Mini-Course in Electrical

Engineering

Chris Jones, Intern

solarcaptain@earthlink.net
Working Safely with Electrical
Components

Working with High Voltages
– It is a good idea to work around the car without power
connected to the system
– Always be aware of when the car is live
– When working on electrical systems, use single hand
or latex protection
– Walkthrough the entire system and watch for exposed
wires or connectors often
Working Safely with Electrical
Components

Minimizing Risks
– Minimize number of people around/or with access to
the car
– Put physical protection between the driver and any
electrical circuits
– Properly insulate all connectors
– Make sure that no connectors are grounded to frame
– Store car with battery disconnected
– Be neat in arranging your circuit
• Loose wiring may snag and be difficult to work with
• Planning your conduit will save you time during the race
Tools of the Trade

Soldering Iron/Gun

Wire Strippers/Cutters

Wire Crimpers

Needle-nose Pliers

Diagonal Cutters

Multimeter

Heat Gun
Schematics

Plan your circuit on paper before wiring

your car

Example: Northview Race Team ‘97

schematics
Connectors

Deciding when to use crimp connectors

Types of connectors that work well

Problems with crimp connectors
Wiring

Selecting wire type and size

Wiring strategies and planning
– Planning how to route your wires
– Running wires between components
– Being neat in placing your wires

How to work with battery cables
Soldering – The Easy Way

Tools you need to get started

– Soldering Irons / Guns
– Solder
– Heat Shrink

Recommendations for effective soldering
Batteries

Explaining Winston Solar Challenge rules

Different types of lead acid batteries
– Automotive
– Deep Cycle (Marine)
– Sealed

How to care for your battery
– Cycling and Voltage limits

Recommendations for the auxiliary system

Replacement batteries
Drive System

Motors
– The different types
• Brush
• Brush less
• Hub
– Selecting what is right for you

Controllers
– Why they are needed
– How to decide on the right controller
Solar Cells

Types of Solar Cells

– Terrestrial Grade
– Space Grade

General Information

How to wire your solar cells
– Series
– Parallel

Explaining Winston Solar Challenge rules
Solar Arrays

Advantages of prefabricated vs. custom-built

arrays

How to build your own solar array
– What do you look for in a base material?
– How do you insulate your array?
– How do you solder solar cells together?
– What do you mount your solar cells to?
– What is encapsulation and how do you do it?

Power Trackers

General care for a solar array
Instrumentation

Meters for the modern solar car

– Voltmeters
– Ammeters
– Amp-hour counters
– Temperature sensors and gauges

The “E-Meter”
Summary

Be safe around your vehicle. Be aware of when

your car is live. Minimize risks.

Have the proper tools to work on your car. It
makes your work much faster.

Plan your circuit before putting it together.

Size your battery system, solar array, and wires
and select your connectors according to your
needs.

Ask others for help when you don’t understand
how to do something.
Q&A

Do you have any questions?

Where can you purchase parts?

General Solar Supplies
Solar Cells

– KTA Services – ASE Americas, Inc.
Ken Koch Ms. Evelyn Bennett
944 W. 21st St. 4 Suburban Park Drive
Upland, CA 91784 Billerica, MA 01821
909-949-7914 508-667-5900 x266
909-949-7916 (Fax) 508-663-2868 (Fax)
http://www.kta-ev.com – Photon Technologies
Robert Mulligan

Power Trackers P.O. Box 790
Severna Park, MD 21146
– Australian Energy Research Laboratories
410-544-0911
(AERL)
410-544-4075 (Fax)
Stuart Watkinson
photontek@aol.com
M.S. 660
Proston, Queensland 4613, AUSTRALIA – Siemens Solar
011-6171-689308 Camarillo, CA
011-6171-689197 (Fax) 805-482-6800
805-388-6395 (fax)
http://www.solarpv.com
Where can you purchase parts?

Motors
Solder for Solar Cells

– Advanced D.C. Motors, Inc.
219 Lamson Street
Syracuse, NY 13206
315-434-9303
315-432-9290 (Fax)
– @ONCE
Attn: Catalog Sales
4 Sunset Way, Bldg. C
Henderson, NV 89014
888-428-6623
800-950-5679 (fax)

– Solectria
27 Jason St.
Arlington, MA 02174
For more information, go to:
508-658-2231 – http://www.winstonsolar.org/info
508-658-3224 (Fax)
http://www.solectria.com

Motor Controllers
– Curtis PMC
6591 Sierra Lane
Dublin, CA 94568
510-828-5001

510-833-8777 (Fax)