Design Of Solar Powered Vehicle

Project –III
Industrial Design Center

IIT Mumbai

Guide:
Prof. U.A .Athavankar

Rajat Shail Singh

Introduction – “The Solar logic”
The greatest problem that faces the world today is Global warming. It is more
apparent here in India than anywhere else , specially Rajasthan where
temperatures over the last few years have risen from 32deg C to 36deg C to last
summer of 42deg C to 46 deg C.

Renewable Energy
The principle forms of renewable energy suitable for places which lie in the tropics is the wind and
solar energy. The solar panels seen on the roof tops are usually for producing hot water and should
not be confused with those used to produce electricity which are photo voltaic panels. They are
made of 2 thin plates of silicon containing slight impurities which when exposed to sunlight
experience a stimulation of electrons. If positive and negative terminals connected by a wire are
added, as in a battery, the electrons will flow round the wire producing electricity.

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The Process
1) Preliminary data collection of the existing solar technology and its analysis.
2) Assessment and locating suitable applications and niche areas for the technology.
3) Comparing different applications zones and locating the most probable areas where
a four wheeler vehicle with the respective technology will work.
4) Identifying the existing vehicles and their characteristics in these selected scenarios
for which the vehicle has to be designed.
5) User study through scenario building in the areas where the vehicle is to be used.
6)Developing a design brief.
7)Basic anthropometric requirements and an ergonomic study.
8)Initial ideation and concepts .
9) Visiting the engineers and the fabricators in udaipur and discussing possibilities with
structure and details.
10) Concept generation.
-over all form
-structure
11) Form exploration through semantic study of the object.
12) Final concept selection and variations.

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The Solar Rickshaw

The introduced prototype and its features are as follows:
1. Self sufficient on solar energy
2. Capable of a speed of 25- 40 km/h.
3. Capable of climbing up hill on an average inclination of 15deg to 30 deg.
4. Seat 4 people.
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Individual Constituent parts Of Prototype

Solar panels- 85 Watt BP solar panels placed on the roof and
Motor- Lynch motor, which offers the best efficiency greater than 90 % and has
a weight of only 9 kgs. At 12 Volts the motor can run at 2.5 KW aprox 4 HP
Batteries- The batteries mainly store the excess power from the solar panels to
give backup for night hours use. They also supply the initial torque to start the
motor. The batteries are 2 x 12 Volt Exide sealed traction, deep discharge
batteries.
Solar Controller- The Solar controller is like a fuse which regulates the current
from the panels to the motor.
Running gear- Bicycle wheels with spokes have been used and on later versions
stronger wheels will be used. A differential is incorporated in the back axle and
3 speed Strumy archer gears used in the drive system.

Brakes Hydraulic disc breaks are fitted to all 4 wheels.

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Size comparative with Maruti 800 and Wagon R

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Design Criteria for Improving Solar Rickshaw as proposed by the client.

1. Ideal balance between weight and stability.
2. Seating to be more comfortable.
3. 18” of room between seat and floor.
4. Wider wheels for more stability.
5. Better suspension.
6. Efficiency of motor suitable for higher gradients.
7. Aero dynamic body
8. Road clearance
9. Passenger cover for monsoon
10. Seat belt and safety features.

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Comparative study between traditional Auto rickshaw
and Solar rickshaw. analysis

Rs 85,000
Specifications of Traditional Auto Rickshaw
-Capital cost of Auto Rick shaw ( including insurance and - Rs 31/lt
registration).
-Petrol cost
24km/lt
-Average mileage of each Auto Rickshaw when new ( A)
6hrs/day
-No. of hours each Auto runs in total on an average (B) mostly
daylight hours 30km/hr
-Average speed of an Auto (C)
-Total consumption of petrol (B) x (C) / (A) 7.5lts/day
-Total cost of Petrol for each Auto Rs 232.5/day
Solar Rickshaw
-Approximate Capital Cost of Solar Rickshaw
Rs 2,00,000
-Avoided costs of fuel per solar rickshaw
Rs 232.5/day
-Total fuel cost avoided in one year through one solar
Rickshaw Rs 85, 862.5
-If in 3 years a market penetration of 50,000 vehicles is projected this translates
into a fuel savings of rs 424.3 carore
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 analysis

Comparative between petrol/diesel operated vehicle and solar

vehicles

Petrol/Diesel Vehicle Solar powered Vehicles

-High fuel costs-approx Rs 232.5 per day per auto Zero fuel costs

-High maintenance
-High annual CO2 emission- roughly 7 Low maintenance
tons/vehicle Zero noise pollution
-Severe noise pollution Does not get affected by inflation in fuel prices
-Regular increase in fuel prices No possibility of adulteration
-Most estimates are based on ideal conditions but Constant research on solar panels is providing
as vehicles age and adulterated fuel, efficiency more efficient conversion ratios which would
decreases. lead to further improvement
Entitled to CO2 emissions credits in accordance
to Kyoto Protocol.

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Possible application areas niche identification
- Intercity public transport
- Inter Airport
- Inter campus-Academic, Industrial e.g. Godrej , Infosys, Maruti
- Safari parks
- Amusement parks
- Zoos
- City tours
- Golf buggies
- Surveillance
- Large span exhibition areas e.g. Pragati Maidan
- Inter village Info kiosks
- Mobile telephone booths
- Mobile banks
- News paper kiosk

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 niche identification

Application selection-

Incampus- non academic e.g godrej, telco, infosys

Zoos- short trails and bird sancturies e.g sultanpur , borivili

national park

Amusement parks- Appu Ghar, Essel world

Exhibition areas

Criteria of selection was based on largest common factors between

application needs and vehicle capabilities.

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 user study

Scenario building and user study.

A. Zoos and Amusement parks Design Implications

Layout -
Scenario - 1 couple + 1child (5 years-
10years)

Episode 1. Quick stops “easy to get out and

get back in”
-To see animals closely
- To take a particular ride
- To use the toilet . - Minimum side paneling , good view of the
-To buy something ( candy floss, peanuts, outside from most of the sides.
icecream) - Minimum opaque surfaces.
- Position of seating or standing in which getting
up and getting out frequently is easy.
- Enough headroom.
- One step ground clearance.
- Non slippery and sharp edges of flooring(
possible nosing or beading)
- “ Rightfull ” placement of supports and grips
(study of postures part of anthropometric study)
Both in motion and static

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 user study
Looking at similar vehicles
Similarity in function, weight and size (basic dimension), number of passengers they carry .

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Design brief
design brief
- Technical specifications which are followed from the existing prototype are:
The basic chassis structure with permissible modification in the size of the
wheelbase.
Over all mechanics of the vehicle constituting parts like motor, battery, controller
and instrumentation remains unchanged.

- Minimum surface area of the solar panels to be 2.4 square meters. The solar
panels are currently 50cm x 120 cm, they can be broken into 3 parts of 50 cm x 40
cm (each panel containing minimum 12 cells.
-Minimum surfaces and skining.
In order to increase higher visibility from inside to outside.

-Light weight vehicle, which means under 350 kg kerb weight to be maintained
approximately.
- Designing a solar powered vehicle for locomotion in areas like non academic
incampus, entertainment parks, safari parks and exhibition areas, to be used by
tourists, middle class families , executives and workers.
-An ergonomically designed vehicle to
accommodate 4 people.

-Possibility of storage space or collapsible area to generate extra storage floor

area.

-Safety of passengers
Safety here does not imply emphasis on collision safety rather safety of
passenger from slipping due to inertia while moving and breaking and arresting the
person in the sitting position if the vehicle topples.

-Strong and distinct visual identity

-Simple interface and minimal interior elements

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 Basic anthropometrics and ergonomic requirements ergonomics

Basic antropometric study to create a minimum dimensional

requirement for sitting and standing.
Volumetric requirement for batteries instrumentation and
other mechanical parts.

Ergonomics –
Study of how people sit and how people get in and get out of a
maruti versus tall boy like wagonr.
Forces acting on a person while standing in a train or a bus.
Most comfortable position and dimensions in a half standing
position which aids in easier ingress and egress to and from the
vehicle.
Supports required to get in and get out and while in motion.
Initial Ideas and images initial ideation and images

Exploring a car like look. Extending the front

area or bonet with bumper like forms ,
placement of windscreen with space for head
light. Extending a flow of line between the front
and the back fenders.

Idea was based on creating a possible

movement through staggering of the panels on
the roof by breaking the panels or maybe
exploring a turtle like appearance.

Turtle- multi faceted roof (breaking

the panel into smaller units

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Toy car approach.

This form emerged out of looking at
toy vehicles seen in places like
amusement parks and entertainment
zones. The aim was to explore
playfulness and friendliness in the form
. Some elements like the oversized
round fenders are seen in bumper cars
and dune buggies.

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Visit to the engineers and the fabricators in udaipur and discussing possibilities in structure and details

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 concept
Concept development
Three level
1) “ Inside out to Outside in” approach form well
integrated with material and structure and
complimentary to the overall functional
requirements, interior elements with certain level
of flexibility , innovation and convenience
2) Exploring attributes like
unconventional
sporty,
light,
dynamic,
extrovert,
3) Experiments with lighter materials like metal
sections (m.s and aluminum), fiber reinforced
plastics and allunimium sheets keeping in mind the
main constraint of accommodating surfacing
surface area of 4’x 7’(14 sq feet)
 semantics
Searching for an expression of “ Product Identity”

1. State concepts as a linguistic expression.

Lexical definition
After the data collection and initial study one realised that,
there was a need to develop a visual identity or profile of the
object which emerged in the linguistic definition as design of
a “ light weight solar powered slow moving public/semi-
public vehicle (car/buggy/ cart) for Indian use.”

2. Identify visual clues, elements which manifest the

concept. In this case “ lightness”
Investigation into visual clues which communicate links to
superordinate concept “ solar powered rickshaw ”

3. Select potential visual clues. Through charts exploring

collecting visual images relating to notions of “Indianess”,
“solarness” and “lightness”. e.g figure 3

4. Assimilate them with product form.

5. Effect streamlined , exposed solar panels ,
-Add new dimension to the current way of looking at the category. low seating, surface defined by the
-Develop a new perspective and view point. repetitive unit of the panel which is
doubly curved. Lightness perceived
-Product acquires its individual and unique position, exclusiveness. through the proportions.

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semantics

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 possible layouts

1 2 3 4

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5 6 7

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Concept one was based on exploring possibilities with the roof surface and integrated
over all structure where structure becomes and aesthetic expression. Possibilities of
user in a semi standing position was explored, in order to reduce the wheel base and
over all dimensions and also aid in easy ingress and egress.

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Tubular frames for

seating ,
combination of
fabric net and
plastic

Concept two was inspired from the taking some

characteristics from the formula racing cars for
the lower portion of the vehicle and light weight
tension structure to support for the roofing
surface.

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Concept three was based on how we sit in tongas and cycle rickshaws and how a
layout could be generated from it.

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Concept four was a based on reducing the

wheelbase by assuming a semi sitting and
standing position. The panels could be
staggered like a venetian blind to reduce
air drag. Standing supports which cloud be
rotated around to change configuration
and direction of standing .

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Concept five was based on changing

level of the flooring of the vehicle
so that people could be placed at
different heights and this height
variation could provide a sleek form
to the vehicle . Entry for the back
passengers could be from the back
side with collapsible panels.

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Concept six was

based on having an
integrated structure
of the floor and the
roof and seating to be
made in such a way
that it provides otion
between semi
standing and sitting

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assembly

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seating

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colours

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dimensional drawing

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Chapter closed