Solar Powered Vehicle Design

by Andreas Marouchos – Managing Director, Ahthavan Sureshkumar – FEA Team Lead and Dan Wong – CFD Team Lead
University of Toronto Blue Sky Solar Racing

University of Toronto Blue Sky Solar Racing is a student directed program that applies higher education in advancing renewable energy technology and environmental decision-making.

Through the design and construction of a solar powered vehicle, Blue Sky Solar Racing facilitates innovative applications of technology. The sight of a solar car and the excitement of solar racing generate the "cool" factor, which often acts as a catalyst that leads to further innovations down the road. The car's unique shape, distinctive sound and intriguing concept captivate the minds of countless onlookers every year; while the spirit of cross-continental racing awakens the heart and imagination of the public at large. Racing across continents at highway speeds using energy harnessed only from the sun requires enlightened design for power management.

Blue Sky Solar Racing car

Each component of the car is thought out and evaluated in three key areas: maximization of total energy efficiency, elegance, and overall safety. While the design and construction are carried out under the rubric of performance and reliability, racing itself is a competition in sustainability. Blue Sky Solar Racing offers a unique learning experience not only through the design, construction, logistical operations, public relations and administration of a world-class solar race team, but also through the use of an intensely multi-disciplinary approach. Engineering, science, humanities, social science, and business students learn from each other how the varying decision making processes affect views on the environment and the role of technology.

CAE solutions are required in the development of a solar-powered vehicle for design efficiency, multidisciplinary design integration and in order to optimize for weight, and minimize power usage.

ANSYS CFX proved to best CFD package in order to provide accurate metrics from which to compare designs and refine the aerodynamics of the car.

ANSYS CFX aerodynamic analysis of the solar car showing velocity contours.

ANSYS Professional and Workbench have been used to perform static stress analyses, in addition to a coupled thermal-stress simulation on the brake rotors.  The stress analyses examined deformation, based on the factor of safety results. The rotor analysis aimed to identify the best steel alloy material, based on thermal and structural characteristics.  Sequentially coupled environments were used to simulate the correct kinetics, thermal loads, and stresses on the part.  We will be using ANSYS software extensively in preparation for the 2007 World Solar Challenge.

FEA stress analysis on A-Arm clevise for Solar Car suspension	FEA stress analysis on A-Arm clevise for Solar Car suspension	Workbench model of experimental brake rotor for Solar Car