As all the important
aspects for construction of the solar vehicle is covered, there is no
requirement of any professional mechanic to supervise you when constructing.
The only requirement is a well-equipped workshop which has a good welding,
electric cutting machine to cut pipes, plates and solid rods and a drilling
machine to drill into metal with different bits. The point wise assembling will
make it easier for the assembling to be done within a few hours once all the equipment,
materials and simulations are in hand.
i. Get the mechanical simulation done
in CAD software and evaluate using CAE softwares according to selection process
does in the above segments with individual designs and requirements. This simulation
is useful to maintain the mechanical properties of the vehicle according to the
standards. This also helps in giving a fancy touch to the design of the
vehicle.
ii. Accumulate the mechanical materials
according to the quantities mentioned in the simulation like the amount of
Al-6063-T1, glass fibre, nuts and bolts, members, spanners, screwdrivers,
grease, rack and pinion steering, four suspensions, chain drive system, two
disc brakes, two disc brake callipers, hydraulic brake set, four wheels, brake
pedals, acceleration pedal, four pedestals with ball bearings, comfortable
seats etc.
iii. Order for all the electrical equipment
with above mentioned specifications like BLDC motor, motor controller, solar
panels, MPPT solar charge controller, Lithium ion batteries, and required
quality of electric wires in abundance. It is also advised to get a soldering
set, wire stripper and some high rating legs for the electric wires, two DC
voltmeters to measure the voltage at batteries and motor, two DC ammeters to
measure the current flowing through batteries and motor, three MCBs.
iv. Mark the Al-6063-Ti meatal and cut
it to make a chassis according to simulation and also give additional members
for seating, motor mounting and steering mounting.
v. Mark two circular rods of equal
length for both front and rear axles, fix the disc brake for the front axle
with nut and bolt, fix two pedestals from both sides of the axle and fasten it tight
without horizontal movement. Weld two solid circular plates perpendicular to
the axle at both ends of the axle which fit exactly to the rims of the wheels.
Mark holes on the plates, drill them and fasten the wheels to the axle. Weld
two small metal parts in the forward direction with holes. Repeat the same with
no small metal parts with an additional chain drive gear in exact middle of the
axle.
vi. Attach both the front and rear
axles to the chassis with the pedestals with nut and bolt. Also connect the
rack and pinion steering set to the front axle by bolting the two ends to the
small metal parts with holes and fix the base of the steering to the main body.
(If the steering is not tightly fixed, the vehicle cannot change direction). Attach
the steering to the extra member provided in point number IV.
vii. Make a cabinet in the rear to hold
the electrical equipment like motor controller, solar charge controller and
batteries. Mount the motor in such a way that the motor chain drive gear should
be exactly in line with rear axle gear and fix the motor.
viii. Chain the motor and the rear axle
tightly and lubricate it with grease. Build the members and form the body of
the vehicle as per the individual designs and mount the solar panels on top of
the vehicle. It is advised to use some thermocols under the panels to reduce
heat and noise while travelling.
ix. Complete the wiring of all the
electrical equipment with safety measures where ever necessary. Do not short
any wires. Fix the brake callipers to both front and rear axle with the support
of members and attach them with pedals at foot. Also connect the accelerator to
motor controller and connect it with pedal near the driver’s feet.
x. Place the seats and fix them. First
switch on the MCBs at batteries and motor respectively and go for a test run.
If the motor is running satisfactorily, fix the rest of glass fibre according
to individual designs. Now the new “on-the-run charging solar vehicle” is ready
and good to go.
