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Altair > Case Studies > Optimizing a Single-Seat Solar Car for Sustained Endurance and Total Energy Efficiency
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Optimizing a Single-Seat Solar Car for Sustained Endurance and Total Energy Efficiency

Technology Category
  • Robots - Autonomous Guided Vehicles (AGV)
  • Sensors - Autonomous Driving Sensors
Applicable Industries
  • Automotive
  • Renewable Energy
Applicable Functions
  • Maintenance
  • Product Research & Development
Use Cases
  • Smart Parking
  • Vehicle-to-Infrastructure
The Challenge
The Western Sydney Solar Team was tasked with designing the most efficient and aerodynamic single-seat solar car possible, while ensuring driver safety and adhering to class rules. The team had a predetermined design of the solar car body shape that was optimized with the primary focus on reducing aerodynamic drag. However, they faced challenges in optimizing the monocoque chassis, bulkhead structure, and motor housing of the car within the existing design. They also had to adhere to strict design load cases set out in the class rules as well as minimum g-force strength requirements to ensure driver safety. Furthermore, they had to design and optimize the roll-hoop to safely accommodate the driver. The team was provided with a geometric model of the car that set out the chassis and structure, but no design existed for the roll-hoop.
About The Customer
The Western Sydney Solar Team is a group of students who participate in the Challenger Class of the Bridgestone World Solar Challenge. The competition requires teams to design and build single-seat solar cars that are built for sustained endurance and total energy efficiency. The cars must adhere to strict size limits and a maximum solar array of 4m2. The team's goal is to design the most efficient and aerodynamic car possible, while ensuring driver safety. They have a predetermined design of the solar car body shape that they have optimized with the primary focus on reducing aerodynamic drag. The team is also responsible for the construction of the solar car, using the technical optimizations provided by Gurit engineers.
The Solution
Gurit engineers were brought in to optimize the car's components within the existing design. They used a design and simulation software to undertake a topology optimization, entering loading, force, and design constraints to produce the most efficient roll-hoop structure capable of withstanding the minimum g-force requirements. The shape of the roll-hoop was then imported into a Finite Element Analysis (FEA) model of the chassis where both structures could be analyzed as one for a more accurate representation of strength and overall stiffness. The engineers then used a composite optimization software tool to analyze the chassis and roll-hoop with the primary objective of minimizing the structure’s mass and the secondary objective of maximizing the structure's stiffness. The optimization was conducted in three phases: shape optimization, size optimization, and ply optimization. The final model was subjected to testing using the design load cases and a no failure constraint to ensure structural integrity with the intended layout of the carbon plies.
Operational Impact
  • The three-phase optimization process conducted by Gurit Composite Engineering significantly improved the performance of the Western Sydney Solar Team's solar car. The composite weight was reduced from 80kg to only 42kg, contributing only 19% to the total vehicle weight. This made the car more efficient and aerodynamic, which was crucial for the team's success in the competitions. The team performed well in the “Unlimited 2.0” category, placing 6th in the Bridgestone World Solar Challenge 2017 despite challenging weather conditions. They further improved upon their performance by winning the 2018 American Solar Challenge. The team was well-prepared to use the technical optimizations to build an even faster aerodynamic masterpiece, demonstrating the effectiveness of the optimization process.
Quantitative Benefit
  • Reduction of composite weight from 80kg to only 42kg, contributing only 19% to total vehicle weight.
  • Placed 6th in the Bridgestone World Solar Challenge 2017.
  • Improved performance by winning the 2018 American Solar Challenge.

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