pitsco Solar Designer User manual

Solar
Designer
28961 V0513
Cautionary and Warning Statements
• Thiskitisdesignedandintendedforeducationalpurposesonly.
• Useonlyunderthedirectsupervisionofanadultwhohasreadand
understoodtheinstructionsprovidedinthisuserguide.
• Readwarningsonpackagingandinmanualcarefully.
• Alwaysexercisecautionwhenusingsharporpoweredtools.
About the Kit
Withthiskit,youcanbuildasolar-poweredcarandothersolarenergy
projectsusingthepartsandinstructions.Followtheseinstructionstobuilda
solarcar.Then,beinventiveanddesignyourownproject.
User Guide

2 Solar Designer User Guide 28961 V0513
Materials Included
• Solarpanel • 2axles
• Bodytube(3/4"x1"x9") • 4washers
• 2front(narrow)wheels • DCmotor
• 2rear(wide)wheels • Gearfont
• Adhesivetab
Items Required (not included)
• 9/64"drillbit • Ruler
• Drillordrillpress • Sandpaper
• Utilityorhobbyknife(optional) • Cool-meltgluegun(optional)
Building Your Solar Car
1. Deburrtheaxlesbybrushingtheendsagainstsandpaper.Thiswill
makeiteasiertopushtheaxlesintothewheels.
2. Usingadrillordrillpresswitha9/64"bit,drilltwoholesintheplastic
bodyasshowninFigure1.HoleAshouldbedrilled1-3/4"fromthe
backofthebody(underthemotorslot)and1/2"fromthetopof
thebody(oppositeofthegroovedside).Drillthroughallfourplastic
surfaces,keepingthedrillbitparalleltothetopandperpendicularto
theside.
3. HoleBshouldbedrilledthesameway,withthecenterofthehole
1-3/4"fromthefrontofthebodyand1/2"fromthetopofthebody
(Figure1).
End View
Rear Wheel
Front Wheel
Axle
Hole A
Hole B
Gear O
Motor
Gear I
Washer
Figure 1

Solar Designer User Guide 28961 V0513 3
4. RemoveGearO(10-tooth,2mmbore)andGearI(40-tooth,1/8"
bore)fromthegearfontanduseaknifeorsandpapertoremoveany
burrs.PushGearOontotheshaftofthemotor.
5. Insertoneaxlethrough
GearIandpositionit5/8"
fromoneendoftheaxle
(Figure2).Slideabrass
washerontothelongend
oftheaxle,andinsertthe
shorterendintooneoftherearwheels(Figure1).
6. InsertthefreeendoftheaxlethroughHoleAinthebodytube.Slide
abrasswasherontheendoftheaxle,andpushtheotherrearwheel
ontotheaxle.Makesurethewheelsturnfreely(Figure1).
7. Useaknifeorsandpapertoremoveanyburrsfromthefrontwheels.
Inserttheotheraxleintoafrontwheel.Slideabrasswasherontothe
freeendoftheaxleandinserttheaxlethroughHoleBintheplastic
body.Slidetheremainingbrasswasherontotheendoftheaxle,and
pushtheotherfrontwheelontotheaxle.Makesurethewheelsturn
freely(Figure1).
8. Connectthesolarpanelwirestothe
motorbyclippingthealligatorclipsonto
themotorterminals(Figure3).
9. Laythemotorintheslotinthetopof
thebodysothegearsfromthemotor
andthewheelsmesh.Theforceof
gravitywillkeepthegearstogether.If
necessary,applyacoupledropsofglue
withaglueguntokeepthemotorinplace.Adjustthewiresand
alligatorclipsasneededtomakethemotorlayintheslot.
10.Peelthepaperbackingfrom
onesideoftheadhesivetape
andplaceit,withthestickyside
down,onthebackofthesolar
panel.Peelthepaperbacking
fromtheothersideofthetab
andpressthepanelintoplace
ontopofthebody(Figure4).
5/8"
Figure 2
Figure 3
Red Black
Motor
Indented
Dot
Figure 4

4 Solar Designer User Guide 28961 V0513
P.O. Box 1708 • Pittsburg, KS 66762
www.pitsco.com
Toll-Free Orders 800-835-0686
11.Yoursolarcarisnowcomplete.Ifyourcarrunsbackward,switchthe
blackandredwiresonthemotor.
Note: Thecarwillrunonasmoothsurfaceinfullsunlightorunderan
incandescent100-wattlightbulb.Fluorescentlightwillnotproduce
enoughenergytomovethecar.
Solar Engineering Ideas
• Modifythecarusingdifferentgearsorcombinationsofgearsto
increasethespeedorpowerofthevehicle.
• Addmoresolarpanels(availableatshop.pitsco.com)inseriesto
increasethevoltage(andspeed)orinparalleltoincreasepower
(Figure5).
• Addmoremotors,solarpanels,orplasticbodiestocreateafour-
wheel-drivesolarvehicle.
• Convertatoycartorunonasolarcell.
• Buildawindmillfromdowelrodsandcraftsticks.
• Haveacontestforspeedand/orpowerwithothersolarengineers
inyourschool.
Series:
1.35 V, 400 mA
Parallel:
.45 V, 1.2 Amps
Figure 5