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Mini-Course in Electrical Engineering

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

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Mini-Course in Electrical Engineering

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  1. Mini-Course in Electrical Engineering Chris Jones, Intern solarcaptain@earthlink.net

  2. 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

  3. 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

  4. Tools of the Trade • Soldering Iron/Gun • Wire Strippers/Cutters • Wire Crimpers • Needle-nose Pliers • Diagonal Cutters • Multimeter • Heat Gun

  5. Schematics • Plan your circuit on paper before wiring your car • Example: Northview Race Team ‘97 schematics

  6. Connectors • Deciding when to use crimp connectors • Types of connectors that work well • Problems with crimp connectors

  7. 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

  8. Soldering – The Easy Way • Tools you need to get started • Soldering Irons / Guns • Solder • Heat Shrink • Recommendations for effective soldering

  9. 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

  10. 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

  11. 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

  12. 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

  13. Instrumentation • Meters for the modern solar car • Voltmeters • Ammeters • Amp-hour counters • Temperature sensors and gauges • The “E-Meter”

  14. 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.

  15. Q&A • Do you have any questions?

  16. General Solar Supplies KTA ServicesKen Koch 944 W. 21st St. Upland, CA 91784 909-949-7914 909-949-7916 (Fax) http://www.kta-ev.com Power Trackers Australian Energy Research Laboratories (AERL)Stuart Watkinson M.S. 660 Proston, Queensland 4613, AUSTRALIA 011-6171-689308 011-6171-689197 (Fax) Solar Cells ASE Americas, Inc.Ms. Evelyn Bennett 4 Suburban Park Drive Billerica, MA 01821 508-667-5900 x266 508-663-2868 (Fax) Photon TechnologiesRobert Mulligan P.O. Box 790 Severna Park, MD 21146 410-544-0911 410-544-4075 (Fax) photontek@aol.com Siemens SolarCamarillo, CA 805-482-6800 805-388-6395 (fax) http://www.solarpv.com Where can you purchase parts?

  17. Motors Advanced D.C. Motors, Inc.219 Lamson Street Syracuse, NY 13206 315-434-9303 315-432-9290 (Fax) Solectria27 Jason St. Arlington, MA 02174 508-658-2231 508-658-3224 (Fax) http://www.solectria.com Motor Controllers Curtis PMC6591 Sierra Lane Dublin, CA 94568 510-828-5001 510-833-8777 (Fax) Solder for Solar Cells @ONCEAttn: Catalog Sales 4 Sunset Way, Bldg. C Henderson, NV 89014 888-428-6623 800-950-5679 (fax) For more information, go to: http://www.winstonsolar.org/info Where can you purchase parts?

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