Parter in this project: Hunter Nakayama (hnakayama@punahou.edu)
Empathy - Inspiration
The goal of this project was to create a Solar Powered boat using our CAD skills and 3D printers. The final goal of this project was to race our boats (we being our class) to see who's design was light enough, stable enough, and fast enough to finish the race course first.
This project worked heavily in tandem with SDG goal #7. Solar Panels are a form of clean energy, as during their process of electricity production, they have 0 carbon dioxide emission.
However, it is important to remember that the process of extracting the resources to create the solar panel is not a carbon free process. Heavy mining machinery and transportation of materials produce large amounts of carbon dioxide emissions.
Resource extraction is one of the most energy intensive processes in the world, and almost all of the energy used is generated from the combustion of fossil fuels.
This project also related to UN SDG #11. Creating carbon free transportation methods is extremely important for the development of sustainable cities and communities. Current methods of transportation used across the world are not carbon free, and are not sustainable sources of energy. It is important to move away and ultimately abandon these energy sources and move towards clean and renewable energy in the future. Communities globally need to move to renewables for the future of life and humanity.
Define - Materials
What is PLA?
PLA (polylactic acid) is commonly used for filament 3D printing and injection molding. It should be noted that PLA has a relatively low melting point (at 60 degrees Celsius is softens, and melts at approximately 170-180 degrees Celsius), hence its usage in 3D printing.
How is PLA Made?
PLA is a polyester made from the fermentation of plant based starch pulp. These materials are left to ferment until they turn into lactic acid, then turned into polylactic acid (the result, PLA).
How Sustainable is PLA?
PLA, unlike petroleum based plastics, is a renewable resource and its production is completely sustainable, as it is made of biomass and is far more biodegradable that its petroleum based plastic.
The sourcing of PLA allows for sustainable production and consumption of PLA products (compared to petroleum based products) for the foreseeable future. This is due to the nature of production, as petroleum based production require fossil fuels, while PLA merely requires plant starches.
How does a Solar Panel Work? - A solar panel uses high energy photons to knock valence electrons, usually off silicon, to generate an electric current. Solar panels do not work with low energy photons, as they do not have enough energy to eject the valence electrons out of the orbit of the silicon atoms. Using the ejected electrons, an electric current flows, powering whatever is necessary. For long term energy storage, solar panels can be hooked up to batteries. Batteries are widely used to store solar energy for cloudy days and/or night time.
Solar panels are one of the most prominent forms of sustainable energy available today. However, many forget that the materials needed to produce solar panels are expensive and harvested primarily by expensive, fossil-fuel driven mining equipment, which has a heavy impact on the environment. It is important not to be ignorant of such facts, as seemingly innocent and “sustainable” practices and machines may have some very serious negative impacts on the environment, as their materials are not usually harvested in the most environmentally friendly or ethical manner.
How does a brushless DC motor work? - DC motors are a type of motor that relies on a direct current power source (opposed to alternating current). Brushless means that it doesn’t require brushes, decreasing maintenance and increasing RPM by decreasing friction heating. Brushless DC motors use 2 magnets to fix a magnetic field within the motor. A center mounted copper wire (in the center of the fixed magnetic field) has a current run through it. When a current is run through a conductive material, a magnetic field is generated. In combination with the fixed magnetic field, the magnetic field around the copper wire is then forced to move in a circular motion, usually rotating an externally mounted axel.
Duct tape is a strong, watertight, cloth based tape. It was invented by a combat engineer in WW2 in 1942. It is a commonplace item nowadays, used to secure items and for other various utility. The name is derived from a post war use of taping ventilation ducts, however, it no longer serves that purpose anymore.
This was not a resource originally meant to be used in this project. This was used as a makeshift solution for when our boat could not more forward properly.
Ideate - Thumbnail Sketches
Making Thumbnail Sketches is the first part of the ideation process. Thumbnail sketches are the first initial rough idea of what our boat will look like. Making thumbnail sketches is one of the most important steps of ideating the project, as it creates a rough image that the project will be based around. Here are some of our thumbnail sketches.
Ideate - CAD Design
This solar boat racer project is more complex than the other projects assigned for us in this class so far. It requires multiple parts to be designed for the boat, including a solar panel mount, a motor mount, a shaft connector, a propeller and a hull for the boat itself. All of these parts needed to be designed around canal dimensions, the solar panel given, and the motor that was given. All of these parts would be designed on the CAD tool, OnShape.
Photo is of a different CAD project of mine listed on this site. The Differential Swerve Drive.
The solar panel mount needs to be form fitting with the solar panel given to us (1.5v solar panel). To save weight, it was necessary to rib the design and remove unnecessary weight from the boat. We thought it was best to avoid solar panel angulation, as we did not know which way the boat would be facing during the race.
The motor mount needs to be light, strong, and secure to function properly. It was designed around my former designs for motor mounts during the FTC robotics season. I thought it was best to use a securing screw on the side, to create the ability to tighten the clamp around the motor. However, this was not a feature used by us during the race, as we found that the motor was already securely mounted.
Designing a propeller in a CAD tool is an interesting challenge, as the irregular shape of the propeller and the curvature creates some slight obstacles when CAD-ing the propeller. To combat this, I used a center helical model and a 3D fit spline to create an outline for a singular propeller blade. Next, I filled in the outline and thickened it out, as well as using a circular pattern to create all 3-4 propeller blades (we made two variations). It was important for the blades to have adequate sizing to generate enough force, but not too much size, as the drag would be too much for the small given motor to run properly. Finally, a center piece was designed to attach the propeller to the propeller shaft given to us.
The Motor shaft connector was needed to connect the motor to the propeller shaft and the propeller. It needed to fit snugly around both of the shafts to ensure proper force transfer between the motor and the propeller. It also needed to be the bare weight needed, as extra weight would decrease the amount of force transfered from the motor to the propeller.
The boat hull is the most challenging part of this process, as it needs to be light, waterproof, and stable. The hull of our boat was relatively thin, and the inside was left hollow to save more weight. However, it was not too thin, to avoid water leaking in through the cracks in PLA (which is not considered waterproof). To solve the stability issue, a keel was installed on the bottom of the hull to help maintain vertical stability. However, one thing we did not fully account for was horizontal direction control. As our boat did not have a rudder, it had a difficult time keeping straight. As displayed later in the prototype and testing sections, we had to make some makeshift solutions for this issue.
Using an OnShape assembly, we put all the parts, which were created in separate part studios in an OnShape file, into one assembly and configured them to export as an .STL file. We used mate connections and feature suppression to fully assemble our boat and make sure all features would provide adequate boat stability.
Prototype - 3D printing and Adjustments
After transfering the .STL file from my computer to the printing computer, the process of 3D printing begins. The 3D printing process begins with conversion of the .STL file into a .gcode file, which the printer can read and print from, using a slicing (slicer) program. The next step is transfering the code and uploading it to the printer. Finally, all we had to do was wait for the print to be finished.
During our race, we noticed that our boat would consistently drift to the left, in a pretty sharp manner. The sharp, protruding edges of our solar panel mount would intersect at the edges of the canal, often stopping our boat and turning it backwards. To fix this, originally we strapped duct tape to the front of the boat to the left edge of our solar panel mount, in hopes of smoothing it out and creating a buffer allowing the boat to glide along the wall. When this did not work, we created a makeshift "rudder" on the right side of the boat to counteract the leftward drifting motion by creating a similar drag force on the other side.
We still do not understand why this leftward drifting motion happened. I jumped to the conclusion that it might have been the torquing forces of the motor, as most old centrally engine mounted propeller planes had this issue as well. This is most likely a false conclusion, as our classmates did not experience this issue.
Testing - RACES!
Our first race had the issue mentioned prior, of our boat drifting suddenly to the left. We did not anticipate this issue, as our boat had all sections mounted on the center and no external drag forces acting upon it in the water. There was no wind either. I believe it might have been the work of the torquing motion of the motor, as most early centrally mounted aircraft had historical problems with.
Our next test involved the implementation of a makeshift rudder utilizing duct tape. This rudder was intented to provide stability against horizontal rotation forces acting upon the boat. This was ultimatly unsuccessful, although it did slow the turning motion of the boat slightly. The boat still rammed into the left canal wall and turned backwards. We were still unsure of the issue at this point, and I maintained my current suspicions of the motor torquing.
Our final race we made one final adjustment. I added a piece of duct tape mounted face-forward on the right side of the boat to create a dragging motion on the right side of the boat, in an effort to counteract the leftwards turning movement.
At first, the dragging portion of duct tape generated too much dragging force, turning the boat to the right. After some slight tweaks, the boat could move straight without the need of a rudder or any major hull redesigns.
This is a video of our final race configuration.