UNIVERSITY OF CALGARY SOLAR CAR TEAM Community Report 2012

A TIME OF CHANGE With the unveiling of the University of Calgary Solar Car Team’s 4th generation car, Schulich Delta, it seems fitting to reflect on change and the impetus for change. Our third generation solar car, Schulich Axiom, performed beautifully at the 2011 World Solar Challenge (WSC) in Australia, allowing us to maintain our position as the number one Canadian team. Both the car and our WSC race team made it home safely—the team with unforgettable memories and experiences, and the car with a legacy as a racing machine. While in Australia, it became clear to our team that there was a need for more communication and collaboration amongst Canadian solar car teams. We are proud to say that our University of Calgary team stepped up and led the founding of the Canadian Solar Car Alliance, a forum for Canadian university teams to share information and help each other with the logistics of building, shipping and racing solar cars.

At the same time, we decided that the new direction could not be made at the expense of the team’s racing legacy from previous generations. While our new car would move toward practicality it would also be designed to maintain our tradition of producing top-of-the-line solar race cars. You can imagine the excitement as the idea took hold. Our new prototype would mark a significant change in direction.

This is what our generation-four car Schulich Delta is all about. Appropriately, delta is the Greek symbol for The experience and discussions with universities change! Schulich Delta is one step closer to being a around the globe sparked discussion in our own consumer reality, yet is still a high-performance solar shop, around the possibility for change. race car. We were seeing a trend in solar car design; in order to make a car as aerodynamic and efficient as possible, design pushed further and further away from practicality. A design for racing sometimes meant sacrifice in terms of aesthetics and functionality. Like many solar cars, Schulich Axiom , is an excellent example. When the team takes Schulich Axiom out on local roads, people often wonder if it’s a spaceship. At exhibitions and school visits, people ask when they will be able to drive a solar car, or when they will start seeing them more often on the road. With a drive to innovate and with a proven track record of solar vehicle construction, the team decided to attempt to build a solar car that would be a step closer to making solar-powered vehicles a consumer reality. We decided to build a car unlike anything we have ever dreamed of 2 before; a car that would fit a driver and passenger with room for golf clubs rather than camel back water packs.

We are excited to tour around Alberta this spring and place it to the test in Australia in October. As our car design has evolved, so too has our team. We have said goodbye to members who have graduated and joined the working world. Jordyn Troyer, outgoing co-chair and business manager is amongst our graduated members. Her work in starting the generation four project has been monumental. We send Jordyn and all our graduated members on their way with big congratulations for their hard-work and dedication to the team, and with appreciation for setting the bar high for members continuing on and those just joining. With a solid foundation, we have much to look forward to in 2013.

Susanna Kubik – Co-Chair, Business Manager Mico Madamesila – Co-Chair, Engineering Manager

TABLE OF CONTENTS 1.  The Solar Car Team Mission ……………………………………………… 4 2.  About The Solar Car Team ………………………………………………... 5 3.  Team Overview ……………………………………………………………..

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4.  Communications Team …………………………………………………….

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5.  Electrical Team ……………………………………………………………... 13 6.  Mechanical Team …………………………………………………………... 17 7.  Accounting Team …………………………………………………………

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8.  Race Logistics Team ………………………………………………………. 23 9.  Sponsorship Team …………………………………………………………. 27 List of Sponsors …………………………………………………………………. 28 2012 – 2013 Solar Car Team Members ………………………………………. 29 Schulich Delta Specifications ………………………………………………….. 30 3

THE SOLAR CAR TEAM MISSION Our team’s mission consists of three components:

Innovate. We continually strive towards innovation and excellence through designing, building and racing cutting-edge solar cars.

Educate. We believe in creating student energy leaders by providing tangible and meaningful experiential learning.

Inspire. We believe in investing in the same community that has supported us through our journey by educating and inspiring youth on the possibilities of sustainable energies.

4 Schulich Axiom Alberta Tour Race Team 2012

ABOUT THE SOLAR CAR TEAM Who We Are. A program of inter-disciplinary students, working towards design excellence, innovation, and building a more sustainable future. The team was founded in 2004 and has grown considerably from a few engineering students to a team of 46 members from disciplines such as Business, Communications, Engineering and Kinesiology.

What We Do. “Innovate, Educate, Inspire” is the team’s mission. We design, build and race solar powered cars across international borders. Our primary purpose is to educate the community about renewable energy and act as a median through which students of various departments and faculties can collaborate in supporting sustainable energy.

Why We Do It. Renewable energy sources are crucial to the Earth’s sustainability. Solar energy is one of the leading sources of green energy and is rapidly developing more practical applications. Through research and innovation, the Solar Car Team showcases the potential and capabilities of solar technology being incorporated into our daily lives.

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TEAM OVERVIEW The University of Calgary Solar Car Team consists of a total of 46 inter-disciplinary undergraduate students. The team is divided into a business and an engineering team, which are further divided into 6 sub-teams. Our communications team is in charge of public relations and community involvement which reaches over 10,000 people annually. As part of our core commitment in educating our community, we have reached out to approximately 3,500 students in 2012 alone with our school visits initiative. The Race Logistics team works closely with our Communications team when arranging our annual Alberta Tour each spring. The Alberta tour typically lasts 6 days and the Solar Car Team covers approximately 3,000km during this tour that visits schools across Alberta while testing the solar car. The Race Logistics team is also responsible for all logistical support during the World Solar Challenge in Australia. The majority of our funds are used towards building the solar car. For the Generation 4 project, the team took 9 months to design and will take 6 months to complete building the solar car, which is led by the engineering team. The electrical team plays the critical role of increasing solar cell efficiency, through research and innovation. They assemble the solar array, which consists of approximately 370 Mono – crystalline Silicon solar cells and building the battery, made up of 1,353 lithium – Ion cells. All of this would not be possible without our accounting team which works with a budget of just over $560,000 and is responsible for managing cash flow, reimbursements and conducts frequent budget reviews. In order to reach this budget, the sponsorship team works hard at developing and maintaining good relationships with sponsors. The sponsorship team raised over $470,000 with the help of 14 sponsors as of January 2013 and is continuously looking for organizations to partner with.

Schulich Axiom in the shipping container ready to be shipped to Australia for the 2011 World Solar Challenge.

COMMUNICATIONS TEAM

Holy Spirit Catholic School visit on SAAT 2012.

Fox Creek School visit on SAAT 2012.

The communications team has played an

Our annual Schulich Axiom Alberta Tour

integral role in the past year in reaching

(SAAT) was held from April 30 to May 5,

out to our local community. One of the

2012. During this six day tour, the team

biggest accomplishments for the team

was able to reach out to approximately

was arranging 18 school visits throughout

1,000 students and community members.

the year. During these visits, the team

The team acted not only as Solar Car

provided interactive presentations to

Team members, but also as ambassadors

students and while bringing along

of the University of Calgary.

Schulich Axiom for display.

our school visit initiative, we were able “Through to reach out to approximately 3,500 students. ” Jillian Stephenson, Communications Manager 8

Schools visited in 2012 SAAT Schools 2012 - Big Valley School - Holy Spirit Catholic School - Lakeland Ridge School - Barrhead Elementary School - Fox Creek School - CP Blakely Elementary - Sundre High School - Turner Valley Elementary

Local Schools 2012 - McKenzie Lake School - Willow Park School

every “Atevent we attend people always ask us, ‘When will I be driving a solar powered car?’

”

Mico Madamesial, Engineering Manager & Project Co-Chair

- Simons Valley Elementary School - Douglasdale School - Calgary French International School - Colonel Walker School - Terry Fox School - Bishop Pinkham School - Cappy Smart School - Western Canada High School 9

Dear Jillian and the Solar Car Team, The team was terrific! Thank you so much for taking the time to inspire young people. It is all too common to learn about a technology like solar transportation, without actually experiencing the concept. Your powerful presentation and showing of the car certainly was experiential education that will benefit students’ learning significantly. The students made many comments about how impressed they were with the car and the team’s presentation. I have had a few students who were a part of “Earth Club” last year who now want to build our own mini solar car! I’m not sure if I will take on this idea or not but I am considering it! I don’t think ours would be made of carbon fiber though, more the wooden “carbon” variety ha-ha. The solar car team presented to approximately 70 students, twice. The total number of Terry Fox students who shared the excellent experience was 135-140. Thank you again and please consider coming back for Citizens in Action day as your team really is a perfect fit. I know you’re busy with other requests but our students never get enough exposure to university students and the idea that they could be at university themselves one day – I truly think you inspire our young people. Sincerely, Tim Mang Teacher at Terry Fox Junior High School

School presentation at school event

Schulich Axiom at Brooks Annual Car Show and Shine.

One of the largest community events that the team was invited to attend this past summer was a two day event in Brooks, Alberta. This event was sponsored by the Brooks and Area Science Olympics and Newalta Corp. The first day of the event was geared towards students of the Brooks and surrounding area. The team had an opportunity to present and demonstrate Schulich Axiom to over 500 students, aged kindergarten to grade 12. On the second day of the event, the car was

Solar Car Team has “The appeared in 18 different media related items since the beginning of 2012.

”

Jillian Stephenson, Communications Manager

displayed at the annual Car Show and Shine. Other large scale community outreach events that the Solar Car Team attended included the BP A+ for Energy Conference, Chinatown Street Festival, Mayor’s Environmental Expo, and Minds in Motion Science Camp. 11

Joshua Chow, member of the Electrical Engineering Team, working on assembling solar cell modules

ELECTRICAL TEAM The greatest accomplishment for the Electrical Engineering Team this year was the procurement of the solar cells that will be used on Schulich Delta. The team takes pride in its ability to assemble the array in house, and as a result it must purchase raw solar cells that have yet to

cells on the “Solar Schulich Delta have an

Undergo assembly into panels. It is often difficult to find suppliers that are willing to distribute top grade cells in this state, but the team was able to acquire Sunpower C60 K-bin cells. The team anticipates improved power production compared to previous generation cars as a result of obtaining these cells.

efficiency rating in excess of 22.5%, approximately 3% increase in efficiency when compared to cells used on Schulich Axiom

”

Ian Haigh, Electrical Engineering Manager Assembling the solar array is one of the greatest challenges tackled by the electrical team. The cells are very fragile and must be soldered into modules with the greatest of care to prevent damage. This is another area in which the Sunpower cells represent an improvement over the previous cells. Previously, the solder contacts were three long strips on both the top and bottom surfaces of the cell. Soldering them was a challenge due to thermal expansion; but the new cells have only three small point-like contacts. To further ease the process of assembly, the team purchased pre-fabricated interconnect tabbing designed for the C60s.

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A side of the communications board.

A partially assembled battery pack module showing the use of nickel tabbing for interconnection of individual cells.

For Schulich Delta, the Electrical Team is

From a man-power perspective, a

developing an application for a tablet

second major challenge lies in

that will display all the critical telemetry

assembling the battery pack for the

data on one large screen mounted on

car. For this car, the team has elected

the dashboard. This not only allows the

to use a battery pack consisting of

driver to access all critical information at

approximately 60kg of lithium ion

a glance, but also opens up the realm of

batteries (an astonishing 1,300

possibility for adding driver

individual cells). All of these cells must

conveniences and comforts typically

be interconnected in series and parallel

found in today’s automobiles such as

functional blocks to develop the

integrated navigation, entertainment, and

desired pack voltage and charge

communications.

capacity. Individual cells will be connected in parallel using strips of

Alongside the tablet, the team has

nickel tabbing welded to the battery

developed a communications board that

through a capacitive welding process.

acts as a hub for the different devices on the car to communicate internally and with external monitoring and display devices. This board is approximately half 14

the size of the analogous board used in Schulich Axiom despite having added functionality.

As the electrical team looks forward to 2013, evaluation of the drive system will be an area of intense testing. The team will examine the utility of a pair of drive motors linked by an electronic differential through a pair of motor controllers and compare this to the weight and possible power savings of a single drive motor. For Schulich Delta, the way the driver receives feedback from the car has undergone a radical change and driver responses will be crucial for further improvements to the system. During the spring of 2013, the Mechanical Team will complete construction of the top shell of Schulich Delta, at which point the Electrical Team will then install the solar cell array. The sensitive nature of the array makes embedding it in the top shell one of

excited to “Webeareableveryto present some of our designs at this time and cannot wait to showcase all the systems of the car through our spring tour.

”

Ian Haigh, Electrical Engineering Manager

the most tedious processes for the team. By spring 2013, the electrical team will have encapsulated cells to make two full arrays. This helps the team mitigate the risk involved with array embedment in the top shell and delayed production as a result. 15

Brandon Roswell and Austin Jang, members of the Mechanical Engineering Team, working on the brakes for Schulich Axiom

MECHANICAL TEAM 2012 began with an idea, supported by “rough sketches, and ended with a nearly complete prototype car. ” Matthew Johnson, Mechanical Engineering Manager The main objective for the Mechanical

To keep the weight down, the team opted

Engineering Team this year was to design

to build a completely composite body

and build a truly unique car that would be

and custom chassis made from leading-

practical for the everyday driver, yet still be

edge, spread tow carbon fiber. Not only

competitive on the world solar racing stage.

does this cut weight, but it also adds

This proved to be a difficult challenge but it

strength to the car, improving safety and

was achieved through strategic project

enhancing surface finish of the body.

planning, ingenious engineering design

Throughout this process, the team took

and countless hours of hands-on

the time to carefully select good quality

commitment from our team.

and reputable local and international suppliers of materials for the car,

The team decided to go with a two-door

including products that improved the

coupe design with a large trunk that would

aerodynamic efficiency, while at the

provide ample storage room. Through the

same time managing to keep costs low.

use of advanced computer design and simulation programs, the team was able to design a body that provides us the necessary size needed for the driver, passenger and cargo while still maximizing our aerodynamic efficiency.

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Upon completion of the design phase of Schulich Delta, the next challenge for the team was to begin construction of the car. This began in the summer of 2012 by constructing a full size positive mold of our car which was then used to cast a negative, fiberglass mold. Completing the construction of the molds proved to be a huge milestone for the project as this mold allows the team to build the prototype car and ultimately, the final car which will be raced in the World Solar Challenge. It took many long days and nights between classes and schoolwork but in the end, the team managed to cast two spectacular molds, one each for both the top and bottom shells of our car. The suspension system for Schulich Delta is a one-of-a-kind design made by the mechanical team members. It was designed with simplicity and performance in mind at all times. Nearly every component of the suspension system is completely interchangeable between the front, back, left and right. This not only makes the suspension easier to build, but also decreases machining time and associated costs dramatically. Pairing this with materials such as titanium and aluminum makes for an extremely light suspension that is sure to keep Schulich Delta competitive on the world stage.

“

This vehicle is completely different from anything we’ve produced before.”

Susanna Kubik, Project CoChair and Business Manager

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Mechanical Engineering Team Members building a negative fiberglass mold

Computer design of the Schulich Delta using Solid Works software

The team finished off the year strong by constructing its prototype car. This is the point where the team was able to assemble all of the components together for the first time, outside of a computer program. The next coming months will be equally as exciting, with the crash-testing of the Schulich Delta prototype car, final construction of Schulich Delta, and the grueling road-testing to prepare the team

We are making an “exceptional, one-of-akind car that will be sure to turn heads and attract global attention from our competitors.

”

Matthew Johnson, Mechanical Engineering Manager

for the World Solar Challenge in the fall of 2013! 19

Best wishes from the community at Chinook Mall before the 2011 World Solar Challenge

ACCOUNTING TEAM 2012 has proven to be a major milestone for the accounting team. The team’s major accomplishment was reviewing all expenditures

Overview of Budget Allocation for Schulich Delta

of the Generation 3 project. During the same period, the accounting team was able to create a comprehensive budget for the Generation 4

38%

44%

project. The team has also been able to improve accountability and efficiency by implementing new processes. With a budget of just over

18%

$560,000 for the Schulich Delta project, the team has begun creating a three-month rolling budget and sending out bi-weekly updates to each subteam manager.

Race Budget Community Initiatives Designing and Building

By being part of the Solar Car Team, I have had “the opportunity to apply classroom knowledge to solve real world problems. ” Stephanie Ly, Accounting Manager 21

2011 World Solar Challenge Race Team Members

RACE LOGISTICS TEAM The Race Logistics Team played a pivotal role in planning the route the team was to take during the Schulich Axiom Alberta Tour (SAAT) 2012. In addition to routing, the team ensured all accommodations for the SAAT members were arranged. During the six day tour, SAAT members travelled over 1,700 km and visited numerous communities throughout Alberta. A particular highlight of Alberta tour was the unique opportunity to race the Fox Creek ReJuiced Beetle. It was a close race, but ultimately Schulich Axiom managed to pull through and cross the finish line first, in spite of having an electrical problem at the very start of the race. It was truly an unforgettable event, which was made better by the incredible turn out from the Fox Creek Community.

Fox Creek Re-Juiced Beetle (left) vs. Schulich Axiom (right)

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Map of the World Solar Challenge race

One of the biggest events that Solar Car Team

Group photo of all the Canadian Teams at WSC 2011

participates in is the World Solar Challenge (WSC) that takes place in Australia. WSC is an international competition where solar vehicles compete in a grueling, cross-country race that totals a distance of just over 3,000 km.

The WSC provides the Solar Car Team with a chance to test its abilities by racing against teams from around the world. It’s a highly dynamic environment that puts the team’s capabilities to the test by solving problems quickly and working effectively as a team. Although it requires a tremendous amount of work, effort, and dedication, the end result is a very rewarding and invaluable educational experience for every member on the race team. The team will be participating in the WSC 2013 race that will be held from October 6 to October 13, 2013, where teams will race from Darwin to Adelaide, driving straight through the outback.

Our race team “ members will head to Australia in the Fall of 2013 and will not only represent the University of Calgary, but also act as ambassadors of the Province of Alberta.

”

Brigitte Sullivan, Race Logistics Manager

The Race Logistics Team looks forward to a busy 2013, when the team will prepare for both the 2013 Alberta tour and WSC 2013. Driver training will be arranged through a variety of methods in order to ensure the drivers will be able to thrive in the challenging environment. The Alberta Tour, which is scheduled for early May 2013, will provide an opportunity for the team to visit more Alberta communities and a chance to test Schulich Delta. In June 2013, the Race Logistics team will assist in shipping Schulich Delta to Australia. During the month of September 2013, race team members will fly to Australia to prepare for WSC. The team’s target for the WSC 2013 race is to remain the number one Canadian team and win the top sportsmanship and safety awards. Alberta Tour 2013 and WSC 2013 Team Members -  Ian Haigh

-  Joshua Chow

-  Stephanie Hladik (Driver)

-  Jack Sreekumar (Driver)

-  Matthew Johnson

-  Brigitte Sullivan

-  Susanna Kubik

-  Connie Tran

-  Mico Madamesila

-  Nizar Walji (Driver)

-  Brandon Roswell (Driver)

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Faculty Advisor, Dr. Lynne Cowe Falls, cheers the team with a Canadian Flag

Solar Team Members with Schulich Axiom at The Chancellor’s Golf Tournament

SPONSORSHIP TEAM The University of Calgary Solar Team greatly appreciates the support provided by

Funding Partners for the Schulich Delta Project

its sponsors. Through the generous support of sponsors, the team is provided with the resources necessary to spread the team’s message of sustainable energy education.

With a budget of just over $560,000 for Schulich Delta, the team has managed to raise $488,598 in financial contribution and $27,585 in in-kind contribution. The Solar

Educational Institutions 44%

Corporate Partners 56%

Car Team is still looking to raise just over $60,000 to complete funding for the Schulich Delta project.

” Our sponsors are the backbone of our “project and we continually strive to build

”

lasting relationships with each one of them. Nizar Walji, Sponsorship Manager

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Educational Sponsor

Lead Sponsor

Platinum Sponsor

Gold Sponsor

Silver Sponsors CANADIAN CENTRE FOR ADVANCED LEADERSHIP IN BUSINESS

Bronze Sponsors

Supporting Sponsors David Johnson * Sponsor list as of January 2013

Airtech International Inc.

2012 – 2013 University of Calgary Solar Car Team Members

Project Co-Chair, Engineering Manager Mico Madamesila

Project Co-Chair, Business Manager Susanna Kubik - 2013 Jordyn Troyer - 2012

Mechanical

Accounting

Ian Haigh - Manager

Matthew Johnson - Manager

Stephanie Ly - Manager Raymond Huynh

Daniel Benavides

Odai Almoqadam

Andrei Buiza

Tawheed Al-towaitee

Joshua Chow

Merryl Arokiasamy

George Co

John Fernando

Sarah Kosowan - Public Relations

Tanner Collin

Kaelan Goode

John Fernando

Yusra Hemed

Marian Yet - Events Michelle Yet - Events

Stephanie Hladik

Austin Jang

Salima Kairzhanova

Derek Lee

Brigitte Sullivan - Manager

Ryan Ma

Jose Podio

Christopher Melendez

Brandon Roswell

Riccardo Palladini Brenda Nguyen

Dallas Rathbone

Jack Sreekumar

Daniel Young

Connie Tran

Nizar Walji - Manager

Steven Tran

Stefano Giovannetti

Electrical

Communications Jillian Stephenson - Manager Steve Cheng - Graphics

Race Logistics

Sponsorship

Mike Vanderveen

Jasdeep Hayer

Albert Vuong

Bonnie Huynh

Sophia Wong Eiden Yoshida Harry Zheng

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Schulich Delta Specifications Electrical

Mechanical

Array Power: ~1000-1200W (projected)

Time to Design: 8 months

Solar Cells: ~370 Mono-crystalline Silicon

Mold Construction: 3 months

MPPT’s: ~10 UC Solar MPPT’s

Car Construction: 3 months

Batteries: 1353 Li-Ion (18650 type) cells

Weight: 320 kg = 700 lbs (estimated)

(61.6kg)

Length: 4.5 meters = 15 feet

Battery Box: Kevlar

Width: 1.8 meters = 6 feet

Instrumentation and Communication: Driver

Height: 1.2 meters = 4 feet

display in steering wheel, tablet interface in

Top Shell: Carbon fiber reinforced EPS

dash, and Wi-Fi link to chase vehicle

(expanded polystyrene) Bottom Shell: Carbon fiber reinforced Corecell, EPS mix Chassis: Carbon Fiber and Kevlar reinforced Corecell monocoque Suspension: Double A – Arm, aluminum and steel Track: 1.4 meters = 4.6 feet Base: 2.7 meters = 8.9 feet Brakes: Four wheel hydraulic disk brakes, two wheel electronic regenerative Motor: Two, rear, in wheel, direct drive motors Storage Capacity: 0.56 cubic meters = 20 cubic feet (estimated) Seating: Two front Body Style: Two door coupe with large rear hatch

For additional information, contact: The University of Calgary Solar Car Team Engineering Block F, Room 262 2500 University Drive NW Calgary AB T2N 1N4 [email protected] www.calgarysolarteam.ca January 2013