Unfortunately these challenging times have taken a toll on the team’s progress, as the college has been shut down for the remaining of the semester. Additionally, Solar Splash has cancelled the June competition. However, our hard work will not go unseen, as the 2021 team plans to take over and test the boat during the upcoming semester. Because our team has kept to the schedule and had planned on testing this month, there are only a few tasks that must still be completed to finalize the boat. These include manufacturing the drive shaft and copper strap terminals to fit the new batteries and cutting and bending the polycarbonate cover for the electrical panel. Additionally, small tasks must be completed including adding stoppers for the cover, installing hooks to hold wires not in use, and labeling all wires and components. Because these cannot be completed at this time, the team will continue the project by putting all their focus in writing a successful final report, as well as creating a virtual senior project presentation. Check back in soon to see updates regarding report material and presentation content!

The team conducted their first dry test of the integrated systems on Friday, 3/6. This test consisted of two parts: wiring each electrical systems (sprint or endurance), wiring the 12V wires to the dashboard, and connecting the batteries to the panel, and the panel to the respective motor.

The team tested the endurance system first. The outcome of the tests indicated that the electrical panel did perform as expected, however one of the relays are to be replaced, as well as the dual potentiometer. The endurance motor proved to be successful, as the team used a dial on the dash to increase the speed. Next, the sprint configuration was tested. No issues were found in the electrical configuration and the motor performed as expected. However, the RPM of the motors were not able to be tested using Chris’ system, as he is still waiting for a new sensor to arrive. In the upcoming weeks, dry tests will continue to be conducted and the RPM of the motors will be examined using the new system.

In the upcoming weeks, the team will be preparing to conduct water testing. In order to do so, all systems must be finalized (such as ensuring water proof coverage, proper mounting, tightening of belts, etc.). Although the dry test proved to be successful, issues may still arise when the boat is brought out to the water. If so, the team feels prepared to tackle any obstacles proposed.

Dry testing is now in effect! Both electrical configurations (sprint & endurance) have been tested, including the bypass systems. Using a 12V battery for preliminary testing, both systems were wired independently. When the on/off and then bypass switch on the dashboard were turned to the “on” position, a click was heard from the solenoid, indicating that it has indeed been activated. Additionally, the components were tested using a voltmeter to ensure that current was running through them. This process was done for both configurations to ensure proper behavior.

In the upcoming days, dry testing with the motors and fully assembled motor mount will be performed to test the compatibility among all systems. If the system succeeds, then water testing will be in our future. However, if the system fails, we will go back to the drawing board. Design is an iterative process, after all!

Thank you to Seaboard Welding Supply for donating 10 feet of 4 gauge wire. This wire is used to connect the electrical components on the panel for the endurance configuration. Because a new layout was created, new wire was necessary as the lengths between the components varied. Spot our freshly soldered wire in pics to come!

The final design for both the sprint and endurance layout have been finalized. The panel that will hold both configurations was measured and cut to fit behind the driver in the stern. The components have been laid out on this board and new wires were soldered, as there were new spatial constraints to be considered.  Next steps include permanently mounting the components on the board and wiring them accordingly. Finally, the switches located on the driver’s dashboard will be fed through and also mounted to the board. (A casing will also be constructed out of polycarbonate to ensure that the components stay dry when in action.) In the upcoming days, the systems will be tested for efficiency and accuracy. Stay tuned for updates regarding dry testing!

Although the semester is coming to a finish, work on the outboard motor mount is still progressing. The design has been finalized, and work has moved onto simulation. The design is currently undergoing static simulation using the ANSYS program. The simulation is currently being used to understand the effects that the torque of the propeller and the weight of the motors have on the system. Through the use of simulations I hope continue to make my design more efficient and reduce the weight of the system by 20%. 

A lot of progress has been made with the drivetrain over the past couple of weeks. The designs for the top and bottom plates of the sprint have been finalized. They are set to be made in the waterjet as soon as materials are ordered and arrive. A new idler wrench has been waterjet recently. The wrench can be used to adjust the tension for both the sprint and endurance outboards. In the upcoming weeks the current endurance outboard will be disassembled so that the pulley and standoffs can be machined. The bottom plate of the endurance also needs to be modified to allow for the new steering attachment.

The steering system recently had a brief redesign. The decision to stay with the butterfly steering wheel and have a turning radius of 90 degrees was finalized. The chain and sprocket pitch was reduced to ¼ inch pitch to reduce the weight and decrease the arclength. The next big challenge was to correct the linkage system. In order to properly achieve the same turning angle in both directions, the length of the I-Bar was modified to be the same as the length from the driveshaft to the tie rod connection point. The desired angle of motor rotation was also reduced from 60 degrees to 40 degrees each direction. The orientation of the I-Bar was flipped and the steering shaft was moved closer to the transom. This allows the mounting plate size to be reduced which will save money and reduce weight.

ALL HANDS ON DECK!

The team plans on cutting the keel of the boat in order to better serve the outboard motor. This will be done by flipping the boat upside-down and using tools to slice the keel approximately a third way up from the stern. The keel will then have to be re-fiberglassed and painted. The team plans on completing this task in mid-December. Stay tuned for pictures! https://thumbs.gfycat.com/DefinitiveRewardingCuscus-max-1mb.gif

A big thank you to Victron Energy for generously donating two Maximum Power Point Trackers (MPPTS). MPPTs are crucial for the electrical system to run at maximum efficiency. The purpose of the MPPT is to convert a higher voltage DC output from the solar panels down to a lower voltage needed to charge the batteries. These components are necessary for the endurance portion of the competition, when the team needs to utilize the energy directly from the solar panels and translate it to the batteries and/or motor. As a thank you to Victron Energy, we will placing their logo on the side of our boat. Thank you, Victron Energy!