials for making a solar car.

2. Glue the two smaller foam board pieces to

the large foam board piece as shown in the

illustration below.

Order a Solar Car Kit:

3. Using a ruler, carefully mark the positions

of the screw eyes on the two smaller pieces

as shown in the illustration below.

SunWind Solar Industries

1-866-248-5350 (toll-free)

Web site: http://www.sunwind.ca/

The Solar Car Kit should contain the following

materials:

• 2 solar panels, with contacts

• 2 wooden axles

• 4 screw eyes

• 5 wheels (2 large, 3 small)

• 4 black rubber tires

• 2 elastic bands

• 1 motor shaft pulley

• 1 alligator clip test lead

• 2 cm clear vinyl tubing

• 1 electric hobby motor

• 1 self-adhesive motor clip

• 1 brass paper fastener

• Fine sandpaper

• 1 piece of foam board (24 cm by 7 cm)

Dimensions of the foam board pieces for the body of the

solar car.

Solar Car

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4. Turn the screw eyes into the foam board

pieces. Be sure the screw eyes penetrate

both layers of foam board.

Mount the axles and wheels of the solar car.

Turn the screw eyes firmly into the foam board.

4. Assemble the rear axle as shown in the

illustration. Do this by slipping the axle

through the screw eyes, then adding the

spacers followed by the drive pulley (the

third small wheel) and wheels. You may

need to sand the axle a little to allow the

drive pulley to slide on.

5. Slip an axle through the screw eyes to

check their alignment. The axle should be

parallel to the end of the foam board. If

necessary, adjust the screw eyes.

B. Mount the Wheels

1. Slip a rubber tire onto each of the two large

wheels, and two of the small wheels. The

smallest wheel will be used later.

2. With scissors, cut the vinyl tubing into small

sections approximately 5 mm in length.

These will be used as spacers on the car’s

axles (see diagram).

3. Test the fit of the wheels and axles. The

wheels should grip the axles firmly. If the

wheels cannot be pressed onto the axles, try

sanding the ends of the axles to reduce their

thickness slightly, and check again for fit.

5. Add the front axle with its wheels and

spacers, as shown in the illustration.

6. At this point, check your car to see how

well it rolls. Put the car on the floor and

give it a gentle push. Make sure it rolls

easily and in a fairly straight line. Adjust

the axles slightly to get a better alignment,

if necessary. If the screw eyes seem loose,

carefully place a drop of hot glue where the

screw eyes come through the foam board to

hold them in position.

If necessary, sand the end of the axle to

obtain a good fit with the wheel.

Solar Car

The rear axle with its drive pulley.

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C. Mount the Motor

1. Push the small black pulley onto the

shaft of the motor, as shown on the

next page. Slip the motor into its clip.

D. Prepare the Solar Panels

1. On the back of each solar panel you

will find a metal connecting bar and

two threaded metal contacts. Each

contact is equipped with a small washer

and a nut. The metal bar and contacts

are used to connect the panels together,

and to connect wires to the panels.

Remove the nuts, washers and metal

bars from the connectors and set these

aside, being careful not to lose them.

2. Connect the two solar panels using one

of the metal connecting bars, as shown

below. Be sure the bar connects the

positive terminal on one panel to the

negative terminal on the other. Secure

the connecting bar using washers and

nuts, tightening them gently using the

pliers (do not over-tighten).

The electric motor in its mounting clip. .

2. Stretch the elastic band over the rear

wheel and place it on the axle-mounted

drive pulley.

3. Position the motor so that the elastic

band makes good contact with both

pulleys without being stretched more

than 5 mm. Once you know where the

motor should fit, mark that location on

the foam board with a pencil. Remove

the backing from the self-adhesive

motor clip, and press the clip and motor

onto the foam board in the position that

you marked.

Join the two solar panels using the metal connecting

bar.

3. Strengthen the joint between the panels

by adding a strip of clear tape on both

sides of the panel.

Position the motor on the car body.

Use clear tape to strengthen the joint between

the two panels.

Solar Car

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4. Use scissors to cut the alligator clip test

lead into two pieces of equal length.

Strip about 1 cm of insulation from the

two cut ends, and in each case twist the

exposed copper wires tightly together.

7. Loop the bared ends of each test lead

over the threaded contact and screw a

nut onto each. Gently tighten each nut

using pliers, making sure the wire is

well secured.

E. Mount the Panels

1. Use the utility knife to carefully cut a

small slot in the large foam board

section as shown below.

Strip insulation from the test lead.

5. Using the pliers, carefully bend the

spare connecting bar to form an angled

support for the solar panels, as shown

below.

Cut a slot for the paper fastener.

2. Use the brass paper fastener to secure

the connecting bar to the foam board.

Push the fastener through the hole in

the bent connecting bar, and spread the

tabs where they poke through the slot

in the foam board.

Use pliers to bend the metal connecting bar.

6. Position the second connecting bar on

the threaded metal contact, as shown

below. This will be used to help

support the panels in a later step.

Secure the connecting bar using the

brass paper fastener.

Connect the wires to the solar panels.

3. Arrange the panel and its support so

that it sits at an angle on the body of

your solar car. Use a small piece of

clear tape to fasten the lower end of the

panel assembly to the foam board.

Solar Car

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