pitsco Clearly Solar Car User manual

Clearly
Solar Car
User Guide
60024 V0413

2 Clearly Solar Car User Guide 60024 V0413
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tools.
How It Works
Solar Panels
Solarcells,alsocalledsolarpanels,uselightenergyfrom
theSunandconvertitintoelectricalenergy.Thisenergy
conversionprocessisknownasphotovoltaics,which
referstoeverythingrelatedtotheprocessoflightenergy
changingtoelectricenergy.
Anordinarysolarcellisusuallyaatpanelofablue
materialwithwirescomingoutofoneside.Thereareno
movingparts,butwhenyoushinelightonit(especially
sunlight),electricityowsthroughthewires.
Mostsolarcellsaremadefromsilicon,theelement
thatisinordinarysand.Siliconhasanunusualatomic
structure:ithasfourelectronsinitsoutershell.These
fourelectronshaveaboutthesamepotentialtobe
sharedwithanotheratomastheirpotentialtograbfour
electronsfromotheratoms.Sosiliconatomsbondwith
othersiliconatomsandsharetheirfourelectrons.This
makesastableconditionandresultsintheseatoms
formingcrystallinestructureslikegrainsofsand.Ina
manufacturingprocess,siliconcanbeproducedinthin
sheetslikethoseseeninasolarcell.
However,asolarcellalsohassmallamountsofother
elementssuchascadmium,selenide,andcopper.Unlike
silicon,whichisnotagoodconductorofelectrons,these
elementshavefreeelectronsintheiratomicstructure
thatcaneasilymovefromatomtoatom.Sowhenlight
hitsthesurfaceofthiscrystallinestructure,theenergy
withinthelightputsfreeelectronsinmotion.Thisis
anotherwaytodescribeelectricity–theenergyfromthe
lighthascreatedelectricity.
Series & Parallel Circuits
Thetermsseries circuitandparallel circuit refertotheway
thatacircuitisconnected.Aseriescircuitisaseriesof
componentshookedtogetheralongasinglepath.The
currentthatowsthroughtherstcomponentwillbe
thesamecurrentthatowsthrougheachcomponent.
Traditionally,thiswashowholidaylightswerestrung.
That’swhytheentirestrandwentowhenonelightbulb
quitworking.Thatonebadlightbulbcreatedanopen
circuitsothecurrentcouldnolongerow.Thehardpart
aboutastringoflightsnotworkingisthatit’sdicultto
tellwhichbulbisbad.Eventually,themanufacturersgot
smartandbeganproducingholidaylightsinaparallel
circuit.
Aparallelcircuitisaseriesofcomponentsconnectedin
awaysothatthereismorethanonepathtomovealong.
Ifonepathisbroken,theotherswillstillwork.Theyare
wiredinsuchawaythatifonebulbgoesout,theother
bulbswillstillshine.
Gears
Gearsareusedinmechanicalsystemsyouseeeveryday
includingcars,mechanicalclocks,andDVDplayers.A
bicycleisanotherexample.Thesprocketsconnectwith
achain,transferringthehumanpedalpowertotheback
wheelandmovingthebikeforward.
Thefourmostcommontasksthatgearsperformare:
• Increasingordecreasingthespeedofrotation.
• Reversingthedirectionofrotation.
• Keepingtherotationoftwoaxessynchronized.
• Movingrotationalmotiontoadierentaxis.
Increasethespeedofrotationbyconnectingasmaller
gearwithfewerteethtoalargergearwithmoreteeth.
Thesmallergearwillbeforcedtorotatefasterthanthe
largergear.
Wecandeterminethenumberoftimesthesmallergear
willrotatebyusingagearratio.Thegearratioistheratio
ofthenumberofteethononegeartothenumberof
teethonasecondgear.Ifa20-toothgearisturninga
10-toothgear,thegearratiois20/10or2/1.Thismeans
the10-toothgearwillrotatetwiceasfastasthe20-tooth
gear.
Gearsnotonlycanincreasethespeedofrotationbut
alsocandecreasethespeedofrotation.Supposethe
10-toothgearwasconnectedtoamotorspinningat30
revolutionsperminute.Ifitisconnectedtothe20-tooth
gearthenthe20-toothgearwillspinhalfasfast–or15
revolutionsperminute.

Clearly Solar Car User Guide 60024 V0413 3
Materials Included
• Gearfont(1) • 3/4"stand-opost(11)
• 2solarpanelswithleadsandalligatorclips(2) • 3smallwashers (12)
• Motor (3) • 6nylonspacers(13)
• 4widerubberbands(2areextra)(4) • 11–nuts(14)
• 6axlebushings(5) • 12–#2x3/8"screws(15)
• 4thinrubberbands(3extras)(6) • 4–#6locknuts(16)
• 11laser-cutacrylicparts (7) • 6–#6x3/8"screws (17)
• 3axles(1-3/4",2-1/2",and2-3/4")(8) • 4–#6x1/2"screws(18)
• 4wheelhubs(9) • 3–#4x1-1/4"screws(19)
• 2–1"stand-oposts (10) • 2–#4x5/8"screws(20)
Items Required (not included)
• SmallPhillipsscrewdriver • Hobbyknife(optional)
• RegularPhillipsscrewdriver • TransparenttapeORcool-meltgluegunwithglueslugs*
• Sandpaper • Smallpliersorneedle-nosepliers
*Eitherwillwork,butifyouplantotakeapartthesolarcarandreuseit,usethetransparenttape.
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4 Clearly Solar Car User Guide 60024 V0413
Preparing Parts
1. Deburrtheaxlesbybrushingtheendsagainstsandpaper.
2. Peeltheplasticbackingoofbothsidesoftheacrylicpieces.Thesecanbediculttostart,soyoumayneedto
useasharpobjecttogetitstarted.
3. Removetheaxlebushingsfromtheirplasticfontanduseeitherahobbyknifeorsandpapertoremovethe
plasticburrs.
Building the Parts
1. GatherPartsA,1"stand-oposts,andfour#6x3/8"screws.
Insertascrewintothesecondholefromtheendonboth
endsofPartA.Screwthestand-opostsontothescrew
ends.
2. Withtheothertwoscrews,attachthesecondPartAonthe
othersideofthestand-oposts.Thiswillbethechassis.
3. Findtwo#4x5/8"screws,twonuts,andPartsC(2)andD.
InsertaPartCnotchintoaslotonPartD.Slideanutintothehole
cutforitinPartC.Insertonescrewandtightenitsoitthreads
throughthenutandholdsPartDinplace.Repeatwithothernut,
screw,andPartConotherside.Thisisthesolarpanelbracket.
4. GatherPartsB,3/4"stand-opost,andthelasttwo#6x3/8"
screws.FromthenarrowendofaPartB,countbacktwoholes.
Insertascrewhereandattachthestand-opostonthescrew
end.PlacetheotherPartBtomirrortherstandsecureittothe
othersideofthestand-opostwiththesecondscrew.
5. Collecta#4x1-1/4"screw,3nuts,andawasher.Putthewasher
onthescrewandinsertitintothemiddleholeatthewideendof
aPartB.Beforepushingthescrewthroughtheotherside,placea
nutontheendandturnitafewtimes.Then,placeasecondnuton
theendandthreaditonthescrewafewturns.
6. Now,pushthescrewthroughtheotherPartB.Placethethirdnut
onthescrewend.Usingthepliers,holdtherstnutwhileyou
tightenthescrew.SpinthesecondnuttowardPartBuntilsnug;
holdthescrewstillwhiletighteningthenutwiththepliers.Finally,
tightenthethirdnut.
7. Fromthegearfont,removethe40-and20-toothgearswiththe
largeaxlehole.Alsoremovethewide10-toothgearwithasmallaxle
hole.Useahobbyknifeorsandpapertoremoveanyburrsfromthe
gears.Alsogathertwoaxlebushings,twospacers,andthe1-3/4"
axle.
Steps 1-2
A#6 x 3/8" screws
1" stand-off
posts
A
#6 x 3/8" screws
Step 3
C
C
D
#4 x 5/8”
screws
Nuts
Step 4 #6 x 3/8"
screw
B
3/4" stand-off
post
#6 x 3/8"
screw
B
Steps 5-6 Nuts
#4 x 1-1/4"
screw
Washer

Clearly Solar Car User Guide 60024 V0413 5
8. Putabushinginthethirdhole
fromthenarrowendofeach
PartB.Inserttheaxleintothe
40-toothgear.Addaspacer
ontheend.Inserttheaxleinto
thebushingonthePartBthat
wouldputthegearonthe
leftsideofthecarwhenthe
narrowendisthefrontandthe
1-1/4"screwisontop.Place
anotherspacerontheendof
theaxleandgentlypushthe
20-toothgearontheend.Thisisthemotormount.
9. The10-toothgearisthepiniongear;placeitonthemotorpostsothepostisushwiththesideofthegear.
Caution:Ifyoupushthemotoronthegeartoohard,themotorhousingcouldcomeout.
Adding the Wheels
1. GatherPartsEandFandallthe#2x3/8"screws.Ifthewheel
hubsareinafont,removethem.Fromthegearfont,remove
the50-toothgearwithalargeaxlehole.Useahobbyknifeor
sandpapertoremoveanyburrs.
2. Usingasmallscrewdriver,attachthehubstothewheelswith
thescrewheadsonthesideoftheacrylicwheel.Ifthecar
willneedextratraction,stretchawiderubberbandoverthe
backwheels(PartsE).
3. Insertthe2-1/2"axleintooneofthehubsattachedtoafront
wheel(PartF).Tip:Iftheaxlesarelooseonthehubs,inserta
pieceofstringthroughthehub.
4. Findfouraxlebushingsandfourspacersandthe2-3/4"axle.
Insertthebushingsintothefrontandbackholesonthe
chassis.
5. Placeaspaceronthe2-1/2"wheel-and-axleassemblyand
insertitthroughthefrontendofthechassis;thefrontisthe
endclosertothemiddleholesonPartsA.
6. Placeanotherspacer
ontheendoftheaxle.
Pressthesecondfront
wheelontotheaxle.
7. Pushthegearonthe
endofthelongeraxle
so1/2"comesoutone
sideofthegear.
Step 9
10-tooth
(pinion)
gear
Step 2
Hub
E
#2 x 3/8"
screws
Step 8 40-tooth
gear
20-tooth
gear
Spacer
Spacer
Bushing
Bushing
1-3/4" axle
Step 3
#2 x 3/8"
screws
2-1/2" axle
Hub
F
Steps 4-6
Spacer
Spacer
Bushings
Bushings
2-1/2" axle
Step 7
50-tooth gear
2-3/4" axle

6 Clearly Solar Car User Guide 60024 V0413
8. Carefullypushoneofthebackwheelsontheshortendof
theaxle.
9. Addaspacerandinserttheaxlethroughthebushingson
thebackofthechassissothegearisontherightside.
10. Addthreespacerstotheendoftheaxleandthenpushon
theotherbackwheel.
Putting It All Together
1. Gatherthemotormount(withPartsB),chassis,two#6x1/2"
screws,andtwolocknuts.Withthe40-toothgearontheleft,
setthenarrowendofthemotormountbetweenthechassis
neartheholeclosetothebackwheels.
2. Insertascrewoneachsideandplacealocknutoneach
screw.Usingpliers,holdthelocknutandtightenthescrew
justtoholdonthepart–theassemblyshouldbeableto
move.
3. Findthemotor,two#4x1-1/4"screws,twowashers,and
sixnuts.Placeawasheroveroneofthescrews.Ontopof
themotormount,insertthescrewjustthroughoneside
ofaremainingholeandplaceanutonthescrewend
andturnitafewtimes.Addasecondnutandturnita
fewtimes.Pushthescrewthroughtheothersideofthe
assemblyandplacethethirdnutontheend,butdonot
tightenityet.
4. RepeatStep3fortheremainingholeatthetopofthe
motormount.
5. Twistthemotor’swireends.
6. Wrapapieceoftapearoundthemotor.Note:Ifyouare
notgoingtotakeapartandreusethecar,youcanuse
cool-meltglueafterthemotorisinthemount.Theglue
ortapeholdthemotorinplace.
7. Insertthemotorinthe
motormountsothe
piniongearisonthe
samesideasthe40-tooth
gear.
Step 5 Step 7
Steps 8-10
Spacers
Spacer
Steps 1-2
#6 x 1/2"
screw
#6 x 1/2"
screw
Steps 3-4 Nuts
#4 x 1-1/4"
screws
Washers

Clearly Solar Car User Guide 60024 V0413 7
8. Wrapthewireendsunder
thewashersandscrew
headsontherstandthird
screws.Usingthepliersto
holdtherstinsidenut,
tighteneachscrew.Besure
themotorterminalsdon’t
touchthegears.
9. Gathertwo#6x1/2"
screws,twolocknuts,and
thesolarpanelbracket.
Placethebracketendsso
theystraddlethechassisattheremainingholesandinsertthe
twoscrews.Usingpliers,tightenwiththelocknutsuntilfriction
tight–donotovertighten.
10. Holdthesolarpanelssidebysideontopofthebracketwiththe
leadsfacingthemotor.Securethepanelswithasmallrubberband
bystretchingitfromunderoneendofthebracket,overthesolar
panels,andundertheotherside.
Operating the Car
Thereareseveralwaystooperatethecar.ThesolarpanelbracketcanbeadjustedtoananglethatbesttstheSun’s
positioneachtimeyourunthecar.Youcanalsoattachthesolarpanelsinaseriescircuitoraparallelcircuit.Make
surethemotormountispushedinapositionwherethepiniongearengageswithagearonthecar.
Series Circuit
1. Placetheblackleadfromonesolarpanelandtheredlead
fromthesecondpanelandconnectthemtothecenterpost.
2. Connecttheredleadfromtherstpaneltothefrontpost,
andtheblackleadfromthesecondpaneltothebackpost.
Setthecarinthesunshineorunderabrightincandescent
lampanditwillmoveforward.
3. Torunthecarbackward,switchtheleadsonthefrontand
backposts.
Parallel Circuit
1. Connecttheredleadfromeachsolarpaneltothefrontpost.
2. Connecttheblackleadfromeachsolarpaneltothe
backpost.Setthecarinthesunshineorunderabright
incandescentlampanditwillmoveforward.
3. Torunthecarbackward,switchtheredleadstothebackand
theblackleadstothefront.
Step 8
Step 10
Series
Parallel
Step 9
#6 x 1/2"
screw
#6 x 1/2"
screw

8 Clearly Solar Car User Guide 60024 V0413
P.O. Box 1708 • Pittsburg, KS 66762
shop.pitsco.com
Toll-Free Orders 800-835-0686
Switching Gears
YoucanalsotrydierentgearcombinationsontheClearlySolarCar.Thesetupintheseinstructionshasthe10-tooth
piniongearconnectingtoa40-toothgearthat–viathesmallaxle–turnsthe20-toothgear.Thisgearmovesthe
50-toothgearthatisattachedtothebackaxleandspinsthewheels.
Youcanalsoremoveabackwheelandswitchthebackaxlesothe50-toothgearisontheleftside.Thenadjustthe
motormountsothe50-toothgearcanengagewiththe40-toothgearthatisconnectedtothepiniongear.
Tip:Ifyoumakeahabitofswitchingthebackaxle,theaxleholewillbecomelooseovertime.Ifthishappens,you
caninsertathreadortwointotheaxleholeonthehubbeforeplacingthetiresbackon.Thiswillgiveyouatighter
t.
Activity: Series vs Parallel Circuits
1. Outdoorsonasunnyday,measureandmarkadistanceof10feet(3.05meters)inwhichtotestthecar.Arrange
thesolarpanelconnectionsonthecarforaseriescircuit.
2. Placethecaratthestartinglineandletitgo.Usingastopwatch,timehowlongittakesthecartotravelthe
distance.
3. Nowswitchtheconnectionstoaparallelcircuit.Again,placethecaratthestartinglineandtimehowlongit
takestotravelthedistance.Lookingattheresults,whichtypeofcircuitworksbetterforspeed?Considering
theinformationonpage2,discusswhythisistrue.Then,discusswhatadvantagestheremightbefortheother
connectionifitisn’tfaster.
4. Setupa20-foot(6.10m)courseandredotheexperiment.Didalongertrackmakeadierenceintheoverall
performanceofeithercircuit?
5. Calculatetheratiobetweentheperformance(intermsofspeed)oftheseriesandparallelcircuittests,rstfor
the10-foottest(3.05m)andthenforthe20-foottest(6.10m).
6. Setupaninclinedlaneandredotheexperiment.Explaintheresults.
Formoreactivityideasforthiskit,visitshop.pitsco.com,searchfortheClearlySolarCarKit,andclicktheActivitytab.