Zephyr Fairing Doors

Aly Scheske // // No Comments
“The last 5% of the work takes 95% of the time.”
-Unknown
These words ring true to CalSol as we approach FSGP. We have nine days until competition starts with the time flying by. Zephyr has been in great shape since early 2015, but going through extensive road testing, debugging sessions, and minor hardware upgrades these past few months. This testing time has proved to be incredibly fruitful for CalSol.
Zephyr’s Fairing Doors has been one project absorbing a lot of attention. The design for Zephyr included fairings around each wheel to improve our drag; however, aerodynamics and maneuverability must be optimized for functionality. Fairing door structures are covers for gaps and spaces between parts of the exterior to reduce form drag and interference drag, in addition to improving appearance. Our design allows for the doors to be “shut” completely over the wheel-well while driving straight, but swing “open” as the driver turns the steering wheel and the wheels and tires turn. We trust that this design and hardware content will greatly improve performance. We are excited to unveil full functionality at FSGP.
Check out the pictures below of Zephyr’s fairing doors!
Rear view of fairing door

Rear view of fairing door

Top-down view of the fairing door wheel-well

Top-down view of the fairing door wheel-well

CalSol members Stephen Lu, Ian Fisher, James McCay, and Danial Gay have put countless hours into this project- the whole team would like to commend them for their hard work!

 

No-Mar Tire Changer Sponsorship

Aly Scheske // // No Comments

Tire-Changer jpgWith 2 weeks until Formula Sun Grand Prix, CalSol members have been excitedly pushing the pace of work in anticipation. This work has been happening full force in multiple disciplines of CalSol- engineering work, logistics work, and industry interaction. CalSol has just gained the partnership of No-Mar.

Not only has No-Mar Tire Changer donated a tire-changer to CalSol, they have also shared valuable industry insight. Via the phone and over e-mail, No-Mar’s knowledgable employees’s has opened crucial discussion points for materials CalSol uses. Their advise has opened CalSol to new ideas and opportunities never thought possible before due to higher quality tools and materials.

No-Mar has meet our needs and anticipated even more. They will be providing us with a Classic Tire Changer kit and a Balancer kit. It would take members of CalSol hours upon hours to physically change a full set of tires on Zephyr. Tires would be extremely tight on the wheel and take brute strengths. With No-Mar’s sponsored Tire Changer Kit, they will allow CalSol members to focus more on improving our engineering aspects of the car, improving efficiency for our team and even Zephyr.

CalSol would like to thank No-Mar Tire Changer for their assistance and contributions – we are looking forward to continually working together!

Their generous support will be returned by a sticker on our car and their company link on our website. We encourage you to please visit No-Mar’s website for more information at  www.nomartirechanger.com.

 

Mid-Summer Update – Powering Up and Strapping In for FSGP 2015!

Viswanath Chatterjee // // No Comments

It’s just three weeks until the Formula Sun Gran Prix at the Circuit of the Americas race track in Austin, Texas, and the CalSol team is looking forward to driving with and competing against the rest of the solar car community! We haven’t posted in a while, and there haven’t been core design changes lately, but the excellent state of this car and this team has us feeling optimistic for FSGP. Addressing potential bugs (mechanical, electrical, and code), implementing optimizations to squeeze out every watt we can, and testing the systems has kept us plenty busy lately, so check out some photos of the work!

 

Tidying up the wires and securing connections in the all-important battery box

Tidying up the wires and securing connections in the all-important battery box

Reinstalling sturdy enclosures to hold up and protect the various boards on the underside of the top shell

Reinstalling sturdy enclosures to hold up and protect the various boards on the underside of the top shell

Revising boards to include additional safeties (gotta love capacitors) and power routing optimizations

Revising boards to include additional safeties (gotta love capacitors) and power routing optimizations. Shout out to Bay Area Circuits for all their help with the PCB’s!

Building the solar array for an off-site "electrical test bed": a scaled-down version of the electrical system!

Building the solar array for an off-site “electrical test bed”: a scaled-down version of the electrical system!

And with a mini solar array comes an equally adorable mini battery box

And with a mini solar array comes an equally adorable mini battery box

Mechanical folks contemplating life. CalSol is life.

Mechanical folks contemplating life. CalSol is life.

Installing an improved hinged fairing door mechanism

Installing an improved hinged fairing door mechanism with a carbon-fiber axle

Road-testing Zephyr, which now has a few hundred miles on it, brings us admirers of all ages

Road-testing Zephyr, which now has a few hundred miles on it, brings us admirers of all ages

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We’ll be sending out updates during the race, or post another photo gallery at the very least. See you all then!

CalDay 2015

Aly Scheske // // No Comments

CalDay is one day and a million stories. It is a momentous day of the Spring Semester at UC Berkeley where new admits have the opportunity to visit campus, view labs, ask questions, take tours, and very importantly- check out student groups. Yale blue and California gold surround you wherever you go. This past weekend, CalSol was thrilled to contribute our story to the mix!

This past Saturday, from 10AM to 3PM, CalSol tabled in front of both Etcheverry (the Mechanical Engineering building) and Bechtel (the general engineering building) on campus. It was spectacular to be able to have two of our vehicles on campus, both Zephyr and Impulse. We were able to reach more visitors and answer more questions. Members of CalSol both shared their personal experiences and answered technical questions about the car. It was nice to have the cars on campus so that we could host mini-work sessions; members were able to explain and demonstrate their pertinent project on the car this way. A few photos below capture events from the day. The weather was beautiful, the crowds were lively, and school spirit was roaring- we could not have asked for a better day!

We hope that this weekend inspired many future Cal students! Go Bears!

 

Zephyr from above

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Impulse

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Etcheverry Breezeway

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Zephyr with the top shell off

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Solar Car Conference 2015

Aly Scheske // // No Comments
CalSol members at the first-ever Solar Car Conference. CalSol members in FXB on the North Campus of the University of Michigan. We were very happy to have attended!

CalSol members at the first-ever Solar Car Conference. CalSol members in FXB on the North Campus of the University of Michigan. We were very happy to have attended!

CalSol visiting General Motors.General Motors was a gracious host to CalSol, showing us great engineering facilities on our  visit to the Technical Center in Warren, MI and their Proving Grounds in Milford, MI. Thank you for your hospitality!

CalSol visiting General Motors.
General Motors was a gracious host to CalSol, showing us great engineering facilities on our visit to the Technical Center in Warren, MI and their Proving Grounds in Milford, MI. Thank you for your hospitality!

Bowling with UT Austin. CalSol bowling at Maplewood Lanes with UT Austin after the end of the conference. Great way to finish on and strike a high note!

Bowling with UT Austin. CalSol bowling at Maplewood Lanes with UT Austin after the end of the conference. Great way to strike up a bond between solar teams!

 

 

This past weekend five members of CalSol attended the first Solar Car Conference! The conference was held in Ann Arbor, Michigan, hosted by the University of Michigan’s Solar Car Team and organized by IEF.

We learned a lot and brought members that represented all crucial areas of the team. This made break-out sections highly effective for logistics, electrical knowledge, mechanical expertise, and project management. It was very lucky that this weekend overlapped with our Spring Break at UC Berkeley so that we could focus on absorbing as much of the information as possible!

We were most excited to hear about future regulations. CalSol was happy to participate in the discussion of what specifications may change so that our future vehicle designs may be optimized.

However, the best part was catching up with old friends and making new friends in the solar car community. It is always great sharing our passion for engineering and solar technology with others!

 

SunPower Sponsor Spotlight!

Brandon Luo // // No Comments

CalSol recently visited SunPower at their Richmond office on November 5, 2014. We displayed our newest racing vehicle, Zephyr, and discussed our progress and future plans and projects. We also took Zephyr for a spin in their parking lot and shared ideas with some of their engineers who helped us with our solar array.



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CalSol incorporates SunPower High-Efficiency Gen-E solar cells in Zephyr. SunPower’s innovative solar cells have been critical to unleashing the full performance of our vehicles. CalSol is also incredibly grateful for SunPower’s continued generosity and support throughout the years by providing us with the resources and facilities necessary to create our solar array. Our success would not have been possible without you!



Thank you again to SunPower!

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Thank you Starlink!

Min Ju Lee // // No Comments

Starlink Co. has yet again provided us with stickers and decals for Zephyr, free of charge. Starlink is a leader in digital printing, and the kind folks at Starlink even expedited our decals order so we can have them on the car before FSGP/ASC! Thank you very much for your support!

 

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The beautiful decals adorning Zephyr’s top shell

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The CalSol & Cal decals also made it on Polytechnique Montreal’s Esteban!

The Team’s Snapshots from FSGP 2014!

Viswanath Chatterjee // // No Comments

Although everything couldn’t quite come together this time, the team certainly had a memorable experience these past two weeks. The mechanical team put in a truly incredible amount of work into Zephyr (I am personally on the electrical team, so I think I can say this without bragging, haha). So much of the car you see is handmade, from the sleek carbon-fiber shell to the welded aluminum chassis, with little tolerance and deviation from the models. Even the current electrical issues are only a temporary speed bump for  Zephyr; we simply didn’t have the resources and time to fix them when they arose unexpectedly last Friday. I am still very proud to be part of this team, and know how much work went into designing and building Zephyr. There will be races ahead for our latest vehicle, but until then, check out some photos from FSGP 2014!

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Zephyr and friends, ready to rayce (despite the clouds)!

The truck space was heavily optimized, significantly reducing mileage

The truck space was heavily optimized, significantly reducing mileage

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Getting ready to load Zephyr into the trailer, departing from Berkeley at sunset

The rather picturesque spot in the Mojave Desert where the trailer's wheel blew out

The rather picturesque spot in the Mojave Desert where the trailer’s wheel blew out

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Switching out the chewed up wheel and what remains of the tire rubber

Sunset in the desert with CalSol

Zephyr being rolled out at the Circuit of the America, not yet adorned with decals

Demonstrating the suspension system to the inspectors, naturally by standing on it

Demonstrating the suspension system to the inspectors, naturally by standing on it

You could say we all had a few bugs in our cars

You could say we all had a few bugs in our cars

 

A lot of mechanical fine-tuning and touch-ups were done at FSGP, to say the least

A lot of mechanical fine-tuning and touch-ups were done at FSGP, to say the least

 

The glorious prototype telemetry box deserved a spot here

The glorious prototype telemetry box deserved a spot here

 

Securing temperature sensors inside the battery box

Securing temperature sensors inside the battery box

 

Zephyr's drivers studying the race track via simulation, mentally noting the turns and optimal speeds

Zephyr’s drivers studying the race track via simulation, mentally noting the turns and optimal speeds

 

Adjusting the rear-view camera placement

Adjusting the rear-view camera placement

 

Doing some late-night work on the power distribution box, the night of a record thunderstorm

Doing some late-night work on the power distribution box, the night of a record thunderstorm

Zephyr showing off its handling during dynamic scrutineering, with an especially impressive slalom run

Zephyr showing off its handling during dynamic scrutineering, with an especially impressive slalom run

We hope you’ll continue to join us in Zephyr’s future adventures, and see you next time!

 

 

 

 

FSGP/ASC2014: We Have Withdrawn

Min Ju Lee // // No Comments

Saturday July 19th was CalSol’s first and last day participating in the Formula Sun Grand Prix 2014 at the Circuit of the Americas. CalSol successfully got Zephyr on the track on Saturday morning. We were able to get a few laps around the track but soon discovered an electrical problem that caused the car to turn itself off after exceeding speeds around 30mph. To provide some context, it was necessary for Zephyr to reliably drive with a speed upwards of 60mph in order for us to take Zephyr on public roads. On the Circuit of the Americas track, one of the very first hurdles was getting past a steep hill before going around the first corner. After a few laps around the track, Zephyr started to cut off its power while climbing the hill.

Zephyr at the starting line of FSGP

Zephyr at the starting line of FSGP

We discovered that the electrical current limit of one of our systems was set too low, thus triggering a safety feature to shut down the car.  This is an anomaly, as we have been able to take the car to speeds upwards of 50mph. We examined every connector, board, wire, and piece of software that we could get our hands on. We were at a constant hustle to get the car running on the track again—but each time it would stall after ten seconds of acceleration. Members frantically ran to and fro along the track with tools, computers, and debuggers.

This went on for six hours. Unfortunately, by the end of the day we had only completed five laps out of the required forty-eight. Though ASC can grant provisional qualification to teams that have a high potential, CalSol decided to withdraw from the race simply because racing a car with an unreliable electrical system on public highways posed a safety risk for the team.

We are very disappointed. We had come out to Texas to race to Minnesota and our FSGP/ASC2014 experience was cut short.

Without a doubt, forfeiting ASC2014 was one of the team’s lowest and the most humbling moments. We learned that the importance of extensive testing wasn’t just some rookie comment, but rather it was an absolute necessity for any team who wants to ensure a reliable vehicle. We experienced first-hand what it meant to push ourselves even when we thought we could not be pushed any further. And the most encouraging part is, we got to interact with the kind and intelligent solar car community who worked across team affiliations to get every car up and running.

In ASC 2012, CalSol reached a respectable 4th place finish on a simple but well-tested vehicle. After ASC 2012, CalSol went great lengths to build a solar vehicle with the most efficient aerodynamics and solar cells, lightest body and chassis, and the most advanced manufacturing techniques that the team had ever undertaken. Despite the measures taken to create the most advanced solar car, we fell short in producing a reliable vehicle.

Like every car, Zephyr succeeded in some aspects and failed in others.

Before packing up, there was one more thing we were able to do in order to help the solar car community. Polytechnique Montréal turned sharply on a tight corner on the track and snapped one of their car’s two Mitsuba motors. The team ingeniously found a way to power the car with a single motor in mere hours, and conditionally qualified for ASC2014. However, being short one motor without a spare was not a comfortable situation for the Montréal team. Since CalSol’s Zephyr uses the same equipment, we let Montréal borrow two Mitsuba motors for the race.

In 2003, CalSol had motor issues and ended up racing with University of Kentucky’s motor. This week we were able to pay that kindness forward. I like to call it solar car karma. Even though we will not be able to race, we are still honored to participate in such an amazing community. We hope that our competitors are able to reach their fullest potential.

CalSol and Montreal collaborating to provide Montreal functional motors for ASC2014

CalSol and Montreal collaborating to provide Montreal functional motors for ASC2014

Montreal's damaged motor

Montreal’s damaged motor

With a great deal of dedication, perseverance, and solar car karma, we are making great progress in solar car innovation. We are using this experience as a stepping-stone for accelerated progress with Zephyr. We’ve identified key issues with over-eager safety systems and are developing a better testing strategy. The best days of this car have yet to be seen, and we are excited to see where we go next.

Min Ju Lee

CalSol team lead

CalSol 2014 team photo

CalSol 2014 team photo

 

Thank you GM for providing us with two Yukons for the race! While Zephyr will not make the trip up to Minnesota, several team members will travel with other teams up north to get the ASC 2014 experience

Thank you GM for providing us with two Yukons for the race! While Zephyr will not make the trip up to Minnesota, several team members will travel with other teams up north to partake in the ASC 2014 racing experience.

FSGP/ASC2014 Update: Scrutineering

Min Ju Lee // // No Comments

Hello everyone! Sorry to keep you in the dark during this past week… if you kept up with our facebook posts, you’d know that this past week was filled with a whole lotta fixing for our team.

The team arrived in Austin, TX with Zephyr that needed a lot of fixing. First of all, Scrutineering was set to start on Monday. Due to our need to fix our defective braking system as described in our previous blog post in addition to an exploded trailer tire, we arrived in Austin on late Monday afternoon to start scrutineering on Tuesday. We added new lights, replaced enclosures, designed temperature sensing system, made new boards, soldered a whole lotta everything, cut here and taped there. We re-did them twice, thrice, four times, as many times until we were ensured that faulty systems were fixed and that we can ensure the driver’s safety.

List of to-do on Wednesday afternoon

List of to-do on Wednesday afternoon

FSGP (Formula Sun Grand Prix) was set to start on Thursday, but we could not get on the track on Thursday because we still had consequential problems that needed to be debugged. In order to qualify for ASC, we must complete 60 laps in 1 day or 90 in two consecutive days. We decided to take our time to ensure that the problems were fixed for good before putting the car and the driver on a track race, to ensure the safety and performance of Zephyr and its driver.

CalSol members busily fixing up Zephyr's mechanical issues

CalSol members busily fixing up Zephyr’s electrical / mechanical issues

Finally on Friday, we were able to get a good to go “green” sticker on all scrutineering stations– solar (modified our array size), body & sizing (installed new lights, modified enclosures, added rear view camera, added paddings), BPS (redesigned and implemented a new temperature sensing system), mechanical (added crumple zones), electrical (added electrical hazard labels), drivers (qualified Ellande, Nick, Aditya, and Aly to be our drivers), and dynamic testing.

Despite the troubles we went through fixing up Zephyr, it performed exquisitely well in dynamic testing. Aditya shocked the team when he zipped through slalom and figure 8 test in record time.

Figure 8 test during Dynamic Scrutineering

Figure 8 test during Dynamic Scrutineering

The team is so excited to get some time on the track race tomorrow. CalSol is team #6– wish us luck & abundant sunshines!

Crazy thunderstorm on Thursday evening + unforeseen fire alarm == rain dance from the teams

Crazy thunderstorm on Thursday evening + unforeseen fire alarm == rain dance from the teams