Methodology

Phase-I: Designing and Procurement of components The project starts with bearing the thought of making a cost-effective, robust Solar Electric Vehicle (SEV). The students are assigned departments with duties based upon their streams, interests and expertise. Keeping in minding the availability of various resources, workmanship and required technology and development capability the project shall kick start with designing and simulation of various components of the SEV on softwares like Solidworks, CATIA, Ansys, Simulia, LabView, Multisim, MATLAB etc. This is to create a soft model that would achieve aims of the project when produced in the real world. Technical analysis of the various models shall be performed in order to meet the stringent competition rules and optimize the SEVs performance and life-cycle. Texas Instruments MSP430 series controllers will be used for R&D of electrical components of the vehicle. Once the design of the SEV is tested and optimized according to the constraints, we will move towards real life fabrication. In order to procure required material of highest quality, various suppliers would be contacted and selected on both technical and commercial viabilities. Technical manpower required will be searched for and utilized proficiently. After all the work on initial findings, students will start fabrication work along with the experts in the industry to gain benefits from their experience. Phase-II: Fabrication
1. Chassis development: Tubular space frame chassis of high quality aluminium6063 pipes is fabricated using Tungsten-Argon metal arc welding. It will then be sent for precision alignment, stress testing with actual loads that would act on it while in operation. 2. Mechanical systems R&D: Steering, suspension and other mechanical systems will be designed and sent for production by various processes like casting, forging, machining followed by heat treatment of metallic components to obtain strength requisite for the SEV. These components will then be mated with the chassis which paves way for wheels mounting and further internal electric circuiting of the SEV. 3. Electrical circuit and components R&D: The electrical components shall be developed and procured in the meantime after discussions with experts like Maharishi Solar, CEL, etc. Then electrical circuiting and placement of various components like battery, motor and their controls will be done keeping in mind the position of solar cells on the body of the SEV, drivetrain, etc. 4. Body and solar array integration : The SEV after undergoing all these steps of fabrication comes to the final stage of body manufacturing and integration of the solar array with it. Here a pattern would wait for it, which would have

been developed after various flow and aerodynamic analysis of the body design on softwares and Wind Tunnel. Then the moulding starts in which first a female mould is prepared after which the actual body is moulded out of it using molten plastic that would be reinforced with fibre during the process making a sturdy and aerodynamic body. Then, that would be fitted with the already prepared basic SEV. The solar cells will be encapsulated and would be placed on the upper part of the body and then joined with internal electric circuit via input cables and MPPT. Motor controller cooling sprinklers will be added for cooling of panels. 5. Electronic Components Designing and R&D : The instrument control panels (Microcontroller based) consisting of programmed indicators (LCDs, LEDs, bargraphs etc.) will be developed which will show all the necessary data like temperature of panels, batteries packs, motoring unit as well as generating unit, capacity of the battery packs, speed, the total distance that can be travelled with the current available power under the present conditions etc. A capacitive touch screen module is under the process of development which will act as a driver control board to control the auxiliary circuit and will be placed on the steering wheel. Automatic sensor based cooling units will be developed for cooling the batteries, motoring unit as well the generating unit. Team is also working towards developing its own MPPT Charge Controller.

Phase-III: Testing and Improvisation: The all prepared Solar Electric Vehicle then undergoes test runs and the fulfillment of various regulations is checked and faults are rectified. After analyzing the real performance of the SEV on various parameters some improvisation can be done for the prepared SEV and the next vehicle. Various reports based on these tests would be made and used for further development and given to the stakeholders and the competition organizers.

IV. BUDGET ESTIMATES

TOTAL COST Item Description Consumables R&D costs Manufacturin g costs Contingencies / Other costs Total Amount (in INR)* Total 7,50,600 2,10,000 7,30,000 30,000 17,20,600

S No. 1. 4. 5. 6.

Phase-I 7,50,600 50,000 N/A 10,000 8,10,600

Phase-II N/A 60,000 7,30,000 10,000 8,00,000

Phase-III N/A 1,00,000 N/A 10,000 1,10,000

I. Consumables Budget for Consumable Materials

PHASE-I
S No. 1. 2. Component Motor Motor controller Description Hub Brushless DC Motor 48V, peak 20kW (Model: HPM-10kW) from Golden Motors, Bangkok HPC500A, 48V , 500 Amp peak from Golden Motors, Bangkok Quantity 1 1 Estimated Cost (in INR) 38,000 21,000

3.

Differential

Spur Differential Gear, Transmission 1 Ratio 8:1, 42 kgs Shipping Cost (Motors + Controller + Differential) Xantrex (Model: SW MPPT 60/150) LiFePO4 cells (3.2V, 100Ah) Battery Management System (BMS) Charger (48V, 15A) Shipping Cost (Batteries, BMS and Charger) 1 32 2 2

23,300 40,000 34,500 1,76,000 25,200 21,600 30,000

4. 5.

Maximum power point tracker Battery Pack and Related Electronics

6. 7.

Solar Panels Instrumentation ( Monitoring System + Control Electronics)

Monocrystalline Silicon solar Panels panels of 18% efficiency (280W each) MSP430 Launchpads Capacitive Booster Module Display Units (LEDs, LCDs, Bargraphs etc) Others Electrical Simulation Software Electrical circuit Designing Software Mechanical Design Software For Chassis Construction For Chassis Construction For Body Construction (Dimension: 50" Wide, .012" Thick, 3K, 4

4 5 2 -

1,50,000 1500 1000 1500 1000 Available for free on net

8.

9. 10. 11.

LabView 2010 Multisim 2010 Solidworks 2010 Aluminium Pipes 12 ft. length 1 inch O.D. * 14 gauge Aluminium tubes 12 ft. length 50mm*25mm*14gauge Carbon Fiber

15 15,000 7 48 Rolls 10,000 1,30,000

2x2 Twill Weave ) 12. 13. Utilities Mechanical Components Seats, Mirrors etc Steering, Suspension, Wheels and Brakes 6,000 25,000 7,50,600

Total

II. R&D costs: S No. 1. 2. 4. 5. Item Description Workshop rent Mechanical systems development Wind Tunnel Testing of SEV National Instruments testing modules Total Estimated Cost (in INR)* 20,000/20,000/1,00,000/70,000 2,10,000 Rs/-

III. Manufacturing costs:

PHASE - II
S No. 1. 2. 3. Item Description Chassis manufacturing Mechanical systems manufacturing Body manufacturing Total IV. Contingencies/ Other costs: S No. 1. 2. 3. Description Phase-I Phase-II Phase-III Total Amount (in INR)* 10,000/10,000/10,000/30,000 Rs /Estimated cost (in INR)* 15,000/35,000/6,80,000/7,30,000 Rs /-

Note: *All the above mentioned costs are estimated and may differ from the actual cost incurred. Financial Information Proposal if approved, Payment shall be made in favor of: Registrar, DTU i. ii. iii. iv. Bank Account No 31007875089 (DTU Sponsored Project Account) IFSC Code sbin0010446 MICR Code - 110002438 Bank Branch Address - State Bank of India, Delhi College of Engineering branch Shahbad Daulatpur, Bawana Road, Delhi - 110042 6