1.3.

2 Solar Hydrogen Vehicle

P R O F I L E ​Talented & ambitious junior engineers enrolled in Principles of Engineering
based in Dublin, CA. Utilizing extensive and successful experience in a wide variety of projects
and collaboration.

TEAM PICTURE WITH PROTOTYPE

Hydro-Sol Motors
Gaurav Agarwal & Leela Banerjee & Sasha Mittal & Edmund Totah
November 1, 2018 - November 27, 2018
Principles of Engineering, Period 6

© 2018 Project Lead The Way, Inc.

Principles of Engineering 1.1.6 – Page 1
 TABLE OF CONTENTS

Design Brief 3

Initial Design Solution - Sketch, Descriptions, Dates 4

Modified Design - Before/After, Descriptions, Justifications 5-7

Final Prototype with Description, Measurements, and Calculations 8-11

Power Source Evaluation 12

13
References 

© 2018 Project Lead The Way, Inc.

Principles of Engineering 1.1.6 – Page 2
 DESIGN BRIEF
Client
Tesla Motors.

Problem
Tesla Motors is investigating the use of solar and hydrogen to power their cars. The company
wishes to gain some insight into the amount of power and speed capabilities of these sources to
support their designs.

Design Statement
We will design, build, and test a prototype that uses a solar module and hydrogen fuel cells
separately. The prototype will be used to gather information about different energy source
combinations to formulate a recommendation on what we think is a better fuel source.

Constraints
1. The vehicle must be made using approved materials.
2. The vehicle must be able to hold the solar module or hydrogen fuel cell securely.
3. Top view of the vehicle must be no larger than 5x12 inches.
4. Vehicle must use a breadboard to be able to easily change between power source
configurations for testing purposes.
5. Deadlines must be met.

Deliverables
Team Deliverables
● A working vehicle prototype to demonstrate to the client.
● A final electronic document electronic form detailing your design process and evaluation
must include:
● Title page and table of contents, Design brief outlining project goals, constraints, and
deliverables, Initial vehicle design solution - sketch with labels, paragraph description,
signatures, date Testing summary table(s) - photo(s) of the vehicle with power source &
note any modifications that needed to be made, measurements & calculations done for the
configuration (voltage, current, force, speed, electrical power, mechanical power,
efficiency), Power source evaluation & testing summary paragraph, Reference list of any
sources used
● Gantt Chart detailing team member responsibilities for each day of the project.
● Group Responsibilities Form completed.
Individual Deliverables
● Design brief notes & team norms
● Project Log
● Brainstorming sketches
● Table of measurements
● Calculations
● Conclusion questions

© 2018 Project Lead The Way, Inc.

Principles of Engineering 1.1.6 – Page 3
 INITIAL DESIGN SOLUTION

Our first brainstorm idea

consists of using big wheels
that allow for a greater
linear speed, as well as a
large gear ratio. Our second
brainstorm idea used
smaller wheels allowing for
better torque, as well as a
band around the wheels to
provide traction and
stability. Eventually, we
decided on incorporating
two basic ideas: using
minimal space by taking
advantage of the lack of a
height constraint, as well as
optimizing for torque. Our
major modification was to
use one small wheel in the
front and two large ones in
the back instead of using
four large or four small
wheels.

Sasha Mittal  Edmund Totah  Gaurav Agarwal  Leela Banerjee 

11/1/18  11/1/18  11/1/18 11/1/18

© 2018 Project Lead The Way, Inc.

Principles of Engineering 1.1.6 – Page 4
 MODIFIED DESIGN

Modification 1: Wheel Change

Before Wheel Change: After Wheel Change:

Description:​ Before the change, the vehicle Description:​ We took the front two wheels
had two pairs of big wheels in both the front and replaced them with one smaller wheel in
and back. the middle. This modification decreased the
  weight of the vehicle, making it faster.
 
 

Sasha Mittal  Edmund Totah  Gaurav Agarwal  Leela Banerjee 

11/4/18  11/4/18  11/4/18 11/4/18
© 2018 Project Lead The Way, Inc.
Principles of Engineering 1.1.6 – Page 5
Modification 2: Gear Train

Description: ​We decided to make a

gear train to attach to the motor and the
wheel instead of the wheel’s axle
directly attached to the motor. This
helps us troubleshoot the vehicle easily
and allow for speed or torque
specifications. We opted for torque
because of the size and weight of our
car. The rubber band holding the two
axles together keeps the two gear
meshed together.

Modification 3: Motor Bracket

Description: ​We adjusted the

metal bracket on the vehicle to
secure the motor in place. This
prevents the motor from moving
around and messing with the
gears of the back wheels.

Sasha Mittal  Edmund Totah  Gaurav Agarwal  Leela Banerjee 

11/5/18  11/5/18  11/5/18 11/5/18

© 2018 Project Lead The Way, Inc.

Principles of Engineering 1.1.6 – Page 6
Modification 4: Rubber Band

Description: ​Since the gears were

not meshing properly, we added a
rubber band around the two axles.
This helped apply the right
amount of force on the gears to
get them to work together.

Modification 5: Gussets

Description: ​We used gussets to

secure the breadboard in place as
well as both the hydrogen and
solar fuel cells. This eliminated
the movement of the cells and
the wires.

Sasha Mittal  Edmund Totah  Gaurav Agarwal  Leela Banerjee 

11/7/18  11/7/18  11/7/18 11/7/18

© 2018 Project Lead The Way, Inc.

Principles of Engineering 1.1.6 – Page 7
 FINAL DESIGN AND DESCRIPTION

Two Hydrogen Fuel Cells In a Series Circuit

Description:
A long Vex metal bar is the “chassis” of the vehicle and has two axles going through it, one in
the front and the other in the back. The back axle is connected to the back wheels and a gear train
using gussets and screws. The front axle is connected to a front smaller wheel also with gussets
and screws. The gear train is connected to an motor held by a bracket with another axle. The
motor connects to a breadboard which held in place in the middle with more gussets. The
breadboard is wired to a power source using banana plugs and wires which transfers energy to
the engine. The electrical energy is converted to mechanical energy by the motor and the axle
turns. Because the gear train is connected to the axle, the gear trains also moves which causes
one of the back wheels to move. All in all, this vehicle uses power sources and an engine to
convert electrical energy into mechanical energy and move the vehicle forward.

Sasha Mittal  Edmund Totah  Gaurav Agarwal  Leela Banerjee 

11/13/18  11/13/18  11/13/18 11/13/18

© 2018 Project Lead The Way, Inc.

Principles of Engineering 1.1.6 – Page 8
 MEASUREMENTS

Power Source Voltage Current Force The time it Electrical Mechanical Efficiency
Configuration takes to Power Power
travel 1
meter

1 solar 2.45 V 0.133 A 1.45 N 11.83 s .326 W .123 W 37.73%

1 hydrogen 0.9 V 0.18 A 2.49 N 59 s .162 W .042 W 26.05%

2 solar 2.43 V 0.142 A 2.51 N 11.83 s .35 W .21 W 61.45%

(parallel)

2 hydrogen 1.9 V 0.18 A 2.8 N 25.39 s .342 W .11 W 32.16%

(series)

Sasha Mittal  Edmund Totah  Gaurav Agarwal  Leela Banerjee 

11/15/18  11/15/18  11/15/18 11/15/18

© 2018 Project Lead The Way, Inc.

Principles of Engineering 1.1.6 – Page 9
 TESTING SUMMARY

We measured the voltage and current for each of the power source configurations using a
multimeter. The 1 solar configuration had a current of 0.133 amps and voltage of 2.45 volts. The
1 hydrogen configuration had a current of 0.18 amps and voltage of 0.9 volts. The 2 hydrogen
configuration was in series and had a current of 0.18 amps and voltage of 1.9 volts. The 2 solar
configuration was in parallel and had a current of 0.142 amps and voltage of 2.43 amps. We then
used a stopwatch and a spring scale to find the force (in newtons) and time it took to travel 1
meter. The 1 solar configuration took 11.83 seconds to travel 1 meter and had a force of 1.45
newtons. The 1 hydrogen configuration took 59 seconds to travel 1 meter and had a force of 2.49
newtons. The 2 solar configurations took 11.83 seconds to travel 1 meter and had a force of 2.51
newtons. The 2 hydrogen configuration took 25.39 seconds to travel 1 meter and had a force of
2.8 newtons. Using these values, we were able to find the efficiency, using four equations (Work
= Force x Distance) (P​out​ = Work/Time) (P​in ​= I x V) (Efficiency = PPout
in
x 100%). The efficiency
of the 1 solar configuration was 37.73%. The efficiency of the 1 solar configuration was 37.73%.
The efficiency of the 1 hydrogen configuration was 26.05%. The efficiency of the 2 solar
configurations was 61.45%. The efficiency of the 2 hydrogen configuration was 32.16%.

Sasha Mittal  Edmund Totah  Gaurav Agarwal  Leela Banerjee 

11/15/18  11/15/18  11/15/18 11/15/18

© 2018 Project Lead The Way, Inc.

Principles of Engineering 1.1.6 – Page 10
 CALCULATIONS

Sasha Mittal  Edmund Totah  Gaurav Agarwal  Leela Banerjee 

11/15/18  11/15/18 11/15/18 11/15/18

© 2018 Project Lead The Way, Inc.

Principles of Engineering 1.1.6 – Page 11
 POWER SOURCE EVALUATION

Based on our calculations, we recommend that Tesla Motors use solar cells instead of hydrogen
fuel cells to power their new car based on the overall efficiency of each configuration and the
overall performance. Both solar configurations had significantly higher efficiencies than their
hydrogen counterparts. The single solar cell had an efficiency of 37.73% while the double cell
had an efficiency of 61.45%; the hydrogen configurations had 26.05% and 32.16% respectively.
The solar configuration had the best combination of speed and torque as the dual solar
configuration had a force of 2.51 newtons and took 11.83 seconds to travel 1 meter. When
testing each configuration, we also took note of each car’s performance into account. When the
solar cells were activated, they ran relatively smoothly, but it could take a few seconds to start
moving. The hydrogen fuel cell configurations moved immediately, but the speed of the car
varied and was inconsistent.

The only issue we foresee with solar cells is the aforementioned time it takes for the solar cells to
collect enough energy to start moving. We believe that this issue can be combated if a larger and
wider array of solar modules are present on the actual car (solar modules are configurations of
multiple cells arranged in rows and columns). We believe that formatting the solar cells into a
module is the best way to scale this design to an actual car because the surface area will allow for
more energy to be absorbed. As long as the solar modules are positioned to maximize the amount
of solar energy, solar cells are the better option than hydrogen fuel cells to power a car.
Additionally, solar will be effective on a larger scale, since its parallel wiring allows for more
flexibility. Even if one solar cell is not receiving light, the other car will still work and function
normally.

Sasha Mittal  Edmund Totah  Gaurav Agarwal  Leela Banerjee 

11/15/18  11/15/18 11/15/18 11/15/18

© 2018 Project Lead The Way, Inc.

Principles of Engineering 1.1.6 – Page 12
 REFERENCES

Structure. (2017, October 04). Retrieved from

https://www.vexrobotics.com/vexedr/products/accessories/structure

© 2018 Project Lead The Way, Inc.

Principles of Engineering 1.1.6 – Page 13