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A Two-Seater Light-Weight Solar Powered Clean

Car: Preliminary Design and Economic Analysis


Sanjana Ahmed1, Ahmed Hosne Zenan2, Mosaddequr Rahman3
School of Computer Science and Engineering, BRAC University
66 Mohakhali C/A, Dhaka-1212, Bangladesh
1
sanjana.ahmed@bracu.ac.bd
2
ah.zenan@bracu.ac.bd
3
mosaddeq@bracu.ac.bd

Abstract— This paper outlines the design of a prototype solar diseases, improve public health and reduce dependency on
powered light-weight economically affordable clean car for the fossil fuels. Unlike conventional cars, solar cars will collect
daily office commuters of Dhaka city. Calculation in this paper energy during still state in traffic congestion rather than
shows that the solar power alone will be sufficient to operate a consuming energy like traditional cars that keep burning fossil
light-weight car from one end of the capital city Dhaka, to the
fuels and generating pollution.
In Dhaka city, a major use of cars is for daily commuting to
other, for a journey to and from the office. A preliminary design
and from office with one of the longest distances being
of the solar car has been performed in this paper by calculating
represented by Uttara to Matijheel route, which covers a
and estimating the required panel size, battery capacity and distance of only about 35 km for the round trip. Calculation
motor power. A plug-in charging option has been supplemented shows solar power alone will be sufficient to drive a light-
to the car for extracting electricity from the mains during times weight car covering this distance. Due to rising fuel prices,
of insufficient energy receptions from the sun. Economic analysis fuel run cars are becoming less popular among the general
performed on the life cycle cost of solar cars, as opposed to people as maintaining such a car is proving to be beyond their
traditional fuel-based cars shows that over the long-term, solar affordability standard. Figure-1 shows how the price of
cars come out to be much less expensive. Over a period of 20 different fuels has increased over a decade with the price of
years, combined cost of solar component replacements and diesel increasing the most. The price of the fuels is also
electricity charges amount to a total over BDT 2 lac, which is affected by annual inflation in Bangladesh which stands at 6%
approximately 1/9th the total cost of operating a fuel-based car in
on an average [3]. This raises the already increasing fuel price
by a factor of 0.06 hence making the conventional cars even
Dhaka, considering the fuel cost, maintenance and annual
expensive. Therefore introducing solar cars as an office
inflation over the same duration.
commuter can help to alleviate the fuel price issue to a great
Keywords— Solar Energy, Solar Car, Light-Weight, Economic extent.
Analysis, Life Cycle Cost. Beside the rising fuel price, conventional cars are also
subjected to externalities cost such as cost related to
I. INTRODUCTION environmental and health damages due to toxic emissions.
Solar cars started their existence through universities and These externalities are completely absent in solar cars making
manufacturers. Starting with MIT in USA, universities from it more desirable to the consumers. The savings from the
24 other countries across the world has currently devoted government investments on fuel powered cars can be directed
research and manufacturing groups in solar cars [1]. towards subsidizing industries in manufacturing and
Manufacturers from the US (Sun Motor), India (Reva), encouraging public in purchasing solar cars. This will further
Taiwan and France (Venturi) are expecting to bring their solar drop the price of the solar cars making it more within the
commuter cars for general public [2]. With high performance reach of the general people.
and low cost solar cells being produced, more sophisticated In this work, a two-seated compact light-weight four-
and developed solar vehicles are coming into existence. With wheeler solar car is contemplated with a provision for external
depleting natural resources and increasing pollution, solar cars plug-in charging option to charge the batteries from the
are attaining their acceptance and importance all around the conventional power supply line during periods of insufficient
world. solar energy. A preliminary design of the electric drive system
Solar powered clean cars can be of great advantage to the which involves estimation of the required panel size, battery
public and the environment especially in the city of Dhaka capacity and motor power is carried out. An economic
which is registered as one of worst polluted cities in the world. feasibility analysis of using the solar car over that of a
It will reduce pollution and pollution related life-threatening conventional fuel based car is also made. The rest of the paper
90
80 Diesel
Gasoline
70
Price in USD/m3

Gas
60
50
40
30
20
10
0
2000 2002 2004 2006 2008 2010 2011
Year
Fig. 2: 3D Model of the proposed solar car
Fig. 1: Fuel Prices and Trends (Source: Kojima, Masami. (2013,
forthcoming). “Petroleum product pricing and complementary policies:
Experience of 65 developing countries since 2009.” Washington DC:
World Bank)

has been organized in the following way: section 2 describes


the preliminary design outline of the electric drive system of
proposed solar car, calculating the motor power, battery
capacity and panel size; section 3 details the economic
analysis of the solar car, and puts forward the economic
comparison of running a solar car vs. a fuel-based car, using
the present worth of different components of the car over a
period of 20 years; and finally section 4 makes concluding
remarks.

II. DESIGN OUTLINE Fig. 3: Block diagram of solar car system

A. The Proposed Car constant voltage at its output as is required by the motor,
A 3D model of the proposed car with tentative dimensions irrespective of the panel or the battery voltage level.
has been designed, which shows the shape of the outer body
C. Safety Features
of the solar car along with the placement of the solar panel at
the roof of the car, as seen in Fig. 2. The model features the The car will be equipped with adequate safety features to
streamlined shape of the car in order to reduce the effect of air avoid unsafe situations that may arise from batteries, over-
resistance, and the two-seater arrangement to keep the size of heated motor, or fault in the connecting cables and/or
the car compact. electrical/electronic components. Batteries will be placed
behind the seats in a custom made chamber constructed on the
B. System Architecture floor of the body with enough ventilation so that air can
The detailed system architecture of the complete electric circulate and any harmful gas released by the batteries can
drive system of the solar car is shown in a block diagram in escape. Dashboard in the front will be fitted with meters to
Fig. 3. The solar panels mounted on the roof of the car will monitor the battery voltage, current and the motor temperature
collect energy from the sun and convert it to usable electrical in order to keep the driver informed about the battery health
energy which will be stored in a lead acid battery through a and whether the motor is running safe. Though the individual
charge controller. The charge controller will ensure healthy component will have its own safety feature, a special ‘kill
life of the battery by preventing over charging and over switch’ will be placed in the front to enable the driver to
discharging of the battery. The solar car will also have a completely shut down the system should any unsafe situation
arise.
provision of plug-in charge when there is not enough sunshine
due to cloud, fog or rain. This provision for external plug in to D. Motor Power, Panel Size and Battery Capacity
charge the batteries from the conventional power supply will
also allow the car to increase its capacity to drive for longer 1) Estimation of Motor Power: The power needed to drive
distance by putting additional batteries and charging from the the car can be calculated using (1) as:
power supply lines. The voltage controller will maintain a P = F ×v (1)
where v is the velocity of the car and F is the force needed to where ηm is motor efficiency. An additional 10% is added to
overcome the frictional force between the road and the tires the total required energy to provide allowance for energy lost
which can be calculated as, during each stopping and starting at the traffic signals and at
other instances, such as, traffic congestion. This energy
F = m × g × C rr (2)
required by the motor has to be supplied by the battery and it
where, m is the mass of the car, g is the gravitational will determine the battery capacity.
acceleration and Crr is the coefficient of rolling resistance of Batteries also have to supply power to the car lights; such as,
the car tires. Different tires have different depending on the headlights, signal and the brake lights. The total energy
the type of tires, load, road type, pressure etc. Tires used for requirement will be summation of energy required by the
solar car are typical bicycle tires and have rolling resistance of motor and by the car lights. However, in deciding the battery
0.0055 on asphalt/concrete roads. capacity, careful consideration of several factors is needed.
Assuming a maximum car speed v = 60km/h, mass m = 500 Due to internal losses, ampere-hour (Ah) lost is always greater
kg (with the car weight about 300 kg, weight of four 40 Ah than the actual Ah delivered by a battery and the loss increases
batteries 50 kg, and weight of two passengers 150 kg) and g = in a non-linear fashion with the increase in the discharge
9.81 m/s2, the maximum power required to drive the car is current according to Peukert’s law [4]. Peukert’s law relates
found to be about 450 . charge Cp lost in the battery to discharge rate I as,
Considering a much a higher friction of the roads in Dhaka CP = I n × t (5)
city due to their uneven nature, it will be prudent to choose a
motor with at least 1.5 times the calculated power rating. Thus where t is the discharge time in hours, and n is the Peukert
a motor with power rating 700W will be appropriate. coefficient, typically 1.1 to 1.3. Applying Peukert’s law, the
minimum battery capacity required for the complete trip with
2) Battery Capacity: Battery capacity depends on the varying motor power requirement is given by,
energy battery has to supply which in turn depends on the total
distance travelled. As the solar car is contemplated to be used ⎡⎛ P 2P ⎞
n
⎛ Pmin 2P ⎞
n ⎤
⎢⎜⎜ max + HL ⎟⎟ × 0 .1t + ⎜⎜ + HL ⎟⎟ × 0 .8t ⎥
mainly by the office-goers in Dhaka, one of longest distances ⎢⎝η m × V B VB ⎠ ⎝η m × V B VB ⎠ ⎥
to travel from one end of Dhaka to the opposite can be C = 1.1 × ⎢
n ⎥ (6)
⎢ ⎛ Pav 2P ⎞ ⎥
represented by the distance between Matijheel and Uttara area ⎢ + ⎜⎜ + HL ⎟⎟ × 0 .1t ⎥
⎣ ⎝ m η × V B VB ⎠ ⎦
which is approximately 17.5 km. However, the actual
travelling distance may be even longer than this if the where, VB is the battery voltage, PHL is the rated power of car
commuter’s residence is located far from the main road. 2 PHL
headlight, is the current required by the two headlights
Therefore, considering this extra distance, a one-way 2V B
travelling distance of 20 km is assumed, which results in a P
and the term is the motor current running at power P.
total distance d = 2×20 = 40 km for a return trip. Then the η m × VB
total energy that should be supplied by the motor is given by, In the above equation Ah needed for the car headlights,
along with that for the motor, also gets multiplied by the
EM = P × t (3) factor 1.1 and will account for the extra Ah needed for the
signal and brake lights. Signal and brake lights have a much
where Travel distance ( )⁄Car speed ( ) 40 , is
the total travel time. Table I: Parameter Values Used to Estimate the Battery Capacity
However, it is obvious that the motor will not run at its full DC Motor
power for all the time, as the power requirement will vary Maximum Power, P 700W
depending on the speed of the motor and road condition. Minimum Power, P 450W
While the smaller lanes in the residential areas are in poor Average Power, P 575W
condition, the highways are in quite good condition for most Motor Efficiency, ηm 90%
of the part. Therefore, for most of the time, the motor will be Total travel time, t 40 min
running at the minimum calculated power of 450 W. To have Car Lights
an estimate of the total energy required by the motor to cover Light Power No. of units
the total distance, a conservative estimate would be to assume Car Headlight 27W 2
that the motor runs at the minimum calculated power of Brake lights 7.5W 2
Pmin=450 W for 80% of time, at the maximum power of Signal lights 7.5W 4
Pmax=700 W for 10% of the time, and at the average value of Battery Parameters
these two Pav=575 W for the rest 10% of the time. Then the Battery Voltage, VB 48 V
total energy required would be Peukert’s number, n 1.2
1 .1 Temperature correction factor, kT 1.3 [2]
EM = × (Pmax × 0.1t + Pmin × 0.8t + Pav × 0.1t ) (4) Aging factor, KaB 1.25 [3]
ηm
Maximum depth of discharge, DOD 80%
lower power rating than that of the headlights and are also Table II: Parameter Values Used to Estimate the Panel Size
used for only brief period of times, thus will require only a PV Panel
fraction of the Ah that is needed for the headlights. Derating factor, 0.9
In order to ensure that the battery can supply adequate Aging factor, 0.9
energy during winter throughout its useful life, a temperature Panel efficiency, ηp 15%
correction factor (kT) and an ageing factor (kaB) should be Solar insolation, h 6 hours
applied in accordance with Ref. [1] and [3]. Further, to ensure Charge Controller
prolong life of the battery, maximum depth of discharge Efficiency, ηCC 90%
(DOD) must be limited to a certain value. Considering all Battery
these factors, the final battery capacity can be calculated as, Charging Efficiency, ηCh 90%

Table III: Design summary of electric drive system of the solar car
C × kT × k a
Battery Capacity = (7) Electric Motor (DC Brushless Motor)
DOD
Power rating 700 W
Further, to provide allowance for unforeseen situations, Voltage rating 48 V
such as, less-than optimum operating conditions due to Battery (Vented lead-acid battery)
improper maintenance, recent discharge, or lower ambient Capacity 40 Ah
Voltage 48V
temperatures, a capacity margin of 10% can be added to the (4 batteries 12V each)
calculated capacity. Using (6) and (7), and the parameter PV Panel (Monocrystalline Si)
values for the motor and battery as listed in Table I, a capacity Wattage 200 W
of 33.73 Ah has been obtained. Therefore, four 12V batteries Output Voltage 64-68 V
connected in series each with 40 Ah capacity can provide the
energy for most part of the year, while still keeping the car
required output voltage of 48 V and the necessary Ah. Vented
compact. Using (8) and (9), and the parameter values as listed
lead-acid battery will be a better choice, as opposed to the
in Table II, panel wattage of 184.1 W has been obtained. Four
conventional lithium ion batteries used in many solar cars, due
50W panels with 16-17 V output voltage connected in series
to its lower price, availability, durability and safer operation.
will meet the wattage as well as voltage requirement to charge
3) Panel Size: The panel size can now be determined on the four series connected 12V batteries. Use of high efficiency
the basis of the total energy the battery should supply plus the (~15%) solar panels would require an area of about 1.33 m2 to
losses in the battery and the charge controller. If ηch is the fit the required panels.
battery charging efficiency and ηCC charge controller It is obvious that solar energy will be far from enough in
efficiency, then the total energy Ep required from the solar winter due to shorter days, weak sunlight and fog in the
panels is given by, morning, and for most of the days during rainy season due to
C × VB rain and cloud. In such cases plug-in charging from grid or
EP = , (8) any other alternate sources can be used to supplement the
η CC × η Ch energy deficiency. A summary of the ratings of the major
where, C is the total charge to be supplied by the battery plus system components of the electric drive system comprising of
the charges lost during discharging according to (6). Then the the motor, battery and the panel is shown in Table III.
panel wattage required is
III. ECONOMIC ANALYSIS
EP This section discusses the economic feasibility and overall
WP = , (9)
h × k d × k aP desirability of using a solar car over the conventional fuel
powered car. Construction projects use the concept of life
where h is the solar insolation in hour, , is the derating cycle cost (LCC) analysis to determine the economic impact
factor to account for the reduced output due to deposition of of current and future costs. LCC therefore comprises of the
dust layer on the panel surface, and is the aging factor to
cost of operating an item over its entire lifetime, starting from
account for the decrease in panel efficiency over the years [7].
the time of initial acquisition till purchases made later [7].
In Dhaka, solar insolation varies from 4.5 hours in winter to
about 8 hours in summer. Choosing a solar insolation of 4.5 A. Life Cycle Cost Analysis of Solar Car
hours will ensure collection of adequate energy throughout the The LCC of the solar car involves the price trend of the
year, however, will also necessitate large panel size that may solar panel itself, the life span, installation and replacement
make the solar car practically inconvenient and aesthetically and finally the costs associated with the operation and the
unappealing. On the other hand, choosing solar insolation 8 maintenance of the panel and the battery. Over the years it
hours will make the car more compact, but the energy has been statistically observed that the price of the solar
produced will be insufficient for most part of the year. panels is decreasing with increasing demand thus promising
Therefore, a solar insolation of 6 hours has been chosen to cheaper but more efficient panels in the future [8].
determine the panel wattage, which will produce sufficient Nevertheless, the initial cost of setting up a panel is quite high
but this initial investment can be compensated by its long life
Table IV: Life Cycle Cost Analysis of a Solar Car
span. Solar panels are expected to run for at least 20 to 25
years without requiring any major replacements. It is Unit Initial Present
considered that with careful handling, monocrystalline panels Component Number
Cost Cost Worth
of Units
may even last till 40 years [9]. Electric lead- acid batteries (BDT) (BDT) (BDT)
also have a high life cycle of 5 years and therefore will not Solar Panel 200 Watt 80 per 16,000 16,000
require frequent replacements [9]. The maintenance and Watt
operation cost of both the panels and the battery are also Battery 4 6,000 24,000 24,000
minimal since these are self-dependent. Manufactured three Battery 5 Yrs 4 24,000 23,280
stage charge controllers usually have a factory warranty of 5 Battery 10 Yrs 4 24,000 22,553
Battery 15 yrs 4 24,000 21,862
years, but they have an expected lifetime of 15 years [10].
Charge 1 10,000 10,000 10,000
Brushless DC Motors usually have a life span of more than Controller
10000 hours that corresponds roughly to 10 years of operation Charge 1 10,000 9,400
with a car with a maximum of 4 hours of daily usage [11]. Controller 10 Yrs
Batteries, motors and charge controllers will therefore need to DC Motor 1 12,000 12,000 12,000
be replaced multiple times before the solar panel needs to be DC Motor 10 Yrs 1 12,000 11,276
replaced. All costs incurred during one life span of the solar Annual 2000 37,740
panel in the car will be considered as the total cost of the solar Maintenance
commuter. This will therefore include the cost of the panel Life Cycle Cost 1,88,111
itself, cost of installing and replacing the battery 4 times (20
years/5 years), the DC motor and the charge controller twice. days of insufficient solar energy. The tariff of electricity
supplied by Dhaka Electric Supply Company (DESCO) to
B. Present Worth
home and business consumers with an average consumption
In order to find the LCC, the present worth (PW) of all the over 400 units is BDT 7.98 per kWh of usage for residential
components needs to be determined and then summed. Present use [12]. Figure 4 shows the total cost of operating the solar
worth of any item is the amount of money that needs to be car with supplementary electricity from the main lines, at
invested at the present time in order to purchase the item ‘n’ different percentages of the total required energy found in (8).
years later, assuming an inflation rate of 100i% and an interest In each of the cases the cost is found over a period of 20 years,
or discount rate of 100d%, and is given by, considering 280 days of office commuting.
n The cost of running a solar car found above has been
⎛ 1+ i ⎞ calculated for a period of 20 years. For the purpose of
PW = ⎜ ⎟ × C0 , (10)
⎝ 1+ d ⎠ comparison, the operational cost of a regular fuel-based car
where C0 is the initial cost of the item at the time of also needs to be calculated for a total time period of 20 years.
investment [7]. As the solar car is small and less powerful in comparison to
For recurring expenses, which adds up to the total cost larger fuel-based cars, specifications of a 650 cc car have been
every year of operation, the individual PW of each element in chosen for the calculations.
the series can be added up to find the cumulative PW. Thus A 650 cc car which runs on gasoline on the streets of Dhaka
expenses such as the fuel cost and maintenance cost can be can cover a maximum distance of about 20 km per litre
calculated using the following equation [7], without encountering any traffic congestions. If however there
are traffic jams on the road, the distance travelled per litre is
1− x n reduced to a maximum of 15 km [13]. For a total distance of
PW = C0 , (11) 40 km travelled every work day of the month, with a current
1− x
where fuel price of BDT 99 per litre, the cost of operating the car for
20 years is calculated below.
⎛ 1+ i ⎞
x=⎜ ⎟. (12) Comparing the LCC of running a solar car found in Table
⎝ 1+ d ⎠ IV with that of a fuel-based car, found in Table V, it can be
The values of the average inflation and interest rates of seen that the solar cars are significantly less expensive to run
Bangladesh have been found to be 6.59% and 7.25%, than gasoline cars. On top of the value calculated, costs in
respectively [3]. The cost per unit of different components, terms of environmental and health hazards also needs to be
required to run the solar car has been found through local taken into account. It can be clearly seen the long run cost of
market survey. Assimilating all these prices and their total running a fuel-based car far exceeds the cost of using and
numbers required the LCC of operating a solar car can be maintaining a solar car, both quantitatively and qualitatively.
calculated, as tabulated in Table IV.
We can further add the cost of electricity when the solar car
will also be powered through main line electric supply during
Table V: Operational Cost Analysis of a Fuel-Based Car
First Year (BDT) Present Worth (For 20 Years)
Component Without Traffic With Traffic Without Traffic With Traffic
Congestion Congestion Congestion Congestion

Fuel 55,440 73,920 10,46,153 13,94,870

Annual Maintenance
Engine Oil, Filter Replacement 12,000 2,26,440
Servicing, Fitness Test, Tax 10,000 1,88,700

Total Operational Cost 12,72,593 18,10,010

certainly be stated that in the upcoming years, with a fall in


solar panel’s price and externalities costs and an expected aid
from the government, solar cars will evolve as the most
economically viable vehicle of the decade.

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