Technical Innovation Project (1)
Solar Powered Tesla
Gasoline cars have been around for decades and have provided car owners with a sense of convenience because of their ability to cover more distance, and the car’s tank can be refilled with gasoline in a matter of minutes. However, with these positives, major downsides negatively affect the earth: global warming and pollution. To solve this, an engineering innovation that will be introduced is a solar-powered Tesla. This new design is an improvement to the original electric car because it will use the sun’s energy to power itself instead of a homeowner’s electricity. However, in certain cases, some people do not have the comfort of having a power station because they may be renting from a homeowner. Most homes are powered by natural gas and using this fuel source means greenhouse gasses are produced causing global warming. However, with our innovation, there are major problems solved such as there will be fewer emissions produced, and charging will be more convenient for electric car owners.
Technical Description of a Tesla Model S
Charging Port
The charging port is an essential part of the operation of the electric car because it is how the car gets power from the charging station. Without the charging port, there would be no way for the car to receive the electricity necessary to power the vehicle.
(Figure 1: https://www.cars.com/articles/the-week-in-tesla-news-93-mile-range-model-3-new-safety-tech-added-semi-truck-stalls-401767/)
Battery Pack
“The battery pack is composed of 16 detachable pieces which total 7000 cells. The battery pack is a vital part of the electric car because this is where the energy is stored and enables the car to have power for it to operate.” “https://www.youtube.com/watch?v=3SAxXUIre28&t=52s”
Figures 2 and 3: https://www.youtube.com/watch?v=3SAxXUIre28&t=52s)
Radiator
The radiator is a rectangular box placed in front of the electric car that houses a fan inside and allows the glycol coolant to flow through it. Once it goes through the radiator, the liquid is cooled and travels to the “metallic inner tubes” which fill the gaps in the battery pack. This part of the electric car plays a key component in the functioning of the battery pack because it prevents the batteries from overheating and ensures a longer battery life.
(Figure 4: https://www.youtube.com/watch?v=3SAxXUIre28&t=52s)
Inverter
The purpose of an inverter is to convert direct current (DC) to alternating current (AC). Direct current is named this because current only flows in one direction. However, alternating current is named this because the current moves back and forth. Batteries have direct current and electric motors need alternating current for them to work. This is because it controls the AC power frequency and varies the amplitude, which alters the motor speed and the motor power output. “https://www.youtube.com/watch?v=3SAxXUIre28&t=52s”
(Figure 5: https://www.youtube.com/watch?v=3SAxXUIre28&t=52s)
Induction Motor
An induction motor has two key components: the stator and the rotor. The stator is made of very thin and flexible steel or silicon laminations that are stacked, and it is housed in a steel or cast-iron frame. The stacked laminations have interior slots that allow for a 3-coil winding to go through the interior enabling a 3-phase current to flow. Once it flows, a rotating magnetic field or an RMF is produced. “https://www.youtube.com/watch?v=3SAxXUIre28&t=52s”
The rotor bars have a polarity themselves, and once the RMF is produced, the “squirrel cage bars” of the rotor experience the magnetic field which causes it to rotate. The rotor can rotate due to the alternating current which comes from the inverter because it allows the polarity of the coiling wire to change constantly. Magnets are attracted to opposite poles and because the poles are constantly changing, the rotor will always stay in motion. However, the rotor’s motion is dependent on whether the stator is receiving current. The figure below shows the inverter on the left and the induction motor on the right. “https://www.youtube.com/watch?v=AQqyGNOP_3o&t=82s”
(Figure 6: https://www.youtube.com/watch?v=3SAxXUIre28&t=52s)
Drivetrain and Transmission
The drivetrain is a key component of the electric car which gives it the ability to move. The “power produced by the induction motor is transferred to the drive train using a gearbox. The transmission is single speed as the motor is efficient in a wide range of operating conditions. The output of the motor is reduced by 2 gears as the primary function of an electric car transmission is to reduce speed and multiply torque. The 2nd gear is connected to the differential enabling the wheels to have motion, giving the electric car the ability to travel from one place to another. “https://www.youtube.com/watch?v=3SAxXUIre28&t=52s”
(Figure 7 and 8: https://www.youtube.com/watch?v=3SAxXUIre28&t=52s)
Regenerative Braking System
Like all cars, the Tesla Model S has calipers that rest on the rotor and houses the brake pads. When the brake pedal is pushed, the brake pads are compressed against the rotor and will allow the car to come to a stop. However, this brake design is different and better than the traditional braking system. With the design of the Tesla’s Model S braking system, when the accelerator pedal is released, the inverter keeps the RMF speed smaller than the rotor speed. The effect of this would be the battery is charged by the motion of the rotor since the induction motor is turned into a generator to charge the battery. In this way, it is a closed system. The closed system enables your car to be charged without the use of your power station and will allow the electric car owner to save money on energy costs.
(Figure 9: https://www.youtube.com/watch?v=3SAxXUIre28&t=52s)
Technical description of a solar panel
The solar panel is an efficient alternative to get a clean source of renewable energy from the sun. There are many different variations of the solar panel however they share the same purpose, and they are made up of generally the same things. There are six components that make up a solar panel
Solar cells
This component of the solar panel is what creates the sunlight gathered from the sun into electrical energy. They are generally composed of two types of silicon which is monocrystalline silicon and polycrystalline silicon however the way that they are placed can be changed.
(Figure 10: https://www.energy.gov/eere/solar/articles/pv-cells-101-primer-solar-photovoltaic-cell)
Glass
This component of the solar panel is placed in the front of the solar cells and its function is to protect the solar cells from the harsh weather outside that can damage the cells and break the solar panel.This is not ordinary glass as it is high tempered glass that is 3-4 millimeters thick. The reason for this tempered glass is that if it does break it does not break in sharp pieces.
EVA film
This component of the solar panel is called ethylene vinyl acetate. It is a film that is made out of polymer, and it is a transparent layer that is used to place on top of the solar cells. The purpose of this component is so the cells do not move out of their place when being made. However other then that, it has a long term use to keep moisture and dirt out of the cells
(Figure 11: https://www.sgnsolar.com/sealing-material-for-crystalline-silicon-solar-cells-eva-film.html )
Backsheet
The backsheet is another component that is added to a solar panel. This component of the solar panel keeps moisture out of the solar panel and it keeps the electricity insulated inside of the solar panel.
(Figure 12: https://www.sgnsolar.com/sealing-material-for-crystalline-silicon-solar-cells-eva-film.html)
Junction box
This component of the solar panel is where you connect all the wires. This part acts as the main system on where the electricity is flown from the solar panel to out of the solar panel so it is an important piece of the system. Another important thing this piece does is that it prevents the energy from flowing back to the solar panel.
(Figure 13: https://commons.wikimedia.org/wiki/File:Junction_box_of_solar_panel.JPG
The Innovation of Electric Vehicles
When you look throughout the history of the innovations of electric vehicles, they all tried to be innovative by getting more milage on the batteries. For example when you look at companies like ford, They have 2 options for the choice of battery. The first choice is the standard 98.0 kwh and the milage on that choice with a 100% battery is up to 230 miles. The second choice is the 131 kwh extended range pack which is up to 300 miles. These are good numbers but those battery models are fords newest models and they are not released yet. However, when you compare those to tesla, Ford is left behind with teslas battery numbers. On average, if a tesla car is fully charged it can ride up to 336 miles. When we get into the numbers more deeper, We can see that the tesla model 3 below, the top milage per fully charged battery is 267 miles and this is the cheapest smallest car.
(Figure 14: https://www.tesla.com/model3)
Below is the tesla model X which has a mile range of 350 miles per full battery. This model is bigger than the model 3 yet it also is more efficient than the model 3 as well.
(Figure 15: https://www.tesla.com/modelx)
Below is the last model for the tesla which is the model S. This model has the best mileage which comes at 405 miles per fully charged battery.
(Figure 16: https://www.tesla.com/models)
While it does look like the tesla might be the newest innovation that solves all the problems that a car might have, you can see that not many people own a tesla because it is an inconvenience to people who don’t have houses with garages. This is because you need a garage to charge your tesla in order for it to run. You can see that this makes it a huge inconvenience for people who live in apartments and that makes up a good amount of the population. Gas is also more convenient in terms of time. With a gas car you can fill your car up for less than 5 minutes and you are good to go. With an EV it takes up to 80 minutes to fully charge your car. With our latest innovation, we aim to fix that. Whenever the car is parked or not being used, The sunlight will charge the car at the spot that you parked it at from the solar panel that is on the electric vehicle.This helps tackle a major problem for people who cannot own a tesla just because of the charging problem, and with this problem out of the way, we can help people switch to electric vehicles and better out environment.
Cost
Owning an electric vehicle can definitely have a lot of pros, but an important aspect that cannot be overlooked is the costs. The average electric vehicle costs about $36,000 to make, while the average price of an electric vehicle to purchase is $60,000. The average price of all vehicles including electric is $45,000. However, researchers and analysts believe that the price gap between electric vehicles and regular vehicles may see a drop in the middle of the decade, as low as $30,000 for the lower-priced models (Eisenstein, 2022). The solar panel costs around $3 per watt. Adding up installation costs, it would add up to about $13,000 to a solar powered system to your electric vehicle which would be expected to last up to 25 years. Adding this to the average price of a regular electric car, the total amounts to $73,000. The average American makes about $51,480, based on 2021 U.S. Bureau of Labor Statistics data. Although prices are expected to drop as time goes on, as of right now it is clear that owning an electric car is a very expensive investment.
One upside that can make this purchase more appealing is considering the energy cost. The average electric vehicle gets 250 miles per charge, with $11 needed to fully charge the battery. The average car gets about 25 miles per gallon, with $38 required to fill with $4 per gallon, and the prices can always fluctuate as well (Eisenstein, 2022). Comparing the two options, if the user drives roughly 12,000 miles per year, they can expect to spend about $550 on the electric vehicle while $1,900 on the gas vehicle, more than two times the amount. A solar panel can save the average user about $1,500 per year, $37,500 over the course of 25 years. Implementing this with the electric vehicle, the user would not have to pay separate costs for charging their electric vehicle. Electric vehicles are definitely an expensive option, especially in these current times, however, in terms of the long run it would be the best choice to save the most money.
Materials and Material Description
The electric vehicle sector has grown considerably to combat climate change in the last few years. The global demand for materials is anticipated to increase as the market expands. For instance, demand for lithium for EV batteries has recently been projected at about 300,000 metric tons, compared with global production of 520,000 metric tons (Lipman & Maier, 2021). However, the demand for batteries is projected to reach 2.2 million by 2028, exceeding the capacity (Lipman & Maier, 2021). In other words, the material used to produce EVs will increase in price due to the surge in demand. Fortunately, the improvement in lithium-based batteries coupled with plummeting costs has made a choice for EVs. Other changes have been noted in other materials such as steel, cobalt, aluminum, composite, and rare earth metals. Model S has been assembled with several materials.
Aluminum
Aluminum has been a primary metal in EV development due to its unique features. For example, the metal has a low density, reducing the overall weight of a vehicle and increasing efficiency. According to Stafford (2018), the aspect has increased energy efficiency in EVs, and Teals Model S contains 661 Kg of aluminum. In the latest EV model, steel is wining against aluminum for the body and chassis due to cost. Stafford (2018) asserts that despite the trend, aluminum is a key material for the production of batteries for the EV.
Steel
Aluminum is one of the primary materials used in the development of EVs. However, steel has been used by most companies due to its ability. For instance, steel is stiff and has high capabilities in absorbing energy in the event of a crash. Stafford (2018) argued that because of the high strength of AHSS (advanced high-strength steels), the thickness of parts could be decreased, thereby keeping weight to a minimum. For instance, doubling the tensile strength of the steel permits a reduction in thickness, reducing the weight by 30% (Stafford, 2018). Notably, the low to high-strength steels have lower ductility since strength is increased, while AHSS strikes a balance between the two features. Generally, AHSS has a yield strength of more than 550 Mpa, reducing the material amount and providing greater ductility.
Figure 17: Distribution of various metals in Tesla Model 3 (Stafford, 2018).
Copper and Rare Earth Metals
Copper is a major material for EVs, whereby EVs contain four times as much copper as that in a conventional combustion engine. Most of the copper is located in the motor, which is needed for rotor and stator windings. Motor technology has changed considerably in the last few years, and rare metals are incorporated in EVs. Tesla has introduced permanent magnet motors in place of all copper induction motors. Stafford (2018) argues that they are more effective and more cost-effective than a motor, which contains copper coils only. However, a concern arises regarding the use of rare elements such as neodymium, where China controls more than 85% of the global supply.
Titanium and Rubber
Rubber comes from the rubber plant, but today more than 70 % of the US rubber is synthetic. Model S used rubber to make tires which are strengthened by other elements. Titanium is used to develop the Model S underbody to protect the batteries.
Leather, Silicon, and Carbon Fiber
Carbon Fiber adds touch to the interior design, while silicon makes the glass for the Model S. Leather derived from animal skin makes the seats.
Figure 18: Source: (Desjardins, 2016)
Time and Labor Power
Manufacturing a car is a lengthy process. The design and prototyping stages alone can take anywhere from 5 years and more. Given that the design and prototyping stages are complete, it can take approximately 18 months to manufacture an electric vehicle. Electric vehicles have fewer components than regular combustion engine vehicles, and they also have fewer moving parts, which is why they usually take less time to manufacture (Ewing, 2020). The average car has about 30,000 parts while a Tesla for example, only has 10,000. Since electric vehicles have fewer parts required, this also results in fewer people being required to manufacture the vehicle. Hybrid cars require around 9.2 hours of labor, while gas vehicles need 6.2 hours and electric vehicles need 3.7 hours (Eisenstein 2019). Time and labor power are both required less compared to gas vehicles, making them much easier to manufacture.
Benefits of an EV
EVs have several benefits compared to conventional vehicles that use diesel and petrol. First, they are cheap to run; for example, the electricity cost required to charge an EV is approximately 40% less than the cost of using petrol for a similar-sized vehicle driving the same distance (Ergon Energy, 2015). Besides, the costs are much lower if they are charged from solar. The average American pays about 15 cents a mile to drive a gas-powered automobile, whereas many EV run on five cents a mile. Second, they are cheap to maintain; for example, a battery has fewer moving parts than a conventional diesel or petrol engine, reducing the frequency of service. Third, EVs are more responsive to acceleration and regenerative braking when easing the accelerator. They tend to have a low center of gravity, improving handling and safety.
Therefore, they are better suited for the environment. The primary motivation of EVs was ecological conservation. They assist in reducing emissions that pollute the environment. Besides, they have increased solar energy usage, which has zero emissions, conserving the environment. Most nations have adopted EVs and developed policies such as subsidies to increase their usage to combat climate change. Furthermore, EVs curb noise pollution as they are much quieter than gas-powered vehicles. They are capable of providing smooth drive with higher acceleration over longer distances. Lastly, they promote better health for the populace. Nations that have embraced EV have reported few respiratory diseases and other illnesses related to polluted air.
Conclusion
The Solar Powered Tesla is a great innovation as it gives consumers a way to travel without producing any fossil fuels and it provides them with a certain amount of flexibility in terms of charging. Fossil Fuels are affecting the earth negatively because it contributes to global warming which is currently causing the temperature and sea level to continuously rise. To add on, polluting the air isn’t good for us as well because breathing in harmful toxic gasses is never good for your health.
The solar component of our innovation will allow the electric car to be able to charge anywhere as long as there is sunlight. Also, not everyone has the luxury of owning a house or having a garage. With the addition of solar panels to the electric car, electric car owners can charge their car on the street or in parking lots while they shop. This component will save the electric car owner money on their electric bill. In this way, the car will be an investment because it will pay you future dividends. It will pay for itself and it will cost you practically nothing to travel.
Bibliography
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Eisenstein, Paul A. (2019). Electric vehicles pose ‘real risk’ for autoworkers, with fewer parts — and jobs — required. Retrieved May 9, 2022 from
https://www.nbcnews.com/business/autos/electric-vehicles-pose-real-risk-autoworkers-halving-number-people-required-n1060426
Eisenstein, Paul A. (2022). Will Owning an Electric Vehicle Save You Money? Retrieved May 9, 2022 from https://www.nbcnews.com/business/personal-finance/will-owning-electric-vehicle-money-rcna20256
Ergon Energy. (2015, 8). Benefits of electric cars. https://www.ergon.com.au/network/smarter-energy/electric-vehicles/benefits-of-electric-vehicles
Ewing, Jack (2020). Tesla Isn’t the Only Startup Disrupting the Car Business. Retrieved May 9, 2022, from https://www.nytimes.com/2020/03/04/business/new-electric-car-companies.html
How does an electric car work ? | tesla model S – youtube. (n.d.). Retrieved May 6, 2022, from https://www.youtube.com/watch?v=3SAxXUIre28
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Self-Reflection
The Techincal Innovation Project allowed me and my classmates to collaborate with one another to create an engineering innovation. We had to create a technical description of this innovation and explain the process of the innovation itself, while also going over some details about it. When doing this assignment, I learned many new things that will benefit me in the future such as working with a group, gathering information, etc. At first, we had a group meeting after class where we all split our parts in the way we thought was the fairest, and worked on them. My parts were to research and write about the necessary costs for our innovation before and after implementing the solar panels in the electric vehicle, as well as the time and labor necessary to make this happen. When finding this information, I had to be very accurate as there are many different vehicles and not many people are familiar with electric vehicles. The hardest part was probably finding the price of the solar-powered electric vehicle. Since this invention isn’t common, I had to calculate the price myself by finding out the costs of the solar panel, the amount per watt, then adding it up to the costs of the electric vehicle. Looking at the energy needed for solar energy to give power to houses and then comparing it to the energy needed for vehicles is what helped me achieve this. After gathering all the research and writing it down I then had to put the information into slides and make them simple yet appealing to the audience. I had to deliver the necessary information while also making sure it wouldn’t be too much for the audience to get bored with. I used bullet points as it was the best way to achieve my goals.
This assignment allowed me to achieve the course learning outcomes of this class. I was able to explore and analyze a variety of genres. When searching for information and articles about electric vehicles that would be appropriate for this assignment and have some of the elements necessary for me to analyze it, there were plenty of genres I had to search through. Some were extremely long and informative, some were very simple and made for school assignments, and others had a balance that was perfect for this assignment. Analyzing each of these articles allowed me to choose the best ones to use. Another learning outcome was developing strategies for reading, writing, collaborating, revising, and editing. When reading and searching, I had to plan it out where I would skim through each one and write notes about them. After this, I looked at my notes and took the articles which suited my paper the best. When it came to the writing part, I strategized it by separating each element into categories and then putting the information into them. Using this information from the articles I put under bullet points. When I started the final draft, this helped me a lot as I had the information necessary right in front of me. In terms of collaborating, I had to work with my classmates. I made sure that the information I used for my part was accurate by comparing it to other articles and comparing the information. I also had to ensure that there was no bias, by confirming that the writing was strictly informative and that there were no opinions or false information inside the articles. Some strategies I used to approach this writing assignment was planning ahead of time and starting a template to plan and get my ideas together. I have used this process before and so far, it has proven to work well. Overall, these are the learning outcomes that I was able to achieve in the class, and the strategies that I used to complete this assignment.
