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.

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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
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05
02
02
07
13
A01
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02
08
01
09
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11
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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.

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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

A4
09
Front wheel axle Nickel-plated steel, Ø 3 x L 55 mm
01
05
01 Gear
14
Rear driving wheel axle Nickel-plated steel, Ø 3 x L 60 mm
06 01
Injected ABS (on PropulsO set), 48 teeth
A 29 mm length tube will be used
as a template to fit the axle.
Functional tolerance is 1.5mm
Fitting
31,75
Scale 1 : 1
Chamfer
0.5 X 45°
Chamfer
0.5 X 45°
29.25
55
60
1.5
29
(29.25)
Assembling the rear wheel axle with the cogwheel
Front wheel axle (5)
Rear wheel axle (6)
PROJECT PART
DOCUMENT TITLE
Name
ClassCollege
Date DEFINITION DRAWING
WHEEL AXLES
MARK PART PROPERTIES NUMBER
TECHNOLOGY
COLLEGE
Student Worksheet

A4
10
01 Aluminium wire Aluminium wire Ø 3 x L 110 mm07
Scale 1 : 1
Chamfer
0.5 X 45°
110
Ø3
Ø7 to 9mm
Aluminium wire before bending
Bended aluminium wire (7)
PROJECT PART
DOCUMENT TITLE
Name
ClassCollege
Date DEFINITION DRAWING
ALUMINIUM WIRE
MARK PART PROPERTIES NUMBER
TECHNOLOGY
COLLEGE
Student Worksheet

A4
11
01
03
04
01
Photovoltaic cell support plate
Expanded PVC 6 x 20 x 40 mm thickness
Expanded PVC 6 x 20 x 40 mm thickness
Spacer plate
01 Aluminium wire Aluminium wire Ø 3 x L 110 mm07
17 02 Countersunk head screws Ø 2.2 x 4.5 Nickel steel, metal sheet, countersunk head, screws Ø 2.2 xL 4.5
02 Double-sided tape 20 x 20 mm double-sided tape
19
Scale 1 : 1
07
07
17
03
04
19
17
Pencil or pen Ø 7 to 9 mm
Shaping the aluminium wire
Assembling the plates and aluminium wire
PROJECT PART
DOCUMENT TITLE
Name
ClassCollege
Date SHAPING AND ASSEMBLY INSTRUCTIONS
ALUMINIUM WIRE
MARK PART PROPERTIES NUMBER
TECHNOLOGY
COLLEGE
Student Worksheet
Important tips for shaping the aluminium wire:
- You will need a template to make it easier to shape it, for
example a pen or pencil with a diameter between 7 and 9 mm,
- Make a full turn with the aluminium wire around the template
Important tips for assembling the aluminium wire on
the various plates:
- The wire ends must be chamfered,
- Screws (17) are used to fix the wire (7) onto the plates
(3 and 4)

Photovoltaic cell
1.5 V
Motor
A4
12
Switch
Converting light
energy into
electrical energy
On/Off Command
Converting light
energy into
mechanical energy
Photovoltaic cell
1.5 V (20)
Switch (22) Motor (21)
Function Function Function
M
Structural diagram
Functional diagram
Part: Part: Part:
DRD de l'arrière 01
+
DRD de l'arrière 01
-
PROJECT PART
DOCUMENT TITLE
Name
ClassCollege
Date FUNCTIONAL DIAGRAM
STRUCTURAL DIAGRAM
CIRCUIT
TECHNOLOGY
COLLEGE
Student Worksheet

A4
13
Wiring the electrical components
Wire routing
Motor polarity
Scale 1 : 1
22
20
21
24
25
23
03
A
As shown on the drawing, wires pass between the
spacer plate (3) and the gear motor (A).
PROJECT PART
DOCUMENT TITLE
Name
ClassCollege
Date WIRING DIAGRAM
ELECTRIC CIRCUIT
TECHNOLOGY
COLLEGE
Student Worksheet
- Photovoltaic cell (20)
- Motor (21)
- Switch (22)
- Black wire (23), length 140 mm
- Red wire (24), length 15 mm
- Red wire (25), length 125 mm
We use wires provided with the photovoltaic cell
The motors used are reversible; they can rotate in both directions.
A test must be done on the first of a serial to determine which motor terminal you must connect the + of the
photovoltaic cell so that the vehicle moves in the right direction. In fact, from one series to another, marks on
motor terminals can be different.
Test to be done on the first of a series:
- Identify how one you can distinguish between both motor terminals.
- Conduct an operation test to identify on which terminal you must connect the + of the photovoltaic cell, for the
whole series to be manufactured.

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ASSEMBLY GUIDE
Stage Activity
100
140
150
120
130
Motor unit assembly
Plan: gear motor assembly plan on page 04.
Parts: PropulsO set, 2 screws TC Ø 3 x 6.5 mm, motor, steel axle Ø 3 x L 60 mm.
Tools: Phillips screwdriver, cutter plier.
Control : function test with a power supply (battery) 1.5 to 3 V.
Aluminium wire and plate assembly
Plan : assembly plan of aluminium wire and plates on page 11.
Part : spacer plate, cell support plate, aluminium wire Ø 3 x L 110 mm,
2 countersunk head screws Ø 2.2 x L 4.5 mm.
Tools : Phillips screwdriver
Control : one can bend the aluminium wire without it moving (rotating)
in the plates.
Fixing the spacer plate onto the motor unit
Parts : 2 cap screws Ø 3 x 6.5 mm, motor unit, aluminium wire and assembled plates
Toolsl : Phillips screwdriver.
Control : good support : no gap in the assembly.
Fixing the motor unit on the chassis
Parts : motor unit, 4 cap screws Ø 3 x 6.5 mm, chassis.
Tools : Phillips screwdriver.
Control : good support : no gap in the assembly.
Fixing the double-sided tape onto the cell support plate
Parts: cell support plate and double-sided adhesive pellets.
Control: positioning ; the double-sides pellets must not exceed the plate sides.
Student Worksheet
– Using the parts supplied in kit K-SLD

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160
170
180
190
200
Fixing the front axle on the chassis and rear wheels on the gear motor
Parts : 2 wheels Ø 28, 2 wheels Ø 48, 2 treads,
4 screws CH Ø 3 x 6.5 mm, chassis, axle Ø 3 x L 55.
Tools : Phillips screwdriver, cutter plier (removing plastic parts).
Control: good support: no gap in the screwed assemblies but the front axle
must stay free of rotation.
Attaching the switch on the motor unit
Parts : motor unit, switch, 2 screws Ø 2 x 6 mm.
Tools : Phillips screwdriver.
Control: good support : no gap in the assembly.
Wiring
Plan: wiring diagram of various electrical elements on page 13.
Parts: motor unit, switch, connecting wires (23, 24 and 25).
Tools: soldering iron, cutter plier.
Control : function test under sunlight or incandescent light.
Fixing the photovoltaic cell on the cell support plate
Parts: photovoltaic cell, cell support plate equipped with 2 double-sided
adhesive pads.
Control : good support : no gap in the assembly.
Fixing the hood on the chassis
Parts: 3 washers Ø 3x9, 3 cap screws Ø 3 x 6.5 mm, cover, vehicle.
Tool: Phillips screwdriver, cutter plier.
Control: good support : no gap in the assembly.
Student Worksheet
ASSEMBLY GUIDE
Stage Activity
- Using the parts supplied in kit K-SLD

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Kit Nomenclature
Red PropulsO
Ref. : PO-GRAP-01-R
01
01
01
01
01
02
02
15
01
01
Photovoltaic cell 4.5 V - 100 mAh under sunlight.
Dimensions 60 x 60 x thickness 3 mm. Ref. : CEL-2V6-160MA
Grey expanded PVC plate 127 x 40 x thickness 3 mm (chassis).
HIPS yellow plate 127 x 40 x thickness 1 mm (cover).
Grey expanded PVC plate 20 x 90 (85 mini) x thickness 6 mm
Double-sided adhesive pads 20 x 20 mm. Ref AD-D08
Sheet metal screws: cylindrical head Ø 2 x L 6.5.
Ref. : VT-TC-2X6
Sheet metal screws: cylindrical head Ø 3 x L 6.5.
Ref. : VT-TC-3X6
Electric motor specially adapted to the solar cell.
2300 tr/min under 1.5 V - Ø 21 - Axle 2 mm. Ref MOT-D21-SOL-A
Steel axle Ø 3 x length 120 mm minimum.
Micro-inverter with slider.
Ref INV-GLI
01
01
Aluminium wire Ø 3 x length 110 mm minimum.
Sheet metal screws: countersunk head Ø 2.2 x L 4.5.
Ref. : VIS-TF-2M2X4M5
02
01
Super capacity chemical capacitor 2.3 V - 10 F. 01
Ref : CDC-10F
The kit described here corresponds to the individual one (to make an object):
The kit for 10 manufacturing differs by the quantity of each part (x 10) and the packaging; parts
are grouped by type.
In the kits, plastic parts have correct dimensions.
Important tips: to avoid losing parts, do not detach them from the PropulsO injection bunch
before use.
Part Quantity Diagram
Option of electrical energy storage capacitor
Student Worksheet

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Electric energy storage capacitor option
The super capacity capacitor is directly soldered to photovoltaic cell terminals.
As soon as the cell is lit, even under a diffuse light, the capacitor begins to load.
Upon starting the vehicle, the capacitor is unloading in the motor; that allows autonomy for up to
8 minutes, depending on its load.
Comment :
To simplify, there is no serial diode with the capacitor. Consequently, in the absence of light, the
capacitor unloads through the photovoltaic cell. Therefore, for the vehicle to work, it must have
already been exposed to light.
Without the capacitor
With the capacitor
Student Worksheet

A4
18
Motor
Photovoltaic cell
1.5V
Switch
Capacitor
Wiring plan
Location of the capacitor
Scale 1 : 1
Structural drawing
M
22
20
21
24
25
2326
26
+
-
+
-
+
-
Brazing
PROJECT PART
DOCUMENT TITLE
Name
ClassCollege
Date ASSEMBLING THE SUPER CAPACITY CAPACITOR
CAPACITOR OPTION
TECHNOLOGY
COLLEGE
Student Worksheet
- Capacitor (26)
- Photovoltaic cell (20)
- Motor (21)
- Switch (22)
- Black wire (23), length 140 mm
- Red wire (24), length 15 mm
- Red wire (25), length 125 mm