ClearlySolar Car

User Guide

60024 V0413

2 Clearly Solar Car User Guide 60024 V0413

Cautionary and Warning Statements• Thiskitisdesignedandintendedforeducationalpurposesonly.• Useonlyunderthedirectsupervisionofanadultwhohasreadandunderstoodtheinstructions

providedinthisuserguide.• Readwarningsonpackagingandinmanualcarefully.• Alwaysexercisecautionwhenusingsharptools.

How It WorksSolar PanelsSolarcells,alsocalledsolarpanels,uselightenergyfromtheSunandconvertitintoelectricalenergy.Thisenergyconversionprocessisknownasphotovoltaics,whichreferstoeverythingrelatedtotheprocessoflightenergychangingtoelectricenergy.

Anordinarysolarcellisusuallyaflatpanelofabluematerialwithwirescomingoutofoneside.Therearenomovingparts,butwhenyoushinelightonit(especiallysunlight),electricityflowsthroughthewires.

Mostsolarcellsaremadefromsilicon,theelementthatisinordinarysand.Siliconhasanunusualatomicstructure:ithasfourelectronsinitsoutershell.Thesefourelectronshaveaboutthesamepotentialtobesharedwithanotheratomastheirpotentialtograbfourelectronsfromotheratoms.Sosiliconatomsbondwithothersiliconatomsandsharetheirfourelectrons.Thismakesastableconditionandresultsintheseatomsformingcrystallinestructureslikegrainsofsand.Inamanufacturingprocess,siliconcanbeproducedinthinsheetslikethoseseeninasolarcell.

However,asolarcellalsohassmallamountsofotherelementssuchascadmium,selenide,andcopper.Unlikesilicon,whichisnotagoodconductorofelectrons,theseelementshavefreeelectronsintheiratomicstructurethatcaneasilymovefromatomtoatom.Sowhenlighthitsthesurfaceofthiscrystallinestructure,theenergywithinthelightputsfreeelectronsinmotion.Thisisanotherwaytodescribeelectricity–theenergyfromthelighthascreatedelectricity.

Series & Parallel CircuitsThetermsseries circuitandparallel circuit refertothewaythatacircuitisconnected.Aseriescircuitisaseriesofcomponentshookedtogetheralongasinglepath.Thecurrentthatflowsthroughthefirstcomponentwillbethesamecurrentthatflowsthrougheachcomponent.

Traditionally,thiswashowholidaylightswerestrung.That’swhytheentirestrandwentoffwhenonelightbulbquitworking.Thatonebadlightbulbcreatedanopen

circuitsothecurrentcouldnolongerflow.Thehardpartaboutastringoflightsnotworkingisthatit’sdifficulttotellwhichbulbisbad.Eventually,themanufacturersgotsmartandbeganproducingholidaylightsinaparallelcircuit.

Aparallelcircuitisaseriesofcomponentsconnectedinawaysothatthereismorethanonepathtomovealong.Ifonepathisbroken,theotherswillstillwork.Theyarewiredinsuchawaythatifonebulbgoesout,theotherbulbswillstillshine.

GearsGearsareusedinmechanicalsystemsyouseeeverydayincludingcars,mechanicalclocks,andDVDplayers.Abicycleisanotherexample.Thesprocketsconnectwithachain,transferringthehumanpedalpowertothebackwheelandmovingthebikeforward.

Thefourmostcommontasksthatgearsperformare:• Increasingordecreasingthespeedofrotation.• Reversingthedirectionofrotation.• Keepingtherotationoftwoaxessynchronized.• Movingrotationalmotiontoadifferentaxis.

Increasethespeedofrotationbyconnectingasmallergearwithfewerteethtoalargergearwithmoreteeth.Thesmallergearwillbeforcedtorotatefasterthanthelargergear.

Wecandeterminethenumberoftimesthesmallergearwillrotatebyusingagearratio.Thegearratioistheratioofthenumberofteethononegeartothenumberofteethonasecondgear.Ifa20-toothgearisturninga10-toothgear,thegearratiois20/10or2/1.Thismeansthe10-toothgearwillrotatetwiceasfastasthe20-toothgear.

Gearsnotonlycanincreasethespeedofrotationbutalsocandecreasethespeedofrotation.Supposethe10-toothgearwasconnectedtoamotorspinningat30revolutionsperminute.Ifitisconnectedtothe20-toothgearthenthe20-toothgearwillspinhalfasfast–or15revolutionsperminute.

Clearly Solar Car User Guide 60024 V0413 3

Materials Included• Gearfont(1) • 3/4"stand-offpost(11)• 2solarpanelswithleadsandalligatorclips(2) • 3smallwashers (12)• Motor (3) • 6nylonspacers(13)• 4widerubberbands(2areextra)(4) • 11–nuts(14)• 6axlebushings(5) • 12–#2x3/8"screws(15) • 4thinrubberbands(3extras)(6) • 4–#6locknuts(16)• 11laser-cutacrylicparts (7) • 6–#6x3/8"screws (17)• 3axles(1-3/4",2-1/2",and2-3/4")(8) • 4–#6x1/2"screws(18)• 4wheelhubs(9) • 3–#4x1-1/4"screws(19)• 2–1"stand-offposts (10) • 2–#4x5/8"screws(20)

Items Required (not included)• SmallPhillipsscrewdriver • Hobbyknife(optional)• RegularPhillipsscrewdriver • TransparenttapeORcool-meltgluegunwithglueslugs*• Sandpaper • Smallpliersorneedle-nosepliers

*Eitherwillwork,butifyouplantotakeapartthesolarcarandreuseit,usethetransparenttape.

1

2

3

4 6

5

7

10

9

11

819

20

1614 15 13 17

18

12

4 Clearly Solar Car User Guide 60024 V0413

Preparing Parts 1. Deburrtheaxlesbybrushingtheendsagainstsandpaper.

2. Peeltheplasticbackingoffofbothsidesoftheacrylicpieces.Thesecanbedifficulttostart,soyoumayneedtouseasharpobjecttogetitstarted.

3. Removetheaxlebushingsfromtheirplasticfontanduseeitherahobbyknifeorsandpapertoremovetheplasticburrs.

Building the Parts 1. GatherPartsA,1"stand-offposts,andfour#6x3/8"screws.

InsertascrewintothesecondholefromtheendonbothendsofPartA.Screwthestand-offpostsontothescrewends.

2. Withtheothertwoscrews,attachthesecondPartAontheothersideofthestand-offposts.Thiswillbethechassis.

3. Findtwo#4x5/8"screws,twonuts,andPartsC(2)andD.InsertaPartCnotchintoaslotonPartD.SlideanutintotheholecutforitinPartC.InsertonescrewandtightenitsoitthreadsthroughthenutandholdsPartDinplace.Repeatwithothernut,screw,andPartConotherside.Thisisthesolarpanelbracket.

4. GatherPartsB,3/4"stand-offpost,andthelasttwo#6x3/8"screws.FromthenarrowendofaPartB,countbacktwoholes.Insertascrewhereandattachthestand-offpostonthescrewend.PlacetheotherPartBtomirrorthefirstandsecureittotheothersideofthestand-offpostwiththesecondscrew.

5. Collecta#4x1-1/4"screw,3nuts,andawasher.PutthewasheronthescrewandinsertitintothemiddleholeatthewideendofaPartB.Beforepushingthescrewthroughtheotherside,placeanutontheendandturnitafewtimes.Then,placeasecondnutontheendandthreaditonthescrewafewturns.

6. Now,pushthescrewthroughtheotherPartB.Placethethirdnutonthescrewend.Usingthepliers,holdthefirstnutwhileyoutightenthescrew.SpinthesecondnuttowardPartBuntilsnug;holdthescrewstillwhiletighteningthenutwiththepliers.Finally,tightenthethirdnut.

7. Fromthegearfont,removethe40-and20-toothgearswiththelargeaxlehole.Alsoremovethewide10-toothgearwithasmallaxlehole.Useahobbyknifeorsandpapertoremoveanyburrsfromthegears.Alsogathertwoaxlebushings,twospacers,andthe1-3/4"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. PutabushinginthethirdholefromthenarrowendofeachPartB.Inserttheaxleintothe40-toothgear.Addaspacerontheend.InserttheaxleintothebushingonthePartBthatwouldputthegearontheleftsideofthecarwhenthenarrowendisthefrontandthe1-1/4"screwisontop.Placeanotherspacerontheendoftheaxleandgentlypushthe20-toothgearontheend.Thisisthemotormount.

9. The10-toothgearisthepiniongear;placeitonthemotorpostsothepostisflushwiththesideofthegear.Caution:Ifyoupushthemotoronthegeartoohard,themotorhousingcouldcomeout.

Adding the Wheels1. GatherPartsEandFandallthe#2x3/8"screws.Ifthewheel

hubsareinafont,removethem.Fromthegearfont,removethe50-toothgearwithalargeaxlehole.Useahobbyknifeorsandpapertoremoveanyburrs.

2. Usingasmallscrewdriver,attachthehubstothewheelswiththescrewheadsonthesideoftheacrylicwheel.Ifthecarwillneedextratraction,stretchawiderubberbandoverthebackwheels(PartsE).

3. Insertthe2-1/2"axleintooneofthehubsattachedtoafrontwheel(PartF).Tip:Iftheaxlesarelooseonthehubs,insertapieceofstringthroughthehub.

4. Findfouraxlebushingsandfourspacersandthe2-3/4"axle.Insertthebushingsintothefrontandbackholesonthechassis.

5. Placeaspaceronthe2-1/2"wheel-and-axleassemblyandinsertitthroughthefrontendofthechassis;thefrontistheendclosertothemiddleholesonPartsA.

6. Placeanotherspacerontheendoftheaxle.Pressthesecondfrontwheelontotheaxle.

7. Pushthegearontheendofthelongeraxleso1/2"comesoutonesideofthegear.

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

HubF

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. Carefullypushoneofthebackwheelsontheshortendoftheaxle.

9. Addaspacerandinserttheaxlethroughthebushingsonthebackofthechassissothegearisontherightside.

10.Addthreespacerstotheendoftheaxleandthenpushontheotherbackwheel.

Putting It All Together 1. Gatherthemotormount(withPartsB),chassis,two#6x1/2"

screws,andtwolocknuts.Withthe40-toothgearontheleft,setthenarrowendofthemotormountbetweenthechassisneartheholeclosetothebackwheels.

2. Insertascrewoneachsideandplacealocknutoneachscrew.Usingpliers,holdthelocknutandtightenthescrewjusttoholdonthepart–theassemblyshouldbeabletomove.

3. Findthemotor,two#4x1-1/4"screws,twowashers,andsixnuts.Placeawasheroveroneofthescrews.Ontopofthemotormount,insertthescrewjustthroughonesideofaremainingholeandplaceanutonthescrewendandturnitafewtimes.Addasecondnutandturnitafewtimes.Pushthescrewthroughtheothersideoftheassemblyandplacethethirdnutontheend,butdonottightenityet.

4. RepeatStep3fortheremainingholeatthetopofthemotormount.

5. Twistthemotor’swireends.

6. Wrapapieceoftapearoundthemotor.Note:Ifyouarenotgoingtotakeapartandreusethecar,youcanusecool-meltglueafterthemotorisinthemount.Theglueortapeholdthemotorinplace.

7. Insertthemotorinthemotormountsothepiniongearisonthesamesideasthe40-toothgear.

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. Wrapthewireendsunderthewashersandscrewheadsonthefirstandthirdscrews.Usingtheplierstoholdthefirstinsidenut,tighteneachscrew.Besurethemotorterminalsdon’ttouchthegears.

9. Gathertwo#6x1/2"screws,twolocknuts,andthesolarpanelbracket.Placethebracketendssotheystraddlethechassisattheremainingholesandinsertthetwoscrews.Usingpliers,tightenwiththelocknutsuntilfrictiontight–donotovertighten.

10.Holdthesolarpanelssidebysideontopofthebracketwiththeleadsfacingthemotor.Securethepanelswithasmallrubberbandbystretchingitfromunderoneendofthebracket,overthesolarpanels,andundertheotherside.

Operating the CarThereareseveralwaystooperatethecar.ThesolarpanelbracketcanbeadjustedtoananglethatbestfitstheSun’spositioneachtimeyourunthecar.Youcanalsoattachthesolarpanelsinaseriescircuitoraparallelcircuit.Makesurethemotormountispushedinapositionwherethepiniongearengageswithagearonthecar.

Series Circuit1. Placetheblackleadfromonesolarpanelandtheredlead

fromthesecondpanelandconnectthemtothecenterpost.

2. Connecttheredleadfromthefirstpaneltothefrontpost,andtheblackleadfromthesecondpaneltothebackpost.Setthecarinthesunshineorunderabrightincandescentlampanditwillmoveforward.

3. Torunthecarbackward,switchtheleadsonthefrontandbackposts.

Parallel Circuit1. Connecttheredleadfromeachsolarpaneltothefrontpost.

2. Connecttheblackleadfromeachsolarpaneltothebackpost.Setthecarinthesunshineorunderabrightincandescentlampanditwillmoveforward.

3. Torunthecarbackward,switchtheredleadstothebackandtheblackleadstothefront.

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

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Switching GearsYoucanalsotrydifferentgearcombinationsontheClearlySolarCar.Thesetupintheseinstructionshasthe10-toothpiniongearconnectingtoa40-toothgearthat–viathesmallaxle–turnsthe20-toothgear.Thisgearmovesthe50-toothgearthatisattachedtothebackaxleandspinsthewheels.

Youcanalsoremoveabackwheelandswitchthebackaxlesothe50-toothgearisontheleftside.Thenadjustthemotormountsothe50-toothgearcanengagewiththe40-toothgearthatisconnectedtothepiniongear.

Tip:Ifyoumakeahabitofswitchingthebackaxle,theaxleholewillbecomelooseovertime.Ifthishappens,youcaninsertathreadortwointotheaxleholeonthehubbeforeplacingthetiresbackon.Thiswillgiveyouatighterfit.

Activity: Series vs Parallel Circuits1. Outdoorsonasunnyday,measureandmarkadistanceof10feet(3.05meters)inwhichtotestthecar.Arrange

thesolarpanelconnectionsonthecarforaseriescircuit.

2. Placethecaratthestartinglineandletitgo.Usingastopwatch,timehowlongittakesthecartotravelthedistance.

3. Nowswitchtheconnectionstoaparallelcircuit.Again,placethecaratthestartinglineandtimehowlongittakestotravelthedistance.Lookingattheresults,whichtypeofcircuitworksbetterforspeed?Consideringtheinformationonpage2,discusswhythisistrue.Then,discusswhatadvantagestheremightbefortheotherconnectionifitisn’tfaster.

4. Setupa20-foot(6.10m)courseandredotheexperiment.Didalongertrackmakeadifferenceintheoverallperformanceofeithercircuit?

5. Calculatetheratiobetweentheperformance(intermsofspeed)oftheseriesandparallelcircuittests,firstforthe10-foottest(3.05m)andthenforthe20-foottest(6.10m).

6. Setupaninclinedlaneandredotheexperiment.Explaintheresults.

Formoreactivityideasforthiskit,visitshop.pitsco.com,searchfortheClearlySolarCarKit,andclicktheActivitytab.