Sol Invictus Will Race in NASC 2008!

Volume 9, Issue 4, Spring 2008 www.prisum.org

Sol Invictus will race in NASC 2008!

Team PrISUm’s online naming from Deus Sol Invictus, ‘the If you can help the team or contest for our ninth solar car Unconquered Sun God.’ With know of anyone who might be resulted in over 50 total submis- the multitude of obstacles this financially willing and able, sions, and early this semester, team has endured, the name please do what you can to lend team members gathered to de- could be one of the most appro- a hand! cide the name once and for all. priate ever for the PrISUm The race was close, but Sol Team. We have to thank you, our Invictus eventually emerged the supporters, once again for your clear winner. We still have not The team is currently seeking incredible support during this determined the identity of the supplemental funding for trans- project, but we are once again namer, however, so it has been portation and entry costs associ- asking for one final push of sup- impossible to assign any ated with the race this summer. port to get us from Dallas all awards! Ironically enough, the team will the way to Calgary! Help us be spending a lot of cash just to make it to the finish line! Sol Invictus literally means ‘the cover the increased costs of Unconquered Sun,’ originating fuel.

Sol Invicuts’ paint design, created by Wade Johanns, an aerospace engineering student on the mechanical team. The car has been painted and is waiting for a frame to house!

Status Bar: Teams ‘Officially’ Entered to compete in NASC Director’s Note 2  Iowa State University  University of Calgary  FH Bochum  Istanbul Technical University Mechanical Update 2  Red River College  Georgia Institute of Technology  Illinois State University (demonstration) Electrical Update 3

 Missouri University of Science and  CalSol (UC Berkeley)

SSUE I

Technology  ETS-Ecole de technologie suerieure Outreach Update 4  Principia College  Northwestern University  Durham University  Queen’s University Solar Car Safety THIS 5  Michigan State University  University of Arizona  Oregon State University  University of Kentucky Fundraising Update  University of Michigan  Western Michigan University 6

 University of Waterloo  Auburn University NSIDE I  University of Minnesota  Kansas State University Sponsors 7  University of Texas Austin Sundial 1 The Sundial Spring 2008

Director's Note Mechanical Update Is it over yet?! Hello all! A lot has happened since cut out holes for canopy, brake

The team has been stretched thin over our last update. The team was able lights, and turn signals. We then cut the past few months, making trips to to finish building the molds back in the shells apart again and added Remmele Engineering, the Northwest November. We would like to give a structural members to support the Airlines Composite Shop, and Don special thanks to Coastal Enterprises solar cells. The new bottom shell Ness Racecraft every weekend to for donating all the foam for the will be secured to the frame while complete the frame and body of Sol molds and their timely response to the top shell with the solar cells will Invictus. our request for more foam when we be removable. We like to take the ran out! top shell off to make work on the Regardless of stress levels, the team mechanical systems easier and to is still going strong! A zombie-like angle the solar cells in direct sun- Solar Car member walking to class is light during the race. not an unlikely sight on Monday Our welder Don Ness is working on mornings, but no need to worry, the frame. It should be done soon we’re getting this car built, one way and ready for heat treat. North East or another.* Machine is current machining some parts for the car; they have been ex- Designs have been finalized and ma- tremely helpful donating there time and material to our cause. chining has begun on the mechanical Team members bag the top shell at North- side. Our solar array recently arrived, west Airlines before pulling a vacuum and we’re researching ways to reflect that allows the shell to cure. light off the canopy to get the most out of those little cells! Business The finished molds were then sent hours are precious, and reserved for out to be machined. Remmele Engi- relentlessly seeking out sponsorships. neering out of Big Lake, MN machined the bottom mold and Ad- With such little time remaining (you vanced Pattern Works out of St. can check out a countdown timer on Louis, MO machined the top mold. our website, www.prisum.org) team Both companies did a great job and members can’t afford to put off any- were extremely helpful. After the thing. We’re pushing forward to fin- molds were machined the team laid them up with fiberglass and spayed Parts for the frame and a brake disc from ish the car with as much time to spare American Waterjet as possible. This will allow us to them with Duratec. Fiberglass and make the proper modifications, Duratec for the bottom mold took The car is coming along, as you can should we notice a problem with our place at Northwest Airlines in Min- see from all the work we have ac- design. All of this means we really neapolis, a huge thanks to the com- complished over the last couple of have to push ourselves to get it all posite shop personnel for taking care months, but there is still a lot of done. of us during the many weekend vis- work to be done in order to race. its! Our goal is to have the car mechani- I’d like to personally thank all of our Northwest is also where we laid-up cally complete by early June in order supporters and to encourage all of carbon fiber and cured the new to get plenty of test runs in before you to continue to follow the team’s shells using their autoclave. By the the big race! With your support we progress throughout the race in July. beginning of March we had both will make this goal and race for the We won’t let you down! carbon fiber shells in our garage win in July! Sarah Kelly, ready for the further work. Project Director Hildegard Garma The team has since then glued the & Michael Bridwell *Donations of caffeinated beverages are ap- top and bottom shell together and Co-Mechanical Directors preciated!

www.prisum.org 2 The Sundial Spring 2008

Electrical Update It's been an exciting semester for the electrical team! tion to the lithium-ion cells, the battery pack will All of our planning and designing over the past year house a lot of student-designed electronics. Most of are starting to come to fruition as we begin building the circuits for the car have been built and tested, and integrating key components of the car. Every- and are performing better than expected. Once all one is very excited to see their designs come to life designs are finalized, we'll order several copies of and watch all of the pieces come together, and with each board, so that we can simply swap parts rather all this energy we're sure to end up with a well-built than spend valuable time repairing broken electron- and reliable electrical system--one of the key com- ics on the race. ponents to a successful solar car. Putting all of The car’s solar array is here! We've been working these parts to- closely with Alain Chuzel of SunCat Solar to design gether into a the cell layout of the new car. SunCat Solar also working car is provided the services to cut, assemble, and encapsu- going to be a late the cells. Sol Invictus will be using the same big task, but cells as the team's 2005 car, Fusion: The SunPower fortunately we A-300. These are the best silicon solar cells availa- are receiving ble on the market, and will ensure that our car is one lots of help of the best. Sol Invictus will also benefit by having from our spon- Just one of the many boxes of high capac- over 20% more cells than Fusion, meaning it will sors. Advanced ity Lithium-Ion batteries the team recently have one of our most powerful solar arrays ever. Circuits is spon- purchased soring the team The other major component of the car, the battery with free PCBs, and Littelfuse has donated fuses and pack, has also been ordered and received! The team other circuit protection devices. E. Jordan Brookes is using 2600 mAh lithium-ion batteries purchased has also been a major sponsor by donating the cop- per foil used to build and wire the solar array, and Cableco Technologies is generously supplying the large cables we use to run power from the batteries to the motor. I would like to extend a sincere thanks to all of our sponsors for making this project possible. As always, you can check out the sponsorship section of our website for a complete list of the team’s sponsors.

A lot will be happening this summer, so be sure to visit our website regularly for updates on our pro- The solar cells arrived last month! Everyone except Scott ject. You can also find information on how you can has been threatened with bodily harm if they so much as help out the team through adoption of a solar cell or look at them the wrong way. battery to help us cover the cost of these components. We’ve recently launched an online donation from BatterySpace.com. These batteries are so new site also to make it even easier for you to support the and produced in such low quantities that Bat- team. We appreciate your continued enthusiasm for terySpace did not have enough available for our car this project, and we look forward to a first-place fin- immediately. We had to wait a while for shipping, ish in the race this summer! but it was worth the wait The electrical team is currently waiting on approval of the cells from NASC Scott Elliott officials to start constructing the modules. In addi- Director of Electrical Systems www.prisum.org 3 The Sundial Spring 2008 Outreach Update

Despite the huge amount of time currently dedicated to Sol Invictus, Team PrISUm has kept the calendar

open for outreach events. Most recently team members helped out with the middle school Science Bowl on campus, and we’ve been so busy this year, members should have no trouble getting their 2 required outreach events this semester!

We apologize if you have had a request for an outreach event that hasn’t been accommodated. We’ve tried to keep up with our usual amount of outreach, but our weekends have been very full!

During our trip to weld the frame, team members were also attending Learnapalooza in West Des The team’s 7th car, Spectrum, was recently taken from Moines. This meant that we were short a truck! The storage at the Iowa Science Center and transferred to the Formula SAE team here at ISU generously let us use Science Station in Cedar Rapids for display.

Outreach events— Spring Semester 2008:

 March 13th (10 am to 4 pm): Engineering Day at the Mall (Ames, IA)  March 18th : Central Iowa Chapter Iowa Engineering Society (Ankeny, IA)  March 22nd (10 am to 2 pm) : Iowa Energy Fair, City Hall gym (Ames, IA)  March 28-29th : State Science & Technology Fair of Iowa Workshops scheduled for the 29th from 1:30 to 2:15 and 2:15 to 3:00 Hilton Coliseum  VEISHEA Week: Display day on central campus, participation in VEISHEA parade!  April 18-19th : Science Bowl  May 3rd (9 am to 12 pm) : Learnapalooza (West Des Moines)  May 31st : Science Day (Charles City, IA)  June 24th (2:30 to 4 pm) & June 26th (9:15 to 10:45 am) : Iowa 4-H Youth Conference

Notice Some New Names?

We’re switching it up around the garage for the next project! As usual, elections were held this Spring to find a new Project Director and Assistant Project Director. And the winners were….

Project Director Michael Steffen, freshman in Electrical Engineering [email protected]

Assistant Project Director Erin Kelly, sophomore in Chemical Engineering [email protected] www.prisum.org 4 The Sundial Spring 2008

Building a Safer Solar Car by Tim Morgan, Asst. Project Director

Following a pair of accidents a safe car without the costly prototyp- and if a battery module isn’t, the pro- at the World Solar Challenge last Oc- ing and crash testing that is required tection circuitry will shut down the tober, and at least one article by a na- for production vehicles. We then use entire battery pack immediately. tional magazine on the subject, the this information to prove to the Iowa A final layer of protection is safety of solar is once again at the Department of Transportation that the the race crew. Every time one of forefront of peoples’ minds. While vehicle is safe so it can be registered Team PrISUm’s vehicles goes on the Team PrISUm works constantly to as a street legal “experimental vehi- road, a crew of people goes with it. ensure the safety of our drivers and cle.” Team PrISUm always operates with a others on the road, in light of recent The focus of most discussions vehicle in front and a vehicle behind events Team PrISUm felt it important of solar vehicle safety is on mechani- of the solar vehicle. These vehicles to let our sponsors know about our cal components; however, the safety alert other drivers of the presence of a work to keep everyone safe. of the electrical components is equally solar car and give team members a The process of making a solar important. For the past few vehicles, mobile mission control from which to car starts long before building any Team PrISUm has been using lithium monitor the performance of the car. If components. Every team member ion batteries to provide extra power there should be a problem with the car, must consider safety first and foremost during acceleration and to store solar we can pull over and have the people when designing parts for the car. Any energy when the car is using less than who actually designed and built the major mechanical part, from the frame the solar array is producing. The parts find and fix the problem. Final- down to the axles is modeled in 3D downside to lithium ion batteries is ly, should a worst-case scenario occur using either Inventor or SolidWorks they can be extremely flammable if and there is a collision involving the and then has finite element analysis not used properly. Laptop battery re- solar car occurs, team members (FEA) run on it using Algor. Finite calls are a perfect example of the dan- trained in emergency first aid travel in element analysis is a computer simula- gers of lithium ion batteries, and a so- the vehicles with the solar car. tion of the expected forces, stresses, lar car uses approximately 100 times Team PrISUm does every- and deflections on a part. This soft- as many battery cells as a laptop. To thing possible to ensure the safety of ware allows Team PrISUm to deter- mitigate the danger of the batteries, all our solar vehicles, both for our team mine with relative certainty if a part solar vehicles, as well as all devices members and others on the road. will fail under normal loads, or in the using lithium ion batteries, are re- While we hope nothing ever goes case of the frame, a vehicle impact quired to have battery protection cir- wrong, Team PrISUm is confident Sol scenario. By considering safety from cuits onboard. On Sol Invictus, the Invictus is a safe car should the un- the very beginning of design and run- battery protection actively monitors thinkable happen. ning computer simulations on the every battery module in the battery parts, Team PrISUm is able to ensure pack to ensure it is operating safely,

Questions or comments? Suggestions or concerns? Feel free to contact us!

General Team Inquiries: Hilda Garma– Co-Director of Mechanical Systems [email protected] [email protected] 515-294-0899 Mike Bridwell– Co-Director of Mechanical Systems Sarah Kelly-Project Director [email protected] [email protected] Scott Elliott-Director of Electrical Systems Tim Morgan-Assistant Project Director [email protected] [email protected] Erin Kelly– Director of Outreach Luke Martz-Director of Fundraising Director of Safety [email protected] [email protected]

www.prisum.org 5 The Sundial Spring 2008

Fundraising Update As always, this semester has been busy for the fundraising team. We are more focused on material donations this semester, as we have begun the build phase of our project.

First of all, we have had many donations of company time.

While Remmele Engineering and Advanced Pattern Works donated machining time, Pearl City Wood Products in Mus- catine, IA allowed us to use shop space to coat the molds in a high-build primer. The team worked day and night and even got some instruction on spraying techniques.

provided Eibach by How do you get a 7,000 pound mold to the twin cities, you Springs and mechanics gloves, might ask! Our trailer won’t handle that load, so we got some help from our friends at Allsteel once again. They On the parts side, we have received many large discounts provided a semi trailer for our bottom mold on three differ- from providers of suspension, steering, and braking system ent occasions to help us get our work done. Northwest Air- parts. Koni North America has provided a huge discount to us on custom-valved shocks, while Eibach springs in Coro- na, CA has generously provided 6 springs to the team at no cost! Two of the springs will come with stiffer rates so that the team can try different setups to see which works best with the car.

Electrically, Rearview systems provided us with two new rearview cameras for the car so we don’t have the extra drag of mirrors. The cameras are mounted inside of the canopy behind a small window.

On the cash side, we continue to stress about funds, but we can’t claim lack of support! Our big cash sponsors, includ- ing BP, Iowa Energy Center, and the College of Engineering Allsteel provided the semi trailer and ISU Campus services came through for us with $10,000 each again this year. Al- provided the muscle when it came to getting a 3-ton mold up liant Energy awarded us a $2,000 grant as well! In addition, to NWA. the colleges of Mechanical, Chemical & Biological, Electri- cal & Computer, and Aerospace Engineering have each con- lines helped the team again (and tolerated us) for countless tributed $500 to the car’s progress. weekends as we finished the molds and finally created our carbon fiber shell. We even slept on their floor! Not only And of course, all of this wouldn’t be possible without you, was the equipment valuable to us, but the staff at NWA gave our faithful fans! Your adopt-a-cells, tires, and batteries are us pointers and assisted us to make sure our shell was the what keeps this team going on a day-to-day basis. On that best it could be. note, we’ve given you another option for helping us out. Hate dealing with checks and snail mail? We’ve got a solu- Other companies are getting in on the action by donating tion for you. Check out our new online donation site. You work on smaller components that will go on the chassis. can pay by credit card, and you still get your subscription to Northeast Machine Company has agreed to machine our the sundial, certificate, and t-shirts by mail. It’s just less posts, hubs, and a-arms at no cost to us. This even includes work for you! material! This is a huge relief off our shoulders.

American Waterjet continues to help out from Winfield, IA. If you have any questions about the team, please con- They have completed the washers that keep our wheels se- tact us at (515) 294-0899. You can also e-mail solar- cure, and have made several mounting brackets for the [email protected]. And please feel free to check for up- frame already. They will soon be helping us with our titani- dates on our progress on our website at um brake discs, and busbar for the battery pack made with www.prisum.org conductive aluminum. www.prisum.org 6 The Sundial Spring 2008 Sponsors Team PrISUm would like to thank all of the sponsors of PrISUm Sol Invictus Platinum Supporter Adopt A Battery (cont’d) Adopt A Cell (cont’d) The Boeing Company Eagle Window and Door Paula Bridwell-Vallone and Joseph Iowa Energy Center Allen and Marie Ihlefeld Vallone BP Amoco Thomas W. Thatcher Brody Construction College of Engineering Ned and Ann Allen Elisabeth and John Thene Coastal Enterprises Larry and Judy Rollstin Howard and Ann Raffety - Grinnell 3M Paula Vallone Middle School 6th Grade Autodesk James and Carolyn Cornette Karl and Melba Gschneidner Gold Supporter Marta Burkgren Norma Buss Sharon Babcock Allsteel Adopt A Tire Altium Paul and Jill Murphy Debbie and Keith Felderman Robert and Beverly Bole Silver Supporter Paul and Bernice Exstrom Richard and Judy Jones Tom and Denise Kelly Musco Lighting Roger and Joan Anderson Robert and Janice Anderson Michael and Karen Margitan Cardinal Supporter Donald and Debby Helgeson Martha Anderson Bruce and Amy Crouse Danner Corporation Susan Barron Advanced Systems, Inc Carl and Elaine Nelson Mary Helen Stewart Advanced Pattern Works Margaret Weatherspoon Charles and Bonita Glatz Walt and Jill Ortmann Nick and Katie Mohr Solar Saint Marshall and Louise England Pam Reinig Garmin John and Elizabeth Kelly Bailey Wall Pacific Power Management Gary and Joyce Krasche David and Teresa Hawver Alliant Energy Shirley King Danielle Pane Solar Benefactor Richard and Lynn Clegg Jay Hinkhouse Gary Kent Joshua and Christine Engelbrecht Stanley Consultants W.E. Campbell Scott and Joyce Hornstein Pearl City Wood Products Eugene and Julieta Garma Iowa Engineering Society William R. Jordan David and Marian Andersen Cushion Seats, Inc Jeffrey and Nancy Sorensen Advanced Solutions Corp. Marc and Nancy Elliott Judy Tucker Randy and Susan Schirm Randall Hacker Solar Sustainer David and Teresa Hawver Jim and Barb Bennett City of Ames Electric Marla R. Shafer Terrence Diaferio Lee County Extension Bandag Incorporated Gary Moody PhysiciansCare Mary C. Grilli Kris Reicks Northeast Machine Co Dr. & Mrs. Thomas Dittmer Deloris Heim American Waterjet Cutting Marilyn & Rolan Jensen Littlefuse Steven and Elaine Weirather Brian and Melinda Drees David and Cathy M Carlyle Cabelco Richard and Barbara Johanns E. Jordan Brookes Co. Marjorie Burkgren David and Laura Martin Lea Johannsen Nicholas M. Mohr Team Sponsor Gloria Hill A. Beth Helgeson Premier Event John Root Ron Nelson Bald Eagle Days Justin Steinlage Adopt A Battery Adopt A Cell Dee A. Dreeszen Carolyn Jameson Ted and Rae Okiishi Carlton & Sally Peterson Diane L. Spore Forth Dodge Machine and Supply Dave Blum Company Bryan Mock Barbara L. Johanns Lowell L. Lauver Guy and Kathy Venz Marta Burkgren & Ron Morgan Glasnapp Transfer Fred Steffen Metalcraft Inc A. Beth Helgeson Robert Anderson Ron and Dawn Billings Keith and Debby Felderman Cassandra O'Flaherty Leon D. Carson Scott Elliott James and Carolyn Cornette Dan & Jane Billings

www.prisum.org 7

Printing Sycamore to thanks Special

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