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Solar Cup Electrical Report 2020

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Solar Cup Electrical Report 2020 Electrical Report Submitted to: Metropolitan Water District Solar Cup Challenge 2020 February 13th, 2020 Lennox Academy, Solar Cup Team Lennox Math Science and Technology Academy 110306 Hawthorne Blvd Lennox, CA 90304 (310) 680-5600 Table of Contents Team Roster…………………………………………………………… 2 Introduction …………………………………………………………… 3 Wiring …………………………………………………………………. 3-5 Block Diagrams…………………………………………………………5-7 Solar Panels……………………………………………………………. 7-10 Solar Panel Schematics…………………………………………………10-12 Solar Panel Installation…………………………………………………12-13 Emergency Stop………………………………………………………. 13-14 Bilge Pump……………………………………………………………. 14-16 Schematic Diagram …………………………………………………….16-20 Battery …………………………………………………………………20-21 Battery Mounts ………………………………………………………..21-23 Motor Selection………………………………………………………..23-24 Electronic Speed Controller…………………………………………...25-26 Telemetry and Instrumentation………………………………………..27-30 Conclusion…………………………………………………………….30 References……………………………………………………………..31 1 Team Roster: Name Role Email Omar Vazquez President, Team Captain [email protected] Abel Castaneda Vice President, Team Captain [email protected] Kary Cabrera Secretary, Team Captain [email protected] Brandon Colo Treasurer, Team Captain [email protected] Giovanna Medina Design Team member [email protected] Cristian Gonzalez Mechanical Team Member [email protected] Ricardo Miranda Electrical Team Member [email protected] Jessica Porras Electrical Team Member [email protected] Citlaly Chavez Mechanical Team Member [email protected] Edgar Ruiz Mechanical Team Member [email protected] Antonio Garcia Mechanical Team Member [email protected] Maya Alfaro Mechanical Team Member [email protected] Andrew Vasquez Mechanical Team Member [email protected] Luis Galvez Electrical Team Member [email protected] Yaired Carmona Design Team Member [email protected] Guadalupe Garcia Design Team Member [email protected] Mariana Lopez Design Team Member [email protected] Kevin Hernandez Electrical Team Member [email protected] Kate Steeper Mentor [email protected] Bryan Monroy Mentor [email protected] James Braslow Mentor [email protected] Jose Rivas Mentor [email protected] 2 Introduction Lennox Mathematics Science and Technology Academy has focused on improving the design and performance of the solar boat every year. The current design for the boat is the culmination of 4 years worth of design. The main focus this time around for the electrical team has been to continue improving the telemetry, motor, and battery system. Last year’s telemetry system did not live up to the expectations of the electrical team. The system was very cumbersome and did not provide accurate information to the ground team. This year's system was inspired by how drone pilots use cameras and monitors to watch where and how a drone is flying. In addition to the improvement of the telemetry system, the electrical team is switching back to an older motor that was used during the first Solar Cup our school entered in 2015; the ME-0909. This is due to a malfunction that occurred during the endurance race last year with the Agni 95R motor and realizing through comparing the two motors that the ME-909 is more reliable and more efficient than the 95R. Finally, we will be focusing on battery efficiency and how to get the most out of our batteries to ensure success in both the sprint and endurance race. This electrical report will discuss in detail the various changes to the boat discussed above and explain how these changes will improve our boat for the 2020 Solar Cup. Wiring This year’s boat will be using the same wiring that was used by last year’s team, which is the Matheon Select Bulk Welding wire cable and UL1007 CSA TR-64 Hook-up and Lead wire. The team selected the Matheon wire because of its ability to conduct 600 volts and tolerate up to 3 221 degrees Fahrenheit. As can be seen in Figure 1, the Matheon wire is a highly flexible annealed 4/0 gauge bare copper conductor with a 1950 stranding insulated by an EPDM (extremely durable synthetic rubber) jacket. Figure 1: Matheon Select Bulk Welding wire cable These wire characteristics, which ensure the flexibility and water/temperature resistivity, make the wire perfect for the boat’s electrical system. This wire will be used for the high current sections of the boat which include the batteries, motor, and speed controller. The next type of wire that is going to be used on the boat’s system is UL1007 CSA TR-64 wire made of 20 AWG wire gauge with a 7/28 stranding of prefused tinned copper wires shown in Figure 2. 4 Figure 2: UL1007 CSA TR-64 wire This wire can handle 300 volts and 176 degrees Fahrenheit which makes it ideal for the low voltage section of the electrical system. This wire is going to be used for the control circuit between the speed controller, contactor, throttle, emergency stop , and fuses. Block Diagram In order to better understand the electrical system, the 2017 team made a block diagram. It's purpose was to quickly inform all members of the different electrical components on the boat and their function. It is a generalized flow diagram that illustrates the process of how the batteries and solar panels work to convert their potential energy to kinetic. Below in Figure 3 is the block diagram made by the 2017 team. 5 Figure 3: 2017 Block Diagram The diagram demonstrates the six main components of the boat to generate movement. This has been a very useful diagram that has been used for multiple teams. This year to perform better in the competition we have again specialized groups to focus on the different responsibilities of the boat. The electrical team has taken multiple measures to not only gain knowledge on understanding the wire schematics, but to also to gain practical hands on experience with the electrical system. As seen in Figure 4, team members were trained to understand how the electrical system works and is wired. This is to ensure that if there is trouble during the competition all members will be able to troubleshoot the system. 6 Figure 4: Electrical Team exploring the boat Solar Panels A solar panel, also known as a PV model, is taking the sun's light and converting it into energy. The rays of the sun are composed of “photons” and these are turned into electricity by the solar panels. On the boat, solar panels are used as a secondary source of energy. Solar panels generate electricity by allowing photons to direct electrons away from atoms (How Do Solar Panels Work?, LiveScience). Furthermore, solar panels are comprised of smaller units known as photovoltaic cells. Photovoltaic cells consist of semiconductors such as silicon, and metals. While one silicon is positive (P-type), the other is negative (N-type). Moreover, an electric field is formed when electrons from the N-type silicon reach the P-type silicon after light strikes the cell. Metals conductors are attached to both ends of the cell to create current. 7 Combined with the silicone, the metal contacts generate an electric field and transfer electrons to wires. Figure 5 shows a visual representation of how solar cells generate electricity. Figure 5. Visual on how Solar Panels work (How Solar Cells Work, HowStuffWorks) One of the goals of the Solar Cup competition is to show how renewable sources of energy can be utilized to supply power; the solar panels component demonstrate the viability of solar energy. They are used in the competition as another source of power, and actually present during the endurance race. The 2019 solar panels where the Renogy 160W Flexible Solar Panels as shown in Figure 6 will be used for this year's boat as well. 8 Figure 6: Renogy 160W Flexible Solar Panel The Renogy 160W Flexible Solar Panel was chosen over 2017’s choice of the GSP 80 Q Flexible Solar Panel as shown in Figure 7. Figure 7: GSP 80 Q Flexible Solar Panel 9 The 2017 team had 4 GSP 80 Q Flexible Solar Panels each giving 80 watts for a total of 320 watts. That will allow the system to have a reserved capacity of 7.87 amps on a sunny day, allowing the system to run at about 18 amps. This year the Renogy 160W Flexible Solar Panel will allow us to run the system on a sunny day at 17 amps because the 2 solar panels will give a 160 watts each, giving the system a reserved capacity of 8.37 amps. Solar Panel Schematics For the endurance race the goal is for the batteries to last 90 minutes while providing a reasonable amount of power. In order to accomplish that the solar panels must supply energy to the batteries. This year we will be utilizing the Renogy 160W Flexible Solar Panels As per Solar Cup guidelines the voltage supplied by the batteries is limited to 24 volts; therefore, the charge controller will be wired in a parallel circuit with respect to the batteries. This will prevent the voltage from passing 24 volts and instead increase the power by increasing the current. Figure 8 shows how the switch is connected to the panels through the charge controller. Wire A7 carries current generated from the panels to the circuit. 10 Figure 8: 2017’s wiring schematic To wire the panels to the battery, Figure 9, provided by the product’s website, instructs how the panels will be connected with the battery and eventually the entire electrical circuit. Figure 10 is a parts list, provided by the product’s website, that tells us what components were included with the solar panel kit. Figure 9: Wiring of charge controller to battery 11 Figure10: Parts lists for Renogy solar panels Solar Panel Installation The placement and installation of the panels will be the same as last year. Custom fitted aluminum “L” brackets were used to attach the solar panels with rivets, as shown in Figure 11.
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