SOLAR ENERGY POWERED EPOXY-RESIN-BODY MADE VEHICLE

ABSTRACT This project showcases the use of Solar Energy as alternative (renewable) energy resource to conventional fossil fuel. Additionally, it demonstrates the use of composite material (Epoxy Resin) in the manufacture of vehicle body as a possible replacement of steel materials. A rectangular mold box of dimensions 271mm x 153mm x 147mm was constructed from strawboard. Interior was lined with release agent (paraffin wax). Epoxy resin and hardener were mixed in a 2:1 ratio. The Mixture was stirred slowly to prevent bubble formation. The liquid was poured into the mold and left to cure at room temperature (25 ) for 8 hours. The cured body was removed and marked. Holes were drilled for small light bulbs, switch, and solar panel mounts. Edges were smoothed using files and sandpaper. The Chassis was primed and painted. 4 electromechanical motors were mounted in position on the base panel. A tyre was fitted to the axle of each of the 4 motors. Solar panel was mounted on the roof of the car. Solar panel was connected to battery via diode and fuse. A motor driver circuit was connected to battery and motor. Switch connecting the circuit and motor was positioned in the hole drilled on the chassis. Multimeter was used to test open-circuit panel voltage and thereafter, all wiring joints were checked for continuity. At the end of the construction, the prototype underwent a series of tests to evaluate performance characteristics such as solar panel efficiency, battery performance, motor performance, body strength and durability, turning radius and maneuverability as well as terrain adaptability. Results show measured Output Voltage: 6V under full sun and measured output Current: 0.2A. Type of battery is 3.7V, 2A rechargeable Li-ion battery. Charging time under full sunlight was 5.5 hours. Discharge duration under continuous operation: ~ 30 minutes. Voltage drop under load: from 6.0V to 4.8V over discharge cycle. It was observed that the system maintains stable voltage over a reasonable load period for the prototype vehicle. Electromechanical motor rated speed was12000 rpm while maximum vehicle speed is 0.484 m/s on flat surface. Material used for the chassis was Epoxy resin reinforced with carbonated palm kernel shell particulate. The weight of the chassis is 815g and drop test on it shows 1.2-meter drop with no cracking. Load test reveals that the vehicle supported additional 1.2kg weight without deformation. It was observed that Epoxy resin provided a high strength-to-weight ratio, maintaining structural integrity while optimizing vehicle weight. Turning Radius of vehicle was determined to be 0.563 meters while response to RC Steering was smooth up to 3.2 meters range. Terrain test results show, Tiled floor as 0.484 m/s; concrete floor as 0.418 m/s; sandy floor as 0.401m/s and grassy terrain as 0.362 m/s. Evidently, the results show the applicability of Epoxy Resin composite material as a good substitute to steel material in construction of vehicle body while minimizing cost of energy by the application of Solar Energy.