Optimizing a Single-Seat Solar Car for Sustained Endurance and Total Energy Efficiency

Gurit engineers were brought in to optimize the car's components within the existing design. They used a design and simulation software to undertake a topology optimization, entering loading, force, and design constraints to produce the most efficient roll-hoop structure capable of withstanding the minimum g-force requirements. The shape of the roll-hoop was then imported into a Finite Element Analysis (FEA) model of the chassis where both structures could be analyzed as one for a more accurate representation of strength and overall stiffness. The engineers then used a composite optimization software tool to analyze the chassis and roll-hoop with the primary objective of minimizing the structure’s mass and the secondary objective of maximizing the structure's stiffness. The optimization was conducted in three phases: shape optimization, size optimization, and ply optimization. The final model was subjected to testing using the design load cases and a no failure constraint to ensure structural integrity with the intended layout of the carbon plies.