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

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

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

Altair

Technology Category	Robots - Autonomous Guided Vehicles (AGV) Sensors - Autonomous Driving Sensors
Applicable Industries	Automotive Renewable Energy
Applicable Functions	Maintenance Product Research & Development
Use Cases	Smart Parking Vehicle-to-Infrastructure
Challenge	The Western Sydney Solar Team was tasked with designing the most efficient and aerodynamic single-seat solar car possible, while ensuring driver safety and adhering to class rules. The team had a predetermined design of the solar car body shape that was optimized with the primary focus on reducing aerodynamic drag. However, they faced challenges in optimizing the monocoque chassis, bulkhead structure, and motor housing of the car within the existing design. They also had to adhere to strict design load cases set out in the class rules as well as minimum g-force strength requirements to ensure driver safety. Furthermore, they had to design and optimize the roll-hoop to safely accommodate the driver. The team was provided with a geometric model of the car that set out the chassis and structure, but no design existed for the roll-hoop. Read More
About Customer	The Western Sydney Solar Team is a group of students who participate in solar car races. They compete in the Challenger Class, where the competing single-seat solar cars are built for sustained endurance and total energy efficiency. The team is required to adhere to strict size limits governing the maximum dimensions of the cars along with a 4m2 maximum solar array. They are free to design the most efficient and aerodynamic car possible within these constraints. The team has a history of performing well in competitions, placing 6th in the Bridgestone World Solar Challenge 2017 and winning the 2018 American Solar Challenge. Read More
Solution	Gurit engineers were brought in to optimize the car 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 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. Read More Log in to view content
Contents

Technology Category

Robots - Autonomous Guided Vehicles (AGV)

Sensors - Autonomous Driving Sensors

Applicable Industries

Automotive

Renewable Energy

Applicable Functions

Maintenance

Product Research & Development

Use Cases

Smart Parking

Vehicle-to-Infrastructure

Challenge

The Western Sydney Solar Team was tasked with designing the most efficient and aerodynamic single-seat solar car possible, while ensuring driver safety and adhering to class rules. The team had a predetermined design of the solar car body shape that was optimized with the primary focus on reducing aerodynamic drag. However, they faced challenges in optimizing the monocoque chassis, bulkhead structure, and motor housing of the car within the existing design. They also had to adhere to strict design load cases set out in the class rules as well as minimum g-force strength requirements to ensure driver safety. Furthermore, they had to design and optimize the roll-hoop to safely accommodate the driver. The team was provided with a geometric model of the car that set out the chassis and structure, but no design existed for the roll-hoop.

About Customer

The Western Sydney Solar Team is a group of students who participate in solar car races. They compete in the Challenger Class, where the competing single-seat solar cars are built for sustained endurance and total energy efficiency. The team is required to adhere to strict size limits governing the maximum dimensions of the cars along with a 4m2 maximum solar array. They are free to design the most efficient and aerodynamic car possible within these constraints. The team has a history of performing well in competitions, placing 6th in the Bridgestone World Solar Challenge 2017 and winning the 2018 American Solar Challenge.

Solution

Gurit engineers were brought in to optimize the car 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 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.

Impact #1	The three-phase optimization process conducted by Gurit Composite Engineering significantly reduced the composite weight of the car, contributing only 19% to the total vehicle weight. This made the car more efficient and aerodynamic, allowing it to perform well in competitions. The Western Sydney Solar Team was well prepared to use the technical optimizations to build an even faster aerodynamic masterpiece. The construction of the solar car was undertaken using high-performance materials, ensuring its durability and efficiency. Despite some challenging weather conditions, the team performed well in the “Unlimited 2.0” competition, placing 6th in the Bridgestone World Solar Challenge 2017 and improving upon their performance by winning the 2018 American Solar Challenge.

Impact #1

The three-phase optimization process conducted by Gurit Composite Engineering significantly reduced the composite weight of the car, contributing only 19% to the total vehicle weight. This made the car more efficient and aerodynamic, allowing it to perform well in competitions. The Western Sydney Solar Team was well prepared to use the technical optimizations to build an even faster aerodynamic masterpiece. The construction of the solar car was undertaken using high-performance materials, ensuring its durability and efficiency. Despite some challenging weather conditions, the team performed well in the “Unlimited 2.0” competition, placing 6th in the Bridgestone World Solar Challenge 2017 and improving upon their performance by winning the 2018 American Solar Challenge.

Benefit #1	Reduction of composite weight from 80kg to only 42kg
Benefit #2	The optimized car contributed only 19% to total vehicle weight
Benefit #3	The team placed 6th in the Bridgestone World Solar Challenge 2017

Benefit #1

Reduction of composite weight from 80kg to only 42kg

Benefit #2

The optimized car contributed only 19% to total vehicle weight

Benefit #3

The team placed 6th in the Bridgestone World Solar Challenge 2017

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Overview

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

Operational Impact

Quantitative Benefit