A4 SoLDrag User manual

www.a4.fr
TECHNOLOGIE AU COLLEGE
September 2011
Solar-powered dragster
D-SLD

CONTENT OF THE CDROM
This project’s CDRom is available in the Company catalogue (ref “CD-BE1”).
It contains:
- The FreeHand version file
- The Illustrator version file
- The PDF version file (readable and printable with AcrobatReader software).
- Photos of the product, perspectives in .DXF format
- The full 3D modeling in the different versions of SolidWorks, Parasolid and eDrawings format.
This booklet and CDRom may be copied for students for internal school use*
September 2011
Etienne Bernot - Jean Luc Mathey - Nicolas Devaine
01
02 - 03
04
05
06 - 10
11
12 -13
14 - 15
16
17 - 18
8 rue du Fromenteau
Z.A. Les Hauts des Vignes - 91940 Gometz le Châtel
Tél. : [phone] - Fax. : [phone]
www.a4.fr
Edité par la Sté A4
Product presentation
Nomenclature and exploded of assembly
Exploded view and motor unit nomenclature
Drawings of two perspectives
Definition drawings of parts to be made
Shaping the aluminium wire
Electric circuit and wiring diagram
Vehicle assembly sheet
Nomenclature of kit
Option of electrical energy storage capacitor
* This booklet may be copied as many times as necessary within school establishments for educational use only, on the
condition that the publisher’s name is included: A4. Copying or distribution for commercial use is not permitted without
agreement from A4. Any copying or distribution of all or part of this booklet outside of school use is not permitted without
agreement from A4.

01
www.a4.fr
Product Presentation
Soldrag vehicle photovoltaic cell:
Function
Manufacturing
Kit
Cell support
Photovoltaic cell
Gear motor
Chassis
Driving wheel
Flexible aluminium wire
Bonnet
On/Off command
Technology Efficiency Cost Use
Monocristalline cells 24% High
Polycristalline cells 18.6%
12.7%
Average
Amorphous cells Low
Aerospace
Home
Consumer products
Electric vehicle powered by solar energy.
Only operates in direct sunlight (unless using the super capacity capacitor) or an incandescent lamp. Under tungsten or
halogen lighting, a minimum of 300 W at 20 cm from the photovoltaic cell is required for an equivalent efficiency. A
fluorescent tube lighting (neon) does not allow the photovoltaic cell to power the motor.
The photovoltaic cell assembled on a flexible wire is adaptable to capture the light more easily.
There is the option of a 10 F super capacity capacitor which can be assembled to store energy, thus allowing a few
minutes of operation without direct lighting.
- Chassis: made of expanded PVC 3 x 40 x 127 mm (supplied in the kit): angles cutting + screws pointing
- Photovoltaic cell support: made of 6 x 20 x 40 mm expanded PVC: cutting + drilling.
- Cover: made of HIPS (High Impact Polystyrene) 1 x 40 x 127 mm (correct dimensions provided in the kit): angles cutting
+ drilling.
- Cell support aluminium wire to be shaped
- Angles to be cut again + small diameters drilling + hot bending on thermo-bender with resistant wire or cold bending.
- PropulsO gear motor: provided in separate parts to be assembled.
- Ø 3 steel axles: to be cut again with ends chamfered.
- Wiring: wires to be soldered for to connect photovoltaic cell, motor and switch.
All parts and materials are available in full. The 560-757 reference kit contains the plastic parts ready to be assembled as
well as all other parts and components (see page 16).
A cell converts lighting energy into electric energy. There are several technologies for photovoltaic cells, with different
properties and efficiencies:
The photovoltaic cell of the SolDrag vehicle is amorphous; it is the best in terms of cost, but it is only efficient in a limited
wave length range, near infrared.

A4
01 01
02
01
03
01
04
02
05
02
02
07
13
A01
01
02
08
01
09
10
11
01
17
16 02
01
18
19
20
02
03
01
22
23
24
01
01
01
25
02
Rear wheel Injected ABS (on PropulsO set), Ø 48 mm
Countersunk head screws Ø 2.2 x 4.5 Nickel-plated steel, metal sheet, countersunk head, Ø 2,2 x L 4,5 mm
Aluminium wire Aluminium wire Ø 3 x L 110 mm1
Chassis Expanded PVC, thickness 3 x 40 x 127 mm
Hood HIPS thickness 1 x 40 x 127 mm
Cap screws Ø 2 x 6 Nickel-plated steel, metal sheet, cylindrical head, Ø 2 x L 6 mm
Photovoltaic cell 3 x 60 x 60 mm, 100 mAh under sunlight
Expanded PVC, thickness 6 x 20 x 40 mm
Spacer plate
Washer 3 x 9 Injected ABS
Front wheel Injected ABS (on PropulsO set), Ø 28 mm
Cap screws Ø 3 x 6.5 Nickel-plated steel, metal sheet, cylindrical head, Ø 3 x L 6,5 mm
Double-sided tape Double-sided tape 20 x 20 mm
Cable wiring Red flexible wire, 1 conductor, length 140 mm
Cable wiring Red flexible wire, 1 conductor, length 15 mm
Cable wiring Red flexible wire, 1 conductor, length 125 mm
Motor unit See detailed nomenclature of assembly on page 4
Student Worksheet
Staples Injected ABS
Change over slide switchSwitch
Front wheel axle Nickel-plated steel, Ø 3 x L 55 mm
Photovoltaic cell support plate Expanded PVC, thickness 6 x 20 x 40 mm
PROJECT PART
DOCUMENT TITLE
Name
ClassCollege
Date NOMENCLATURE
ASSEMBLY
MARK PART PROPERTIES NUMBER
TECHNOLOGY
COLLEGE

A4
03
18
02
20
07
10
11
A
03
04
19
17
01
08 17
16
Unmarked screws are 18
Student Worksheet
Exercise
Colour in the movable parts
05
09
22
16
A01
PROJECT PART
DOCUMENT TITLE
Name
ClassCollege
Date EXPLODED VIEW
ASSEMBLY
TECHNOLOGY
COLLEGE

A4
04
01 Motor Ø 21 - Output axle Ø 2 - 2300 tr/min at 1.5 V.
21
Rear driving wheels axle Nickel-plated steel, Ø 3 x L 60 mm
06 01
02 Cap screw Ø 3 x 6.5 Nickel-plated steel, metal sheet, cylindrical head, Ø 3 x L 6.5 mm
18
01
Screw without head
01
Right flank
Injected ABS (on PropulsO set)
01
Left flank
Injected ABS (on PropulsO set)
12
01
Gear
Injected ABS (on PropulsO set)
13
14
Injected ABS (on PropulsO set)
15
21
15
13
12
18
06
A
14
Student Worksheet
Exploded view of motor unit A
PropulsO gear motor equipped with a motor
specially adapted to the photovoltaic cell used.
Important tips for the gear motor operation:
The axle mustn’t be distorted. This is likely to happen
when it’s cut with a saw and badly held in a vice.
Don’t forget to chamfer the axle ends (see page 09).
The fitting of a non-chamfered axle at ends destroys
the pinion hub, removing a chip during the process.
The pinion risks being unbalanced and free of
rotation on its axle.
An oil drop on the endless screw can improve the
gear’s operation.
PROJECT PART
DOCUMENT TITLE
Name
ClassCollege
Date EXPLODED VIEW and NOMENCLATURE
MOTOR UNIT
MARK PART PROPERTIES NUMBER
TECHNOLOGY
COLLEGE

A4
05
Scale 1 : 1
Student Worksheet
Exercise
Measure the three dimensions and pencil them onto the drawing
PROJECT PART
DOCUMENT TITLE
Name
ClassCollege
Date PERSPECTIVES
DRAWINGS OF TWO
TECHNOLOGY
COLLEGE

A4
06
01 01 Chassis Expanded PVC, thickness 3 x 40 x 127mm
Drilling spots are used to position and hold screws
They are made with a needle or a 1.5 mm diameter drill.
Scale 1 : 1
15 x 45°
127
40
33.5
11 22.5 14
10
27
Student Worksheet
PROJECT PART
DOCUMENT TITLE
Name
ClassCollege
Date DEFINITION DRAWING
CHASSIS
MARK PART PROPERTIES NUMBER
TECHNOLOGY
COLLEGE
Drilling Spot

A4
07
02 01
Scale 1 : 1
Fold line
Fold line
10
20
15 x 45°
127
10
40
30°
10
30°
Hole Ø 3
Student Worksheet
PROJECT PART
DOCUMENT TITLE
Name
ClassCollege
Date DEFINITION DRAWING
BONNET
MARK PART PROPERTIES NUMBER
TECHNOLOGY
COLLEGE
Bonnet HIPS 1 x 40 x 127 mm
Cutting and drilling drawing (before bending)
Bending drawing
Hot bending on thermo-bender with resistant
wire or cold bending after grooving.
The three drilling spots are 3 mm diameter and open.

A4
08
01
03
04
01
Photovoltaic cell support plate
Expanded PVC 6 x 20 x 40
Expanded PVC 6 x 20 x 40
Spacer plate
Drilling spots are used to position and hold screws.
They are made with a needle or a 1.5 mm diameter drill.
Scale 1 : 1
Ø3.5
6
20
40
10
17
5
Drilling spot
Student Worksheet
Cell support plate (4)
Spacer plate (3)
20
10
10
Drilling spot
5
20
10
3.5
17
Drilling spot
Ø3.2 x 10
6
40
17
PROJECT PART
DOCUMENT TITLE
Name
ClassCollege
Date DEFINITION DRAWING
CELL SUPPORT
PLATE AND SPACER
MARK PART PROPERTIES NUMBER
TECHNOLOGY
COLLEGE
Drilling spot