Creación de un automóvil radiocontrol impulsado con energías renovables

TREBALL FINAL DE GRAU COGNOMS: LINARES MOYA NOM: ENRIQUE TITULACIÓ: GRADO DE INGENIERÍA DE DISEÑO INDUSTRIAL Y DESARROLLO DEL PRODUCTO PLA: 2022 DIRECTOR: ALIAU PONS, JUAN JOSE DEPARTAMENT: INGENIERÍA GRÁFICA Y DISEÑO QUALIFICACIÓ DEL TFG TRIBUNAL PRESIDENT SECRETARI VOCAL DATA DE LECTURA: Aquest Projecte té en compte aspectes mediambientals: €Sí €No ABSTRACT This project has been focused on the design and creation of a radio-controlled vehicle powered by renewable energies to demonstrate to the people in a simple way that renewable energies are the future of transportation. In addition, this project includes that the product has to be fully functional adding the steering system by bluetooth and designed to be manufactured in additive printing. The methology used in this project is the Design Thinking where is started by empathizing through a study of the current state of the art, where the buying and learning behavior of humans, the environmental impact of the use of non-renewable energies in automotive transport, the current and future technologies of the sustainable car framework and the key components of the radio control systems are studied Then it's defined a briefing where the design was directed from the definition of the user and his needs applied to the functionality of the product from the study of references which allowed to see functional design opportunities leading to a design path. Then, the design is ideated starting with the form-function, conceptual designs, studying the usability between the product and the user, mechanics, aesthetics, materials used, components purchased and the machinery used for production. With all this data and with a clear design idea, the parts needed for 3D printing were designed and the assembly was assembled and the corresponding drawings were made. Then it was prototyped with the 3D printing technology and assembled the final product Finally, the budget was made where the costs of the project, the materials and components and the production costs were taken into account with seeing that the majority of it is the engineering costs. The author is happy with the result since he has been able to meet his goals of creating a fully functional radio control from additive manufacturing. Although he would have liked to be able to improve sustainability and work more on inclusivity and user learning Keywords (10 maximum): Radio control Sailing Sustaineability Pollution Inclusive Usability Educative Fun Additive Printing INDEX OF CONTENTS INTRODUCTION 8 Motivation 8 Childhood 8 Sport and hobby of the wind 8 Energy awareness 8 Environment 9 Socio economic behavior 9 Methodology 9 Design Thinking 9 Structure 9 Empathize 10 Define 10 Ideate 10 Prototype 10 Testing 11 Objectives 11 STATE OF THE ART 12 Consumerism and Understanding behavior 12 Behavior consumption influencers 12 Environmental impact of the use of non-renewable energies in the automotive sector 17 Sustainable automobile transport framework 20 Radio control 38 BRIEFING 41 Aproach 41 Utility phrase 41 User analysis 41 Chain of users 41 Usuary type 42 Person 43 Functional frame and precedents 44 Holes and windows 46 Cience and technology 48 Design choice 49 Benchmarking 49 LandSailers Analyzed 50 Source:https://aeroplageshopcom.surinternet.com/epages/box15060 .sf/sec34d97ad607/?ObjectID=5004181 52 Comparative table 56 Analysis of the most relevant aspects 57 Swot matrix 58 DESIGN 60 Mindmap 61 Form-Function 61 Conceptual design 64 Product-user 66 Product-mechanics 69 Dynamics 69 Steering 74 The tension and torsion of the mast 76 The tension servo and the anchor point of the sail 76 Product-aesthetics 76 Shape 77 Color 77 Surface finish and texture 77 Product-material 77 Base 83 Casing 83 Rims 84 Steering arm 84 Weel anglers 84 Material Election 85 Sail 85 Product-purchased components 88 Product-manufacturing 92 3D Printer 92 Sewing machine 93 Silicone gun 94 Hand soldering iron 94 Dial Caliper 95 Screwdriver and Allen wrench 95 Flat and circular hand sanders 95 CAD DESIGN 95 Parts designed 96 Base 96 Steering arm 97 Rear wheels anglers 98 Case 98 Rims 99 Normalized and bought parts 99 Assembly 99 MODEL 102 Manufacturing 103 3D printing parts 103 Sail 109 Surface finishing 110 Assembly 111 Sail 111 Steering system 111 Rear wheels and axle 112 Electronics 112 POJECT COST 114 Engineering cost 114 Components and materials costs 115 Production cost 116 Final cost 117 CONCLUSIONS 118 ACKNOWLEDGEMENTS 120 WEBGRAPHY 120 FIGURE INDEX Figure 1. Design thinking structure………………….………………………………………10 Figure 2. Moslows pyramid…………………….…………………………………………….15 Figure 3. Global emisions……………………………………………….………………….. 18 Figure 4. Anual greenhouse gas idex ……………………………………………….……..19 Figure 5. Average impact of biodiesel ……………………………………………………..21 Figure 6. Adoption biodiesel ……………………………………………….………………..22 Figure 7. Average impact Co2 biomethane ……………………………………………….23 Figure 8. Adoption biomethane Global …………………………………………………….24 Figure 9. Adoption biomethane EU ………………………………………………………...24 Figure 10. BEV sustainability depending on energy source …………………………….26 Figure 11. Global EV adoption ……………………………………………………………..27 Figure 12. Average EV autonomy ………………………………………………………….27 Figure 13. Adoption biomethane EU ………………………………………………………29 Figure 14. Solar panel types ……………………………………………………………….30 Figure 15. Europe solar adoption ………………………………………………………….31 Figure 16. Blackbird …………………………………………………………………………32 Figure 17. Wind zone ………………………………………………………………………..33 Figure 18. Wind angle direction……………………………………………………………. 34 Figure 19. Kite movement ………………………...………………………………………..35 Figure 20. Landsailer ………………………………………………………………………..36 Figure 21. Sail riving directions ……………………………………………………….……36 Figure 22. Wind forces on sailing ………………………………………………………..…37 Figure 23. Relative Wind direction forces …………………………………………….……37 Figure 24. Greenbird world record landsailer speed…………………………………..… 38 Figure 25. Person. ……………………………………………………………………………44 Figure 27. Helix linear wind powered vehicle …………………….……………………… 45 Figure 28. Helix powered RC ………………………………………………………….……45 Figure 29. Sail powered custom ……………………………………………………………45 Figure 30. Sail powered large scale …………………………………………….…………45 Figure 31. Pantera RC Land Yacht kit ………………………………………..……………50 Figure 32. K'WEEE RACE vers.1.2 ………………………………………………..………51 Figure 33. K'WEEE ULTIMATE vers. 2.4 …………………………………….……………52 Figure 34. T'Weeester RACE………………………………………………………………. 53 Figure 35. T'Weeester ULTIMATE ………………………………………………….………54 Figure 36. Bat 1 RC Tierra Yate …………………………………………………….………55 Figure 37. Mind Map………………………………………………………………………… 61 Figure 38. Firsts conceptual designs……………………………………………………… 64 Figure 38. Conceptual designs…………………………………………………………….. 66 Figure 39. Center of gravity and lateral center of resistance dynamics …………..……70 Figure 40. Righting Moment Dynamics ……………………………………………………71 Figure 41. Righting Moment graph …………………………………………………………71 Figure 42. Caster Angle …………………………………………………………………..…72 Figure 43. Camber Angle…………………………………………………………………… 73 Figure 44. Weel anglers…………………………………………………………………….. 74 Figure 45. Steering system concept ……………………………………….………………74 Figure 46. Final steering system ……………………………………………………………75 Figure 47. Mast torsion……………………………………………………………………… 76 Figure 48. Anchor point of sail …………………………………………………...…………77 Figure 49. Anchor point of sail calculations ………………………….……………………78 Figure 50 Da Vinci 1.0 Pro material compatibility ………………………………...………80 Figure 51. Sail cloth material characterístics………………………………...…………… 87 Figure 52. Da Vinci 1.0 Pro ………………………………………………………………….95 Figure 53. Characteristics Da Vinci 1.0 Pro …………………………….…………………95 Figure 54. Singer 1507 ………………………………………………………………………96 Figure 55. Final modeling base.…………………………………………………………… 98 Figure 56. Final modeling steering arm. ……………………………………..……………99 Figure 57. Rear wheels anglers.……………………………………….………………… 100 Figure 58. Final modeling case.…………………………………………..……………… 100 Figure 59. Final modeling rims. …………………………………………...………………101 Figure 60. Final landsailer modeling………………………………...…………………… 102 Figure 61. Final landsailer modeling lateral view .……………………………….………103 Figure 62. Final landsailer modeling top view ……………………………………...……104 Figure 63. Layout 3D printing ……………………………………………..………………106 Figure 64. Printing; Printer configuration …………………………………………………107 Figure 65. Printing; General configuration …………………….…………………………108 Figure 66. Printing; Speed configuration …………………………………………………109 Figure 67. Printing; Extrusion ratio .configuration………………………………….…… 110 Figure 68. Printing; Supports configuration ………………………………………………110 Figure 69. Printing; Retraction configuration ……………………………………..………111 Figure 70. Model …………………………………………………………………………….115 TABLE INDEX Table 1. Chain of users ……………………………………………………………..………42 Table 2. User………………………………………………………………………………… 43 Table 3. Functional frame and precedents ……………………………..…………………46 Table 4. Disruptive holes …………………………………………………………..……..…47 Table 5. Type disruptive holes …………………………………….………………..………47 Table 6. General window ……………………………………….……………………………47 Table 7. Type window……………………………………………………………………...…47 Table 8. Benchmarking comparative table. …………………………..……………………57 Table 9. Swot matrix. ………………………………………………...………………………58 Table 10. Form-Function. ……………………………………………………………………62 Table 11: Phisical properties ABS ………………………………….…...……….…………81 Table 12: Mechanical properties ABS………………………….…………..……………… 81 Table 13: Phisical properties PLA …………………………….……………….……………82 Table 14: Mechanical properties PLA ………………………….………..…………………83 Table 15: Phisical properties PETG …………………………………..……………………84 Table 16: Mechanical properties PETG ……………………………………………………84 Table 17. Engineering Cost. …………………………………………………………….…116 Table 18. Components costs.…………………………………………….……………..… 117 Table 19. Production costs …………………………………………………………………118 Table 20. Total project cost ………………………………….……………………………..119 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Within the economic situation the most important factors are: Income Depending on the amount of income that a consumer and his family have, will define the level of expenditure that they can have on products or services. This is analyzed in two ways: - Disposable income, which is the income remaining after taxes are taken out. - Discretionary income, which is the income remaining after basic necessities such as rent, food, etc. have been covered. These serve to see what amount of excess income can be used on consumer goods, the disposable being a larger range including basic fixed and variable expenses and the discretionary being smaller concentrating on status and lifestyle climbing goods. Assets and Savings If the consumer has assets or savings, depending on the value of these, the consumer's spending behavior will vary. Personal After the cultural, sociological and economic aspects, the next layer is formed by the personal aspects of each consumer. These are mainly determined by the age, gender and lifestyle, because those determines the lifestile; a teenager don’t have the same lifestile or preferences than an elder. The same happens to genders, as mens difers to womens in preferences too. This personal factors are to determine an specific target of consumer. Psicological Consumer psychology represents the consumer's personal view of the product, although this has intrinsic factors that are difficult to measure or influence. It’s divided in 4 factors: ● Motivation First of all, the consumer's motivation for the purchase, where englobes what needs wants to satisfy with it. This is described graphically with Maslow's pyramid called Hierarchy of Needs, which expresses human needs and priorities. 14 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Figure 2. Moslows pyramid. Source:https://www.google.com/search?q=Hierarchy+of+Needs&rlz=1C1VDKB_esES975ES975 &sxsrf=ALiCzsamiax8pXBZuhWcRPECXv6zWm5ytQ:1653726095487&source=lnms&tbm=isch &sa=X&ved=2ahUKEwj1sejj4YH4AhUKh_0HHfv9BqsQ_AUoAXoECAIQAw&biw=1583&bih=96 0&dpr=1#imgrc=FHoX0imBZJNPuM This graph expressed the needs as a stairs, to fullfill the higher need firstly is needed to fullfil the previous, as if the consumer don’t have the basic needs it’s impossible that can get to the self fulfillmet. The hierarchy is divided in 3 parts: - Basic Needs: As can be seen in the graph, the most basic needs such as physical and safety needs do have a great importance within human needs, but when are acomplished, are taken for granted. - Psychological needs: Social, family and love acceptance together with the need for self-esteem make up an important part of human needs. - Self-fulfillment: And finally would enter self-fulfillment, where the consumer would feel the maximum potential. In this project, physical needs and self-fulfillment will be omitted, since these needs are individual, deviating from the field of study of this project, which focuses on understanding the factors that may impact the consumption decision in a general. Therefore, this will focus on security and psychological needs, since these affect to the perception of the product and imply an image of the consumer towards society. ● Perception Perception is a process on the part of the customer of gathering information, which subsequently allows him to form an image of the product. This aspect is one of the most important when it comes to the product development as it impacts directly to it. From all the information that the consumer manages to collect, either from 15 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya social networks, TV, Internet or going arround phisical shops, forms an impression that can fit with the rest of personal factors. The way in which the consumer receives information has changed over time as society has moved towards modernity. But one thing that is characteristic of today is the bombardment of information that a consumer receives throughout the day and the amount of options and alternatives that exist in the marketplace. This makes the information less storable for the consumer, since he is not able to retain it all, being very important the impact generated by that product. Thus, consumers instinctively have a selective attention to filter the information they are most interested in and ignore the information they are not interested in. So the clue to catch the preception is the diferentiation and intrinsic values of the product. ● Learning The humans use the cognitive learning where the consumer uses the knowledge acquired during his life through study and experience, which enters through the senses, the environment, memory and reasoning to use the product. When the consumer buys a product, he acquires knowledge through the experience with it, his previous knowledge and his innate abilities. This factor is also one of the most important ones for this project, since an objective is the education of the consumer to get awareness of the renewable transport and what can bring. So, how do humans best perceive ideas and information to learn? - Activity, experience and context Learning consists of making sense of the world around us, assimilating new information, comparing it with our current knowledge and negotiating the meaning of these interactions. This assimilation is much more effective when doing activities as perception is much greater. - Social activity Human beings learn best socially, sharing and collaborating. This is due to human nature, promoting teamwork to solve problems and ensure survival. In contrast, competitiveness promotes aversion, diminishing creativity and interest. - Novelty The human brain is attracted to novelty, to things that stand out. If what is to be learned is novel or is used in a new context, it remains more marked in the memory. - Motivation Motivation determines the quality of learning, so good learning begins by 16 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya arousing the user's interest. Making them feel and be excited creates intrinsic values and a vision of what they want to happen. - Form of speach Through the explanation of concepts in a clear, concise and orderly manner, it allows the user to better understand them and assimilate them in a faster and more efficient way. ● Attitudes and beliefs Humans have always had attitudes and beliefs which shape human behavior and thinking and therefore buying behavior. Understanding these factors can help to understand both individuals and social sectors and thus focus products towards customer satisfaction. 2.2 Environmental impact of the use of non-renewable energies in the automotive sector To understand the impact that the use of non-renewable energies has had on the automotive sector, it is necessary to know what consequences their use has on the environment and human beings, and what weight it has with respect to other sectors. The extensive use of fossil fuels in automobiles over a long period of time has led to a phenomenon known as the greenhouse effect. In reality, far from the concept that is held, this effect is a natural phenomenon and benefits the ecosystem. Greenhouse gases, being water vapor, nitrous oxide (NO2), carbon dioxide (CO2) and methane, are in their natural state in the atmosphere. In the process where the sun emits thermal radiation, it hits the earth's surface, emitting most of it back into the atmosphere. The gases retain part of the thermal radiation, which heats the planet, allowing life. Therefore, the gases emitted by cars that use non-renewable energies generate changes in the equilibrium of the gases on the atmosphere, don’t allowing the heat leave the atmosphere and retaining it, heating the ecosystem changing both the planet and its complex ecosystem, as well as in all living beings that live on it, including humans. These particles are: - Carbon Oxide: These damage the oxygen absorption mechanisms that living beings have, damaging their pulmonary health. - Nitrogen oxides (NOx): These irritate the lungs and cause respiratory infections such as flu or pneumonia by lowering the defenses of the human metabolism. They react with hydrocarbons such as methane to generate ozone, which is 17 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya doubly irritating. - Sulfur dioxide (SO2): This compound damages the respiratory tract, irritating the lungs and making breathing difficult as well as increasing heart failure. It is also associated with asthma and chronic bronchitis. According to the European Environment Agency, transport generates more than 30% of global CO2 emissions, of which 60.7% are generated by automobiles. This means that around 18% of global CO2 is emitted by automobiles. In addition, automobiles are also responsible for 80% of NOX emissions. So, the extensive use of fossil fuels in the automotive industry has caused CO2and NO2to be above natural levels, saturating and generating a denser layer of gases, preventing solar radiation from escaping and causing the planet's temperature to rise, a phenomenon known as global warming. The National Oceani & Aymospheric Administration (NOAA) pointed that globally, this phenomenon and the emission of the mentioned gases have been in an uptrend: Figure 3. Global emisions Source:https://research.noaa.gov/article/ArtMID/587/ArticleID/2877/Greenhouse-gas-pollution-tr apped-49-more-heat-in-2021-than-in-1990-NOAA-finds 18 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Figure 4. Anual greenhouse gas idex Source:https://research.noaa.gov/article/ArtMID/587/ArticleID/2877/Greenhouse-gas-pollution-tr apped-49-more-heat-in-2021-than-in-1990-NOAA-finds What can be seen in the last image is the Anual Greenhouse Gas Index from the NOAA, which measures the gases trapped in the atmosphere indicating the rate of progress of global warming. This reveeled that from 1990 to 2021, the greenhouse gases trapped 49% more heat in the atmosphere. But what are the main impacts of this phenomenon? - Desertification of fertile areas: Rising temperatures result in less rainfall, which can lead to areas of fertile soil degrading to the point of desertification, making them unusable for cultivation. - Acid rain: Automobiles also release sulfur dioxide, which in combination with NO2, SO2 and moisture produces acid rain. This causes damage to both land and water, damaging vegetation, crops, acidifying water and corroding surfaces, among other things. - Sea level rise: The increase in temperature affects water temperature, causing polar ice caps to melt, resulting in a rise in sea level. This causes flooding of coastal areas. - Species migration. 19 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Animals have patterns which are guided by climatic conditions, including the temperature and humidity of the ecosystem in which they live, which also undergoes changes. In reaction to these changes, animals adapt to the new conditions; some change from being diurnal to nocturnal animals, and others change their migration pattern to colder places. Those that fail to adapt die, endangering their survival as a species. This affects terrestrial animals as well as marine and aerial animals. - Agriculture and livestock farming Global warming alters factors such as the length of the seasons, changing the stages of growth in agriculture. It also causes the proliferation of insects, invasive weeds and diseases that endanger crops. In livestock farming, it harms the lives of animals, causing changes in metabolism, reproduction, health, etc. - Food shortages Food shortages are caused by many factors but one that influences this trend is global warming. Land is becoming drier and less fertile, reducing food production and leading to starvation in the world. - Health The heat caused by global warming will increase respiratory and cardiovascular problems as well as facilitate the spread of infectious diseases such as malaria and cholera. Considering the direct consequences of the consumption of non-renewable energies in the automotive sector and the trend so far, it is necessary to reduce the use of these energies in order to delay and reduce the negative effects of global warming and pollution. 2.3 Sustainable automobile transport framework After seeing the history of the use of non-renewable energies in the automotive sector and the consequences of the use of these energies it’s seen that it is necessary to change the way in which humans use private transportation so that it is both useful and not harmful to the planet. Non-renewable energy technology and vehicles, infrastructures continues to develop strongly to increase efficiency and reduce current emissions, but this project won't focus on this field, but rather on sustaineable and renewable energies and the technologies that support them. The drive technology avaliable are the combustion engine and the electric engine, where different tipe of fuels and energies provides the energy that make them move. Combustion Engine The main alternatives are: Biodiesel 20 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Biodiesel is a renewable, biodegradable fuel that is manufactured primarily from vegetable oils and animal fats for use in diesel-powered vehicles. The properties of biodiesel are very similar to those of diesel of fossil origin, so it can be used in diesel engines in proportions ranging from 2% (B-2) to 100% (B-100) of the fuel. The comparison of biodiesel with respect to diesel is: - It improves engine lubricity and the engine is easier to start. Thanks to lubrication, it avoids wear of moving parts. - It reduces the emission of particulate pollutants although it also increases the emission of nitrous oxides as shown in this graph: Figure 5. Average impact of biodiesel Source:https://afdc.energy.gov/vehicles/diesels_emissions.html It’s important to mention that although the use of biodiesel increase the NOx emissions, the selective catalytic reduction (SCR) technology minimizes emissions to almost zero. - It reduces power at its maximum concentration (B-100) by 10%. - With high concentrations the fuel will coagulate at low temperatures - Although studies and engine manufacturers indicate that the maximum level of biodiesel in the blend should be 20% (B20), beyond that components, such as fuel pump hoses and seals containing elastomers, are damaged in the long term so modifications must be made to existing diesel engines to not damage any part. Another biofuel is the ethanol which is a renewable fuel made mainly from the fermentation and distillation of sugarcane, sorghum, corn, wheat, barley, sugar beet, sweet potatoes, cassava and cellulosic biomass. Ethanol is used in gasoline engines, which is blended with gasoline for use, where 98% 21 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya of US gasoline is partly ethanol. The most common is E10, which contains 10% ethanol, although the maximum concentration is E85 (85% in blend) only for use in flex-fuel vehicles, which indicates that they have two tanks for the use of gasoline and E85 ethanol separately. This factor makes this type of fuel uninteresting for this project as it is dependent on a fossil fuel. The trend of the biofuel sector looks like the image below, where the global biofuel production is seen: Figure 6. Adoption biodiesel Source:United-States-Environmental-Protection_fig1_313085412 How it can be seen, the biodiesel it’s the less produced biofuel in the world, which is indicative of a use that is not socially widespread, since it is considered an alternative fuel. Not like ethanol, which, being an additive normally used in conventional gasoline, has much more production and consumption. Biomethane Renewable natural gas or biomethane is a gas produced from the purification of biogas generated by organic matter from landfills, farms or gasification processes. This fuel is available both in its gaseous form as compressed natural gas (CNG) and in liquid form as liquefied natural gas (LNG). Compressed natural gas (CNG) vehicles are used in a similar way to gasoline vehicles as both fuels are injected into internal combustion engines. What differentiates them is that the natural gas is stored in a high-pressure tank with a gas volume of 1% and is transferred through the fuel lines, reduced in pressure to a level compatible with the injection system and introduced into the combustion chamber. 22 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya LNG is produced by purifying the natural gas and supercooling it to -260°F in a process known as liquefaction, where the gas is converted to liquid. The remaining natural gas is primarily methane. This fuel is very expensive to process and store at cryogenic temperature but it’s denser than its gaseous form and so it’s used in trucks that need a longer transport range. For this, won’t be studied. The advantages and disadvantages of CNG are as follows: - The main advantage is the low emissions it has; from its production, this fuel is generated from waste that society creates and methane emissions are collected before they go into the atmosphere. Then, in its combustion, it generates between 60% and 70% less emissions than gasoline, as can be seen in the following graph: Figure 7. Average impact Co2 biomethane Source:https://www.irena.org/publications/2017/Mar/Biogas-for-road-vehicles-Technology-brief - It generates similar power and acceleration - The energy is, as it shows this data: 1 gallon (gal) of gasoline = 1 GGE (Gasoline Gallon Equivalent) 5.66 lb of CNG = 1 GGE 1 gal = 8.345404452021 lb 5.66/8.3454 = 0,6782 1-0,6782 = 0,3218 0,3218*100= 32,18% The CNG have 32,18% less energy than gasoline - The adoption have been steadelly increasing globally 23 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Policristaline Each cell is conformed with multiple silicon crystals. This makes it a cheap option but leads to a constraint movment of the electrons reducing it’s efficiency. Monocrystalline Each cell is conformed with a single silicon crystal. This makes it more expensive although it guives more freedom to the electrons to move, improving it’s efficiency. Figure 14. Solar panel types Source:https://news.energysage.com/monocrystalline-vs-polycrystalline-solar/ Although it has not yet been possible to generate a vehicle that is powered solely by solar-energy technology, there are already car models that generate up to 10% of the car's autonomy at peak sunshine using the monocrystaline type. This gives the technology a wide room to grow as it is a promising technology that can be implemented independently of battery and electric motor technology by adding an extra layer of renewable energy source. Adoption In recent years, several companies have been planning to launch electric vehicle models with solar energy recapture systems, which vary in range, capacity and cost to suit all types of sustainable consumers. 30 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Figure 15. Europe solar adoption Source:https://www.fortunebusinessinsights.com/solar-vehicle-market-104333 As shown in this graph, the growth of the solar-powered EV market has been increasing and will continue to grow progressively as the technology develops and companies are able to apply it to their EVs. Wind Wind-powered vehicles harness the wind to generate propulsion energy. These are separated into three categories: - Power-generating turbines These first are turbines that harness the motion of an EV to receive air, which spins it and generates energy that subsequently provides it to the battery and electric motor. This makes it a power generation technology similar to solar panels, as they provide additional power generation. There are already prototypes of cars that use turbines for power generation at the front, since being perpendicular to the forward motion of the car the air reception is greater. Although these systems are being developed, they are also very controversial, since in order to maintain a car at the same speed, energy must always be added due to the loss of energy from the wind impacting the surface, among other factors. This means that a reduction of the coefficient of friction with the air makes the car more efficient. This is the opposite of wind turbines, which need air friction to generate energy. At the moment the energy generated by the turbine compared to the energy lost due to the coefficient of air friction is less, making this system inefficient and for the moment unusable. That is why EVs are more focused on reducing the friction coefficient and optimizing the energy recovery of regenerative braking, which consists of taking advantage of the kinetic energy of the wheels while not accelerating and even 31 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya braking, changing the direction of energy transmission from the wheels to the battery, recharging it. - Propeller This type of vehicle uses a propeller positioned at the top to propel itself in the wind thanks to the direct gear reduction transmission from the propeller to the wheels. This type of vehicle serves to propel itself only with the wind either upwind or downwind, depending on the position of the propeller. At first, when the vehicle is stationary, it needs enough wind force on the propeller to be able to move forward, and when it generates some speed, the turbine generates more force, accelerating and gaining speed. In 2010 the "Blackbird" was created, the first vehicle propelled only with the wind that demonstrated that it could go at 2 times the speed of the wind driving downwind and 1 year later it reached 2.8 times the speed of the wind. Figure 16. Blackbird Source:http://mit.zenfs.com/852/2013/06/IMG_2967.jpg In 2016 he changed the blades to test with the headwind also obtaining the world record with a speed of 2.1 times the wind speed. While the fact that a vehicle can be propelled faster than the wind just by the same wind either headwind or downwind is amazing, that doesn't make it useful. The fact that the propulsion can only be linear by having to align with the wind direction makes them functionally useless since a transport needs to be able to have a wide range of mobility to direct the user to the destination. 32 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya - Sails and kites These vehicles are propelled solely by the wind thanks to an element that collects the wind and provides it with traction, such as sails and kites. When it comes to the way these propulsion systems are steered, they are quite a bit more complex having a wider range of pull than propellers. This is because they are mobile and can position themselves relative to the wind with such variable angles that they create a movement space called the power range or wind window, which has a maximum pull angle and two ends of minimum pull with a variable traction range. This on the other hand also makes them much more difficult to maneuver and optimize their performance. Something to keep in mind is that the propulsion systems are not directed from the natural wind, but by the apparent wind, which is the combination between the natural wind and the wind generated from the relative speed between the ground and the vehicle. , which is in the opposite direction to the speed of the vehicle. This causes the apparent wind direction to constantly change in both direction and strength. Kites A kite is a flying aerodynamic profile that generates traction and is tied to strings that allow it to transmit force and be directed. This traction is generated when the air flows around the surface of the kite which, due to its shape, generates a pressure difference that propels the kite in one direction, and when it is tied, it propels the vehicle, the most common being the so-called kitebuggy. This one has space for 1 or two passengers and three wheels, a front one that works as steering and two fixed rear ones for stability. Regarding mobility, kites have what is called the wind window: Figure 17. Wind zone Source:https://elitewatersports.com/pages/the-wind-window 33 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya As shown in the image, the zone of use of the kite when stationary is a quarter of a sphere, with the center being the support point of the vehicle. The kite cannot pass beyond the plane perpendicular to the wind from the support point and in the horizontal plane the usable zone reaches the last 15º, the latter making the kite fall. and the zone of maximum force is centered in the central zone, where the kite is most perpendicular to the wind. In order for the vehicle to move, the kite must be directed in the desired direction and kept in the power zone. To brake, the kite is positioned outside the power zone. When applying movement the dimensions of the window change: Figure 18. Wind angle direction Source:https://www.coastalwindsports.com/BetterBuggyBasics.html As shown in the images, when movement is added to the vehicle, the apparent wind changes angle. This, as it increases with speed, from the plan point of view, the power zone is reduced and when in motion, the kite does not pass the point of attachment with a plane perpendicular to the direction of movement because the kite it always tends to pull ahead of the attachment point. 34 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Figure 19. Kite movement Source:https://www.coastalwindsports.com/BetterBuggyBasics.html In the lateral plane, the kite can move in the power zone without changing the direction of the kite, raising and lowering it to create more pressure and generate more force. The optimal thing is to tilt the kite 45º so as not to generate ascending and descending forces that reduce the propulsion power. Something to note is that only with the kite, a kitebuggy created a world record reaching the speed of 133.4 km/h The main problem of this type of propulsion system is its complexity and dimensions, as the kite has to be attached to strings which range from 10 m to 40 m. This makes kites impractical as a method of propulsion as a method of transport for vehicles, since the roads are not of such large dimensions and objects between the kite and the vehicle can intercept with the strings. Sail The sails are tensile or solid structures that collect the wind to generate power. They can be triangular or rectangular trapezoid shapes having a point at the top and a side parallel or nearly parallel to the ground at the bottom. Both the vertical and horizontal sides have solid elements to give rigidity and shape to the sail, being the mast and boom respectively. The mast is fixed anchored to the vehicle and the boom is a movable element that is tied by a rope with a system of pulleys, allowing from the tension or distension of this to open or close the angle of the sail with respect to the direction of movement. Vehicles propelled by sails are called sand yachts and normally have a front wheel that is steered by hand or foot and two rear wheels for stability. These have room for one or two people. 35 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Figure 20. Landsailer Source:https://www.google.com/search?q=sail+sandsailing&rlz=1C1VDKB_esES975ES975&sxs rf=ALiCzsYJd96oAiXqHLJSCNYM88385W2PmA:1655017616437&source=lnms&tbm=isch&sa =X&ved=2ahUKEwjipv-Iraf4AhUngv0HHcxgA5gQ_AUoAnoECBwQBA&biw=1443&bih=960&dp r=1#imgrc=tqyQa-Nfsvt2YM As far as steering is concerned. The sails have an actuation window with different angles. As they are attached to the mast, which is a vertical axis, they have movements in the ground plane. The driving directions are: Figure 21. Sail riving directions Source:https://asa.com/news/2021/02/19/points-of-sail/ As can be seen in the picture at angles of 30º on either side of the wind direction the sail does not have sufficient strength to overcome the headwind force. Although, this graph is represented a sea yatch, where the water don’t bring much resistance 36 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya However, this changes when the sand yacht starts to move, as it generates an apparent wind which generates an aerodynamic force that is divided into the force with direction and sense to the apparent wind called drag (D), and the component perpendicular to this called lift (L). The total aerodynamic force is also divided into a forward propulsive force (Fr) and a lateral force (Flat) that is transmitted to the wheels and the ground. In this image can be seen a sea yatch, but the principles are the same. Figure 22. Wind forces on sailing Source:https://en.wikipedia.org/wiki/High-perf ormance_sailing#cite_note-Bethwaite-2 The most optimal propulsion is provided by optimizing lift and reducing drag. This happens when the apparent wind angle is aligned with the leading edge of the sail: Figure 23. Relative Wind direction forces Source:http://nbnjrotc-sail.blogspot.com/2011/01/lets-begin-at-beginning-how-boats-sail.html By having wheels, the lateral drag is very high thus allowing less energy loss compared to water vehicles, increasing the speed and thus the apparent wind. As the vehicle increases its speed, the apparent wind force also increases, reducing in turn the relative strength of the natural wind by changing to a smaller and smaller angle of attack. This means that at higher speeds, the sail must have a flatter shape in the direction of motion becoming solid for better reception of forces. Proof of this is the sand yacht that holds the speed record, reaching 203.1 km/h, exceeding 3 to 5 times the wind speed: 37 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Figure 24. Greenbird world record landsailer speed Source:https://www.sailingscuttlebutt.com/2014/02/20/breaking-speed-sailing-world-record-stand ing-inside-sail/#:~:text=The%20current%20overall%20speed%20sailing,highly%20engineered, %20highly%20funded%20project. As can be seen, the sail is solid and resembles the shape of an airplane wing. The minimum apparent wind angle with respect to the trajectory of the vehicle is 7º to 9º. The sails therefore have a number of advantages and disadvantages: Disadvantages: - Being elements that use the wind to generate force, they are totally dependent on it, being this a natural energy that cannot be controlled. - The vehicles cannot be propelled against the wind and the wind direction range determines the efficiency of the force that the sail can provide. - They are elements that have relatively large dimensions compared to the vehicle. Advantages: - They are a physical element that generates propulsion in a totally renewable way. - It can be an extra element to an electric motor, providing an aid to propulsion. - The dimensions do not protrude from the floor of the vehicle so as long as they are not too high they should not collide with objects. These transportation mtehods are used as a sport and not as a method of real transportation. 2.4 Radio control The radio control technology will be studied to understand the main aspects to have in count at the design process. 38 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya The first thing to know are the main electric components that are needed to build a basic RC: - Transmitter (Tx): This is the one that transmits the user's movement indications via levers and buttons to the vehicle. Transmitters normally require 12V to operate, usually supplied by 8 AA batteries. An alternative to the transmitter is to add a bluetooth receiver with which you can connect the cell phone and from a downloadable program to send the steering signals to the vehicle. - Receiver (Rx): This component receives the signals from the transmitter and transmits them to the individual channels where the electrical elements that make the determined functions such as servos and motor are connected. As the receiver and the transmitter must have this transmission bridge, they must operate with the same frequency. This component is powered by the motor controller. - Power supply This element is a power supply module that can be plugged in via USB and has a direct output voltage of 5 V to perform the voltage of the mounted electrical elements. It also regulates the charge and discharge voltage of the battery. - Servos: These elements are small electric gear motors that connected to potentiometers generate rotations from 90º to 360º. They also have variable torque forces depending on the application. They are connected to the receiver from where they receive the movement commands. They all have the standard three-pin connectors, with ground (black), +4.8 to 7.4v (red) and signal (white). - Batteries These are the element that provides power to the system. They come in many types but the most efficient are lithium-ion batteries as described above. The characteristics to take into account are: - Amperes(A): Current generated by the battery. - Volts(V): Voltage of the battery. - Milliampere Hour (mAh): Determines the capacity of the battery: 39 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya As in previous processes, these functions are classified as critical, major or minor. Analyzing the functions of the precedents, holes will be looked for where these do not fulfill the functions, determining the opportunity of the product to supply these gaps. It’s represented in a table showed below: Table 3. Functional frame and precedents Source: Own elaboration. 3.6 Holes and windows After having performed the analysis of functions and precedents, the different distinctions are analyzed: - Disruptive holes: it is where no precedent fulfills a given function. These represent an opportunity in the whole precedent sector and are marked in red. 46 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Table 4. Disruptive holes Source: Own elaboration. -Type disruptive holes: Is where one type of precedent fulfills a certain function and the other not being this function critical. These represent an opportunity in the sector of the precedent type that does not fulfill the function and are marked in orange. Table 5. Type disruptive holes Source: Own elaboration. With these holes two windows can be formed: The first one is based on a more general spectrum, putting together complementary functions and disruptive derivatives: Table 6. General window Source: Own elaboration. The other is based more on the type of candle by taking the holes dedicated to it by putting together the general functions: Table 7. Type window Source: Own elaboration. In this one the terrain diversity function is ommited because the contradictory technical 47 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya characteristic, as how more compact a car is, more impact have the terrain on it’s performance. The last one will be chosen for the design as a compact size is needed for a wider age inclusion and feasible additive manufacturing. 3.7 Cience and technology Once the window has been analyzed and chosen, the functions that make up the window are analyzed through science and technology in order to solve them: - Easy assembly and disassembly The following aspects improve this factor: - A minimum number of parts The fewer the number of different parts, the faster, more intuitive and trouble-free the assembly process will be. - Accessible connections Connections must be easily and conveniently accessible. - Easy-to-handle parts The assembly parts must be easy to handle to allow for a more comfortable assembly. The science that can solve this function is a combination of anthropometry and biomechanics, which study the dimensions and dynamics of the human body respectively to allow better ergonomics and handling of the elements. By wanting to be inclusive for different ages this field becomes more complex. On the technological side this can be solved thanks to 3D printing, which allows the creation of complex pieces that save the connection of many parts as well as making them ergonomic. - Compact size This factor can be improved only by technology since to improve the compact size being an RC is to choose smaller electrical and mechanical components: - Microelectronics: the electrical components described above in 2.4 Radio Control come in many dimensions to supply the different applications they can have. - Mechanical parts such as wheel bearings or hardware should also be smaller in size - Bluetooth steering This factor is solved through Bluetooth technology, which implemented in an RC receiver can receive signals from a Bluetooth device, in this case a cell phone, through an app. - Easy to learn 48 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya This factor is determined by science in the form of psychology, which is the study of human behavior, more specifically, the psychology of learning, which studies the human learning process. 3.8 Design choice From the previous sections, the final choice of the aspects that will mark the design of the RC driven by the wind is summarized. This will stand out for: - First, its ease of assembly and disassembly thanks to a reduced number of parts, which will be ergonomic and those that are necessary will be accessible. This will be achieved thanks to the additive manufacturing technology which can perform a wide variety of complex forms. This will improve the setup so users can start playing without a lot of headaches. - To be compact thanks to electronic and mechanical components of small dimensions, providing a portable, ergonomic and inclusive dimension of the RC. - Have Bluetooth technology for handling, which will be implemented in the RC receiver. This will allow the user to connect the mobile to the RC through an app to direct it, avoiding the need for a transmitter for that function, by reducing the total cost of the product and the need to provide power to the transmitter. - And finally, a clear, concise and orderly explanation of the product's usability will be implemented for better user learning. Additionally, the following will be taken into account: - A sustainable production so that in addition to its sustainable use, so is its creation. - A sustainable and friendly aesthetic. - A fast charge as well as a long-lasting autonomy for the longest time of enjoyment. 3.9 Benchmarking After the analysis and assimilation of the design aspects to be taken into account, the benchmarking tool is used. This is useful to understand the current business and product situation in the market through research, analysis and comparison of leading products. 49 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya The analysis will first be based on a description of the product and the 1-5 rating of the following aspects: - Price - Dimensions and Weight - Functionality - Materials and sustainability - Aesthetics And finally, a comparative table will be made based on a rating from 1 to 5 of the aspects analyzed and a selection of the most interesting products will be made. 3.9.1 LandSailers Analyzed MIA Trike-a-Sail™ Pantera RC Land Yacht kit Figure 31. Pantera RC Land Yacht kit Surce:http://www.micro-flight.com/mia_trike_ a_sail_pantera_rc_land_yacht.html This RC land yacht is manufactured by a small aviation radio control company called MIA Micro-FLIGHT™, located in USA It’s the only model that manufactures The RC comes in the form of an assembly kit which contains Frame, Wheels, Mast, Sail, Servos, Wiring and final assembly which are assembled in the respective order. - Price: 238,20€ - Dimensions and weight - Total dimension; 813 x 1220 x 533 mm - Sail dimiension: 405 x 965 mm - Weight: 1135 - 1360 g - Functionality This is suitable for light to medium winds in flat areas such as parking lots, yards or hard beaches. As a highlight, it have the option of adding a structure to the rear where it’s added a propeller with a brsheless motor to assist in propelling the RC in low wind conditions. 50 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya It is operated by a 2-channel radio control for the front steering and the sail and to perform those is needed a 4 AA bateries in the RC. The transmitter and receiver are not included in the kit, which have to be purchased separately by the user. Pric - Materials and Sustainability: - The body is made of CNC machined wood. - Parts are made with 3D printing - Metal standard elements like bearings and axis - Nylon sail - Foam tyres - Aesthetics It has a handmade aesthetic with low development, drived for the body which comes in the form of a 2D wooden plank, with the servos and electronics in view. The flat sail with saturated and common colors, uses green as the brand image. AEROPLAGE This is a small company located in France purelly dedicated to the manufacturing and sale of simple and competition landsailers. This company sells the sail cars unassembled, being these kits with the components included, in which the transmitter and receiver are excluded. It has 4 models to choose from: K'WEEE RACE vers.1.2 Figure 32. K'WEEE RACE vers.1.2 Surce:https://aeroplageshopcom.surinte - Price: 199€ - Dimensions and weight - Class 1 landsailer: 750x1000x500 mm - Weight: Unknown - Functionality It can be used on flat areas like yards, hard beaches and parking lots and works from 6 km/h of wind. Thanks to its rigid chassis, carbon rear axle and wheels with micro bearings it provides stability and good handling. The mast can be disassembled and removed from the trolley for storage. In addition you can add 2 ballast tanks that will allow you to gain power when the wind is strong without changing 51 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya rnet.com/epages/box15060.sf/sec34d97 ad607/?ObjectPath=/Shops/box15060/P roducts/AR0007 the sail immediately. It is operated by a 2-channel radio control for the front steering and the sail and to perform those is needed a 4 AA bateries in the RC. - Materials and Sustainability - The body is made with marine grade aluminum. - Metal standard elements like bearings and axis - Dacron sail with 4 batterns - Foam tyres - Aesthetics It has a handmade aesthetic with medium development. Thisi is leaded for: - The electroincs are hided in a tropezoidal shape body less the sail servo - The dacron sail is more reflective which causes more atention. K'WEEE ULTIMATE vers. 2.4 Figure 33. K'WEEE ULTIMATE vers. 2.4 Source:https://aeroplageshopcom.surinternet.com/epages/box15060.sf/sec34d97ad607/?Objec tID=5004181 It’s the advanced version of K'WEEE RACE vers. 1.2. Modifications for this model are: - Price: 245€ - Functionallity It improves it’s efficiency at ease upwind tight thanks to it’s sail, which have 5 batterns instead of 4 which leads to more rigidity and better attack angle ratio. In the other aspects it has the same components and features 52 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya T'Weeester RACE Figure 34. T'Weeester RACE Source:https://aeroplageshopcom.su rinternet.com/epages/box15060.sf/s ec34d97ad607/?ObjectID=5004181 This RC is more focused on competition. Modifications for this model are: - Price: 299 € - Dimensions and weight - Class 2 landsailer: 1000x1500x750 mm - Weight: Unknown - Functionality - Mounting is easily accomplished with a mast and shaft clipping system, making it more portable and quicker to assemble. - Large ballast tanks for increased power capacity. - Ultra-light sail for improved performance - Carbon rigging - Large wheels to increase speed and reduce terrain abruptnessvis also possible to adjust the center of gravity, the center of the sail, and the sail traction point thanks to its 3 points. - Materials and Sustainability - Dacron sail without batterns - Aesthetics - It has a more profesional aesthetic with medium development. - The body have a contour slightly more fluid. T'Weeester ULTIMATE 53 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Figure 35. T'Weeester ULTIMATE Source:https://aeroplageshopcom.surinternet .com/epages/box15060.sf/sec34d97ad607/? ObjectID=5004181 It’s the advanced version of T'Weeester RACE. Modifications for this model are: - Price: 390 € - Functionallity: - Carbon battened mylar sail with variable width neck sleeve to give better bend at maximum tension which improves performance. - Carbon batterns - Stepped desmountable mast to perform portability - Carbon axle to reduce weight - Thiner wheels to reduce weight and upgrade maximum speed It’s the advanced version of T'Weeester RACE. Modifications for this model are: - Price: 390 € - Functionallity: - Carbon battened mylar sail with variable width neck sleeve to give better bend at maximum tension which improves performance. - Carbon batterns - Stepped desmountable mast to perform portability - Carbon axle to reduce weight - Thiner wheels to reduce weight and upgrade maximum speed - Aesthetics - It has a professional aesthetic with medium-high development thanks to the sail which the battened pattern and it’s perfectly sheathed batterns The following products were developed and placed on the market but are no longer available for sale. This may have been due to many factors such as low demand or a high price compared to other more common RC alternatives, although it is uncertain. 54 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya HobbyKing ™ Bat 1 RC Tierra Yate Figure 36. Bat 1 RC Tierra Yate Source:https://hobbyking.com/es_es/hobbyki ngtm-bat-1-rc-land-yacht-arr.html This RC land yacht is manufactured by a big company based in Hong Kong dedicated to the sale of radio control products, both complete products and electronic components and accessories. In it’s wide range it’s the only model that manufactures. The RC comes in various forms: - In assembly kit. - Almost ready to run Comes all included, including servos, receiver and a transmitter with usb rechargeable lithium ion battery. - Price: 140 € (Original) This one passed to 28€ and then to cannot be sold. - Dimensions and weight - Total dimension; 730x1000x500 mm - Sail dimiension: 0.15m² - Weight: 800 g full equiped - Functionality This is suitable for light to medium winds in flat areas such as parking lots, yards or hard beaches. The radio equipment is well protected against shocks, dust, water and mud thanks to an hermetic housing with clipping closures. It is operated by a 2-channel radio control for the front steering and the sail and to perform those is needed a 4 AA batteries in the RC. - Materials and Sustainability: - Plastic pre-moulded body - Carbon boom mast and rear axle - Foam wheels - Flashy mylar sail - Metal standard elements like bearings and axis - Aesthetics It has a professional aesthetic with high developement, drived for the body which comes whith a variable and fluid form, with all the electronics hided in the body. 55 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya should it have corresponding to the previous factors These elements are defined and summarized in the following table: Module Component Function Form Base Base Upload and contain all the components on it's site Triangular or rectangular As small as possible to reduce weight taking into account that all the interior elements fit with a centered center of gravity. Shell Shell Protect all components loaded on the base Hollow shape and as close as possible to the interior components and the base to reduce weight and aerodynamic load Allow the passage of components that have interaction with the base and are on the outside Give aerodynamics Control Servo arm Transmit the rotary force of the servo in a circular motion Elongated rectangular String Transmit servo arm rotation into a sail anchor point tension Circular section without stiffness Steel rod Transmit the circular motion of the servo arm into a circular motion of the steering arm with as little angular deviation as possible Rigid circular section Electronics Transmitter Send landsailer direction and sail tension signals from the user to the receiver to move them Orthohedral shape The controls to send the signals are usually levers or sliders Servos They provide rotational motion to the servo arms. Orthohedral shape With the exact dimensions for the force needed Receiver Receives signals from the transmitter to redirect them to the servos Flat rectangular shape 62 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Module Component Function Form Electronics Step Up Power supply module that can be plugged in via USB Flat rectangular shape Regulates the charge and discharge voltage of the battery Converts an input voltage to a higher output voltage to adapt to the voltage of the mounted electrical elements On-off switch Switch that sends the signal on or off the electrical circuit of the landsailer Orthohedral switch Battery Provide power to receiver and servos Cylindrical or orthohedral shape Cables Connect all the electrical components to comunicate and give power Circular section without stiffness Traction system Sail Provides propulsion to the landsailer Triangular or Rectangular Trapezoidal Mast Be the anchor point and position of the sail Rigid circular section with some bending Allow the sail to rotate Bloom Give rigidity to the lower part of the sail to be able to maintain an angle of this Rigid circular section with some bending Dynamics Steering arm Position and hold the wheel Circular or rectangular section with curves to start from the rotation point of the base and surround the wheel until it is positioned perpendicular to the flat face of the wheel Transmits the movement of the steering servo to the wheel Rear axle Rear wheels positioning Rectangular or cylindrical Cushioning Weels Cover They allow the movement of the landsailer by raising it from the ground and receiving the tractive force of the sail and transmitting it to the ground Circular or rectangular section Cushioning 63 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Module Component Function Form Dynamics Weels Rims Adapt the wheel cover to the center of rotation of the steering arm Outer ring adapted to the cover and circular inner ring for the bearings Contain and center bearings Cushioning Aesthetically shaped spokes Bearings Reduce friction between the wheel anchor point and the wheel Circular Screws Screws Join the different mobile elements such as the steering arm and the three wheels Circular section with a wider head Table 10. Form-Function. Source: Own elaboration. 4.3 Conceptual design To start the conceptual design were taken the components and forms described above Figure 38. Firsts conceptual designs Source: Own elaboration. 64 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya The main things that wanted to be conceptualized where the form, distribution of components and systems. A compact component distribution is sought, which cannot be achieved with a narrow base shape. The angulation of the sail is also sought, which is played with to give different shapes to the sail, from triangular, rectangular and trapezoidal, which is the most suitable visually for the author and functionally for reasons that will be explained later. The steering wheel is steered with a system of wedges and a servo that pulls or lets go to change direction. The housing covers all the base components and only lets through the steering with holes for the ropes and the rear axle with the wheels. Then is proceed to focus more in the design of each part and mechanism: Figure 38. Conceptual designs Source: Own elaboration. 65 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya The next parts and systems are described: Base For the form of the base the length of the battery was taken to ptimize space and weight distribution. The charger and reciever are positioned flat to the base on the sides after the axis; the charger on one side to allow charging and the receiver on the other side to balance the weight. The front is rounded to let the steering axis do the turn and don’t get hitted with the base. Steering The steering is achieved with a steering arm that holds the front wheel and finishes with a vertical steering axle where the steering arm pivots. The pivoting is generated by a servo which is connected to the steering arm through rods that translate the rotational motion of the servo into a linear motion of the rod that pushes the steering arm, which is anchored on a rotating shaft and rotates. Sail The sail starts next to the steering shaft in the front of the land sailer and finishes in the rear part of it without exceeding too much to let space to the electric components and steering system The mast is positioned backwards to optimize the size and capacity of force that can perform. DEFINIR VELA Y SUS PARTES 4.4 Product-user The purpose of this section is to define the product through the interaction between the product and the user. First, the user's interaction with the product and with each part of the product is defined on the basis of functions in order to redefine and improve these functions and the components involved based on the user's needs. This analisys is based on experience by the author in the landsailing RC sector. The user interaction is based on the following functions: Charging The user needs to charge the RC battery in order to power the electrical components. This is done by connecting the usb charging cable to the Step up usb port with a linear movement parallel to the connector. For this function, the user can do it in several ways: - In the air: He will hold the RC with one hand with the position of this with the palm upwards holding the base or in a C-shape on top making pressure on the 66 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya sides of the casing and with the other he will connect the usb micro. - On the ground: While connecting the micro usb on one side, hold the housing on the other side. Assembly and disassembly The assembly consists of a sequence of 3 assembly operations: ● Insert mast into sail Insert the mast into the hole of the sail which is in the lower part of the sail. You must hold with the index finger and thumb of one hand near the tip of the mast and with the other hand hold the sail entry hole loosely to be able to insert the mast. Then slide the mast inwards with a linear movement and when you can no longer insert it because you have your fingers in the hole move the hand of the mast towards the other end and perform the same movement until the mast collides with the end of the sail sheath. To remove the sail, instead of pushing inwards, pull the mast and sail outwards. ● Inserting the mast with the sail into the mast support. This involves taking the sail with the mast mounted and inserting it into the mast support. This is achieved by pinching the two ends of the mast with your fingers with each hand to give more stability and positioning the mast in the hole and pushing it into the mast holder. To dismantle it, instead of pushing, pull the sail and mast. ● Hooking the rope to the sail The rope protruding from the housing is taken and passed through the hole in the sail. This is achieved by pinching the end of the rope with your fingers and passing it through the hole in the sail as if it were a needle, of course with a larger hole, and tie a knot at the other end. For disassembly is the reverse process; the knot is undone and the rope is pulled out of the hole in the sail. Power on To turn on the RC the user has do two things; turn on the switch and connect the mobile app. - To change the switch position from off to on the user have to do a lateral movement of the switch lever. For this function the user will hold the RC as in the load both in the air and on the ground and with the other hand, normally with the hand closed and the thumb extended as this physiognomically is sideways and is in the perfect position to make pressure, will make a movement of the finger to turn it on. - To turn on the mobile app it’s needed to install it in a first time. 67 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Then it’s needed to connect the App with the RC bluetooth reciever and it’s done like every bluetooth device connection; Serch the device and connect it. Usage ● Drive To drive, the user uses the mobile controls, which are the steering on the left side and the wing tension on the right hand. These come in the form of digital joysticks that are directed with the thumbs of each hand. ● Reposition When driving the landsailer, many times it stops due to poor positioning with respect to the wind or lack of it. The user does two things: - Grab the landsailer by the sides of the casing with your C-shaped hand and press down with your fingers to lift it up and turn it. - Hold it by the sail with one hand, pinching the mast part with your fingers and stretching upwards to lift it off the ground and turn it. This is not how it should be done because the mast and support are not intended for vertical movement, although the author of the work has seen it done many times. ● Undump The landsailer, when propelled by the sail, has a center of traction elevated from the ground, a little below the center of the sail vertically due to its narrow shape above. By having this displaced traction, it creates a torsion, which if the wind is very strong compared to the weight of the landsailer, it manages to lift the wheel against the wind. This can be controlled with the traction of the sail and being able to drive on 2 wheels. This is very complicated so it also twists so much that it tips over. When placing the tip of the sail with the mast touching the ground and the body looking upside down, having the base from above. What is done in these cases is to pull the mast up with the hand pinching it until by its own weight it is positioned in the base form. ● Transport To transport it from one side to the other the user can do it in several ways, but the most comfortable would be: With one hand with the position of the palm upwards holding the base and with the other holding the mast to avoid twisting in the wind. With the hand in the shape of a C from above making pressure on the sides of the casing and with the other equally holding the mast. After analyzing all the functions are compared with the needs of the user: - The charge and the power involve bought products those can’t be modified, just repositioned. So the position will be the more accessibleas possible. 68 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya - The Assembly and dissassembly have to be fast, accessible and intuitive. To improve the time to mount or dismount the landsailer the mast and the sail can be permantently mounted and be transported toguether. On the other hand, the weakest points of the sail, being the cover of the mast and the boom, can be perforated in the transport, damaging and even breaking the sail. So the way to really improve the assembly is the way the rope is attached to the sail. To improve this, instead of tying a knot at the end of the rope, there will be a hook attached to the end of the rope that with a rotation of the wrist can insert the tip in the sail hole. - For use and transport 2 things are needed to improve them: - The mast has to be thick to withstand all impacts and pulls and bends by the user - The casing, being a point of grip with the hand in the form of a c from above, must have that shape from above to adapt to the shape of the hand and thus have a better transport and grip in general. 4.5 Product-mechanics The mechanics of the landsailer is divided mainly into 4 sectors: 4.5.1 Dynamics When it comes to designing a land vehicle, a determining factor in its performance is dynamics. The dynamics determine how the movement, performance and durability of the landsailer will be. The most important points that determine the dynamics are: - The relation of length-wide - The positioninf of the center of mass and center of propulsion - The tyre angles The positioninf of the center of mass and center of propulsion This positions determine the dynamisc of all the vehicle. The positioning of this two determine the center of laeral resistance, which is the point along the length of the landsailer where, if you push it sideways, it will slide sideways without rotating. The lateral resistence is then the force that opose sideways movement of the landsailer, which the more the better perfrmance will have. The center is determined by the center of mass and the center of propulsion. If the center of mass is aligned with the center of propulsion in top view the lateral resistence is maximized as it’s represented in this image: 69 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Figure 39. Center of gravity and lateral center of resistance dynamics Source: http://www.rclandsailing.com/design.html This factor won’t be studied in this project as the center of propulsion is determined by an aerodinamic study of the sail. But it can be done aproximatelly to have a slight better performance with this knowledge. Relation of length-wide The length/width (L/W) ratios affect the righting moment. This concept is defined as a moment avaliable until the landsailer flips. Maximizing this moment leads to be capable of getting more force without flipping maximizing its speed and stability. This happens because the moment arm (d) (the distance from the center of gravity (CG) to the line about which the heeling yacht rotates, whis is ther line between the rear wheel and the front weel) changes as the L/W ratio changes. In the image below is showed this: 70 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Figure 40. Righting Moment Dynamics Source: http://www.rclandsailing.com/design.html Whith this relation the righting moment versus the L/W ratio is showed: Figure 41. Righting Moment graph Source: http://www.rclandsailing.com/design.html In this graph is showed that the maximum righting momentum is achieved at 0,8-1,5 L/W ratio, beeing the peak the 1. This are not the best ratios for a global performance because at ratios less than 1 the fore-aft stability becomes an issue when the windward wheel (situated on the side 71 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Combining all these factors, we have that for the sail to generate an angle change of 35º from the 90º rotation of the servo, the following requirements must be met: Figure 49. Anchor point of sail calculations Source: Self made 4.6 Product-aesthetics To define the aesthetics of the product, the factors defined above must be taken into account. And these are: - Fun - Friendly - Inclusive The perception of shapes in the human subconscious generates a reaction depending on the user, so in order to create an inclusive and friendly character in a product, it must be taken into account that if it is pulled too much towards friendliness, it will affect the sector of users who want something less friendly and aggressive. This means that for the definition of the following aspects of aesthetics, we will try to 78 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya reach inclusiveness by designing in the middle ground between the perceptual extremes. But on what aspects is aesthetics based? Mainly on the user's perception of: - Shape - Color - Finish and texture 4.6.1 Shape The first factor that determines the shape is the size, which for product differentiation at the market level it was decided to make the landsailer more compact. This factor improves the aesthetics at an inclusive and friendly level, since a small product transmits harmlessness and ease. If the product has angular and pointed shapes it might appeal to a more active type of user and not a calmer one because of the perception that the product is fast and complex. On the other hand, a fluid shape also generates a rejection by the active part but is liked by the passive part as it represents simplicity and tranquility. In order to generate an inclusive form, it is necessary to reach an middle ground, where neither sharp nor totally fluid shapes are generated, but rounded angles are sought to reduce aggressive shapes, thus improving the user's perception at a general level. 4.6.2 Color For the definition we want to clarify that this factor is fully determined by the manufacturing materials of which the external elements of the landsailer will be made. As these are made of plastic printed by the 3D printer, the aesthetics of the plastic will be used with the basic predetermined colors of the filament with surface finish on the parts that need it. These colors are mostly flat with high contrast, the most common being blue, red, yellow, white and black. 4.6.3 Surface finish and texture For the finishing, it is intended to leave the manufactured elements with a minimum of surface finish, which will give a basic style to highlight the shape. 4.7 Product-material To define the materials, the elements to be manufactured must first be defined. These are separated in 2 groups; the 3D printed parts and the sail: The 3D printed parts are: - Base: Due to its complexity and need for customization for the distribution of internal 79 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya components. - Casing: Due to its need for perfect coupling with the base - Rims: For their customization at an aesthetic level - Steering arm: To be able to adapt it perfectly with the gear steering system - Wheel anglers: Because it is an element that does not exist in the market for these dimensions and to customize the angle as well as the axle. The gears will not be manufactured due to the lack of precision of the 3D printer. After start the analisys there’s things to have in count: - All these elements can be manufactured from 3D printing, so only the applicable materials for this type of manufacturing and for the specific machine will be studied. According to this, the 3D printer that the author has in possesion is the Davinci 1.0 Pro from XYZ Printing. Figure 50. Da Vinci 1.0 Pro material compatibility Source: https://drive.google.com/open?id=1rYU95EMGJGFLrcL4TScq2YnIxhwzekRC As it can be seen from the printing material compatibility sheet from XYZ, this printer have the possibility to print in: - ABS - PLA - Normal PLA - Antibacterial PLA - Tough PLA - PETG - Each part will be studied separately according to its structural and superficial needs. 80 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya - The objective of the manufactured elements is that they have the greatest mechanical resistance as well as a reduced weight to improve their range of use. - They are all exterior elements that are exposed to the elements, so they will be treated superficially accordingly. So after the start of the analisys the available filament materials for the Davinci 1.0 Pro will be studied: ABS Characterístics: Acrylonitrile Butadiene Styrene or more known ABS it’s an opaque petroleum based thermoplastic. Like its name, it’s formed between those 3 monomers. It’s commonly used in electronic housings, auto parts, consumer products, pipe fittings, lego toys, etc. The phisical propperties are: Density 1.08 g/cm3 Glass Transition Temperature 90-102 °C UV Light Resistance (long periods of time) Bad Moisture Absorption at Equilibrium 0.41 % Table 11: Phisical properties ABS Source:https://www.matweb.com/search/DataSheet.aspx?MatGUID=3a8afcddac864d4b8f58d4 0570d2e5aa The mechanical propperties are: Elongation at Break 48 % Elongation at Yield 5,5 % Hardness Rockwell R 106 Strength at Yield (Tensile) 73 MPa Young Modulus 2 GPa Table 12: Mechanical properties ABS Source:Own elaboration 81 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya https://www.matweb.com/search/DataSheet.aspx?MatGUID=3a8afcddac864d4b8f58d40570d2 e5aa Next, the advantages and disadvantages related to the application of an exterior and non chemical environment. Advantages - Tought and have very good impact strength - Chemical resistance and heat stability - Rigidity and processability - Good electrical and termical insulator - 100% reciclable as it can be heated, cooled and reheated various times without losing it’s properties. Disadvantages - Poor weather resistance - It can burn with high temperatures and continue to burn once the flame is removed leaving toxic fumes - Scratches easily - Low continuous service temperature, meaning that the cold don’t affect it’s mechanical solvency. - No biodegradability - The instalation where manufacturing needs ventilation due to the toxic elements that releases when printing with it. - Need a superficial treatment to have a good aesthetics, normally athetone. Price Between 10-20 € depending of the color and quality PLA The PLA can be choosde between 3 types: Normal PLA Polylactide (also known as Polylactic Acid, Lactic acid polymer) or better known as PLA is a biodegradable thermoplastic based on lactic acid, which can be produced 100% from renewable resources as corn. It’s widely used in the packaging sector thanks to its biodegradability but it has multiple applications as healthcare and medical industry. The phisical propperties are: Density 1.28 g/cm3 Glass Transition Temperature 57 °C UV Light Resistance (long periods of time) Very bad 82 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Moisture Absorption at Equilibrium 0.25 % Table 13: Phisical properties PLA Source:https://www.matweb.com/search/DataSheet.aspx?MatGUID=ab96a4c0655c4018a8785 ac4031b9278&ckck=1 The mechanical propperties are: Elongation at Break 65 % Elongation at Yield 38,5 % Hardness Rockwell R 106 Strength at Yield (Tensile) 40 MPa Young Modulus 2,25 GPa Table 14: Mechanical properties PLA Source:https://www.matweb.com/search/DataSheet.aspx?MatGUID=ab96a4c0655c4018a8785 ac4031b9278&ckck=1 Next, the advantages and disadvantages related to the application of an exterior and non chemical environment. Advantages - Biodegradable relatively compostable material made with renewable materials - Easy to manufacture - Does not give off odor when printing with it. - Good asthetics without superficial treatment Disadvantages - Poor mechanical performance beeing not suitable for impact or thoughtness aplications. - Have a very bad performance outdors, reducing it’s durability and performance over time. Antibacterial PLA https://www.xyzprinting.com/en-US/material/antibacterial-pla Is a special filament which uses silver ions to inhibit bacterial growth by at least 99 percent almost estinguishing the risk of infection. This is used mainly in food and healthcare. The characterístics are the same for the rest of the factors. 83 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Tough PLA This is a special PLA filament which has a 750% more impact resistance. This allows to have the PLA properties adding this extra resistance to impacts. Though the price is doubled from the PLA passing from 20 € to 40 € PETG PETG is a Copolymer due to combination of PET and Glycol, two polyesters. This last adds resistance to the PET, which is the plastic material used for the bootles. The phisical propperties are: Density 1.26 g/cm3 Glass Transition Temperature 57 °C UV Light Resistance (long periods of time) Bad Moisture Absorption at Equilibrium 0.28 % Table 15: Phisical properties PETG Source:https://www.matweb.com/search/datasheet_print.aspx?matguid=4de1c85bb946406a86 c52b688e3810d0 The mechanical propperties are: Elongation at Break 140 % Elongation at Yield 39,5 % Hardness Rockwell R 110 Strength at Yield (Tensile) 47,5 MPa Young Modulus 2,6 GPa Table 16: Mechanical properties PETG Source:https://www.matweb.com/search/datasheet_print.aspx?matguid=4de1c85bb946406a86 c52b688e3810d0 Advantages - Does not create odor when printing with it - The glycol stops the material to crystalyze and brittle the part - Good esthetics - Good impact resistance and very good flexibility. 84 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya - Can be 100% recyclable Disadvantages - Difficulty to print as is quite easy to warping (a part from the base sags upwards compressing the area and creating a non-uniform geometry) and shrinking (the reduction in size of the final model due to temperature changes from the melted thermoplastic, to the cooled extruded material layers) of the part. - It will brittle if not stored correctly because of the absorbtion of water. - Have a very bad performance outdors, reducing it’s durability and performance over time. The price is expensive as beeing the double of the ABS. It goes from 20-30 € After beeing studied the diferent materials that are aplicable to the 3D printer the needs of every piece that will be manufactured with it are studied. 4.7.1 Base It is a structural element that serves mainly to support all the electronic elements and is responsible for supporting the force of the wing to transmit it to the wheels. Structurally - It must have mechanical resistance to support: - The hits - The weight of the internal components - The torsion of the sail - Shaft bending - To the scratches below because of the terrain Superficially - To rain and humidity In conclusion, the base have to be mainly mechanically resistant. 4.7.2 Casing It is a structural element that serves mainly to protect all the elements between it and the base. Structurally - It must have mechanical resistance to support the impacts - Hardness for the grip of the user and other elements that can scratch the surface Superficially - To the scratches because of the rollovers and the constant gripping - To the sun, mainly ultraviolet rays - To rain and humidity In conclusion, the casing have to be both good mechanically with impact resistance 85 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya and hardness and superficially to UV rays and to humidity. 4.7.3 Rims Are rotatory elements centered on the rear axle and the front steering arm. Structurally: - Have to resist impacts from the ground - Scratches from the irregularities and little parts from the ground Superficially: - To the sun, mainly ultraviolet rays - To rain and humidity In conclusion have to be mainly mechanically resistant. 4.7.4 Steering arm The steering arm is a dynamic element that rotates trough the steering axis from a screw and holds the front wheel sorrounding it. Structurally: - Supports the flexion and torsion forces from the front wheel. Superficially: - To the sun, mainly ultraviolet rays - To rain and humidity In conclusion have to be mainly mechanically resistant. 4.7.5 Weel anglers The weel anglers are the part that unifies the rotatory axle of the rear weels and the rear axle creating a toe in angle. Structurally: - Suport the flexion of the rear axle and the forces of the wheel. Superficially: - To the sun, mainly ultraviolet rays - To rain and humidity In conclusion have to be mainly mechanically resistant. 4.7.6 Material Election Analyzing the needs of every component, all the components need good mechanical performance as every one is a structural or a dynamic component that suports forces of tension, flexion, torsion or impact. The need to have a low weight is needed to have a better performance without loosing the mechanical properties 86 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya For this factors the elements will be manufactured with the same material being the ABS. The pros are mainly the very good mechanical properties, the copmared low density and price that have but the cons are significant, as it’s a petroleum based thermoplastic the sustainability of it even beeing 100% recyclable is way reduced. In a project environment where the 3D printer were not an essential point of departure it could have been studied other materials that coud have achieved the mechanical needs of the parts without taking off the sustainability factor. 4.7.7 Sail The sail is an element that is manufactured with cloth so firstly will be determined the structural and superficial needs and then an analysis of the best material will be selected. The sail need to be: Structurally: - Light to reduce weight - Flexibility to make the contact of the wind in the sail smoother and less impactfull. This is a characterístic for a non high performance land sailer. In the last one the aparent wind is necessary to have a better performance, where the best quality would be that not stretch under load, meaning that can hold the shape at high pressures of the wind. - Hard to be resistant to stretch and chafes Superficially: - Resistant to UV rays - Rain and humidity So, which materials are good fot sails? The following are a few that can be used for this purpose. Figure 51. Sail cloth material characterístics Source:https://www.northsails.com/sailing/en/2019/12/fibers-fabrics-a-sailors-guide-to-finding-th e-right-materials 87 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya https://es.aliexpress.com/item/10000090266440.html?spm=a2g0o.order_list.0.0 .6c3f194diUMySp&gatewayAdapt=glo2esp These are nylon anti-blocking nuts to be able to thread up to a point on the bolt without fully tightening it against the wheel to stil permit the movement of it and still remain locked in place. This are M2 to fit with the screws. - Gears https://es.aliexpress.com/item/32852529728.html?spm=a2g0o.order_list.0.0.6c 3f194diUMySp&gatewayAdapt=glo2esp The gears are 13 and 15 mm diameter with 2 mm for the axis. 4.9 Product-manufacturing For the product manufacturing the machinery disponible will be determined so the product can be manufactured without any inconvenience. The main machinery used is: - 3D Printer - Sewing machine - Silicone gun - Hand soldering iron - Screwdriver - Flat and circular hand sanders All the technical data can be find in the annexes 3 TECHNICAL DATA SHEETS AND MANUALS. 4.9.1 3D Printer The 3D printer is used to manufacture all the 3D pieces designed for 3D manufacturing. The machine in possession is the da Vinci 1.0 Pro: Dimensions 468 x 558 x 510 mm Weight 23 kg Power supply 100 V ~ 240 V 200 W 94 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Figure 52. Da Vinci 1.0 Pro Source:https://www.xyzprinting.com/es-ES/product/da-vinci-pro This machine have the next characterístics that affect the development and manufacturing of pieces: Layer resolution of 20-400 micrometers - Bed printrer capacity of 200x200x200 mm - Max bed temperature 90º - Extrusor diámeter 0.4mm - Filament diámeter 1.75mm - Max extrussor temeprature 240º Figure 53. Characteristics Da Vinci 1.0 Pro Source:https://www.xyzprinting.com/es-ES/product/da-vinci-pro The ABS used for the printing is the following: https://www.smartmaterials3d.com/abs-filamento#/3-tamano-l_1000g/11-color-true_bla ck/26-diametro-175_mm Filament from Smart Material 3D with 1,75mm filament diámeter with 3 types of different colors: - Red - White - Black 4.9.2 Sewing machine The sewing machine is used to make the mast, boom and the sailing battens covers on the sail bending the cloth and sewing it. This process is made with the Singer 1507, a sewer that was already in possession of the author and is more than enough to sew the thin cloth and thread. 95 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Figure 54. Singer 1507 Source: https://es.matri.eu/singer-1507-maquina-coser The thread used is a 100% Recycled Polyester Thread that the author had in possession. 4.9.3 Silicone gun The silicone gun is used to join the different parts with a fast, sealing and insulation material as is the silicone. The silicone is a non esthetical material so the only parts sticked with it are the interior elements. The parts sticked with the silicone are: - Electronic parts: - Servos - Battery - Direction gears, screws and nuts - Reciever - Rear axle - Traction ring The silicone bars used are model SALKI 430308 are 8x95mm compatible with the gun. https://www.leroymerlin.es/fp/751324/barra-de-cola-termofusible-salki-430308-universal 4.9.4 Hand soldering iron For the electronic components to work, they must be connected to each other with cables to form the electrical system. The elements that need soldered wiring are: -Step Up - Receiver - Switch on/off - Drums 96 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya To weld these wires to the different components, it’s needed a tin wire and a handheld tin welder, which is a steel tip that is heated from a resistor. 4.9.5 Dial Caliper It is used to measure the actual dimensions of electrical and mechanical components in addition to the actual part dimensions when printing accurately in small dimensions. 4.9.6 Screwdriver and Allen wrench A basic screwdriver and an allen wrench to screw and tighten the screws with the nuts 4.9.7 Flat and circular hand sanders So that the pieces have a better finish after 3D printing and can be assembled, they are sanded. To perform this sanded are used little manual sandlers to have a better accuracity to a better finished part. The sandpapers used are: - Round 2 mm diameter - Flat 4 mm thick - Flat 10 mm thick 5. CAD DESIGN Once the entire study and conceptual design process has been completed, together with the definition of the shape and characteristics, the 3D representation of the complete model of the RC landsailer is made. Process To define the way it’s parts and the general assembly are designed, the process used it’s described: - Parts To model the parts the 3D modeling begins with the element common to themost elements, this being the base, which for it’s design takes al lthe necessities of its components to be defined. Then, when it’s drawed, the attached components are designed as the design progresses. - Assembly When more than one piece has been designed, work is done separately with the general assembly to check that all the pieces fit correctly and that the design is progressing as planned. Changes are made in the process of design, as while designing between parts and the assembly new adjustments and improvements can be seen. 97 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Program For the 3D modeling, a CAD (Computer Aided Design) software known as SolidWorks, specifically the 2021 version, has been used. 5.1 Parts designed Next, the pieces and their forms together with their modifications will be shown and described, which in the end will form the general set, this being the RC landsailer: 5.1.1 Base Figure 55. Final modeling base. Source: self made The base, as has been mentioned in the process, has been the first element to be designed, since it is the central element of the landsailer where all the elements are united. For this design we have taken into account: As a general aspect: - The reduction and optimization of resistance. - The accessibility of the elements that need it As specific aspects: - The dynamics of the landsailer with its L/W ratio Finally it has been dimensioned in a 1:1,15 - The position of the sail - Sail center It has been positioned into the front so the sail can be biger and the center comes forward. - Mast For the positioning of the sail center forward, the mast support is an extension of the direction axis support staying in the top of it. For this reason the hole mast and direction support have been sized biger to resist better the forces. - Position and shape of the battery. The battery is a big element and it have high weight compared to the whole 98 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya product. For this reason it is positioned in the rear as close as possible to the axis to reduce space and have the best lateral resistance as the center of mass comes backward close to the rear wheels. The battery, as it have a cylindrical form, needs to have a toppers to limit it’s movement. - Shape and dimensions of the Step Up The delimitation of the step up zone is made in the left of the base to have a clear assembly. - Receiver shape and dimensions The same is done with the reciever in the right zone. - The clipping of the casing To clip the housing to the base, some notches are made in the base so that the equivalent protuberances in the casing adapt and do not allow it to be removed upwards. 5.1.2 Steering arm Figure 56. Final modeling steering arm. Source: self made The steering arm is designed to go right between the wheel and the base with the steering axle. This reduces the space used, leaving more free for rotation, since having a lot of angle in the direction, the wheel tips over a lot and can touch the ground when turning if it is not well attached to the wheel and have the minimum to transmit the movement. Of course, the arm has been designed to have a good thickness to rotate without the posibility of breaking during it’s use. Although, continuous impacts on the direction arm can have consecuences to it’s durability and performance. that it can break. 5.1.3 Rear wheels anglers 99 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Figure 57. Rear wheels anglers. Source: self made The rear wheels anglers are designed to be compact elements that allows a rear axle that is planar to reduce it’s space and the screw, which is the wheel axle, to be attached at the same time. 5.1.4 Case Figure 58. Final modeling case. Source: self made The case is one of the last element to be designed as it covers all the elements inside the base, including the last. As it can be seen the case have two holes: One for the rope to be attached to the sail to perform traction The other for the alignment of the mast support to enter the mast in. In the back a release of clipage system is made to unclip the case of the base so it can be opened. It have a sleeve with two holes in the sides to let the user pull up with the fingers. This will flex the back of the case releasing the clipage points that are in the zone allowing the user to pull up the case to perform maintenance. 100 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya A hole for the usb micro charger and the switcher on-off are made to allow the usability. 5.1.5 Rims Figure 59. Final modeling rims. Source: self made The wheel rims are designed to allow space for the cover, so that it is possible to put it on and that it does not come out of place with use. It also takes into account the space for the bearings since with its width it is capable of having one on each side to improve the stub. And finally, an aesthetic design is added to the spokes. 5.2 Normalized and bought parts For the rest of the elements a representation of the normalized and bought elements is done taking with reference the dimensions and images. 5.3 Assembly 101 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Figure 60. Final landsailer modeling Source: self made 102 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Figure 61. Final landsailer modeling lateral view Source: self made 103 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Figure 67. Printing; Extrusion ratio configuration Source: Self made For the extrussion ratio is to determine the percentage of material extrussion for the frame and the filling. Those are left to 100% to avoid low filler structure. Supports Figure 68. Printing; Supports configuration Source: Self made 110 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya For the supports it’s choosed to hace a edge of 10 mm surrounding the pieces to have a better fixing to the bed to avoid warping. The supports are applied at a low density to perform a better cleaning. Retraction Figure 69. Printing; Retraction configuration Source: Self made For the retraction configuration its for the retraction of the filament when a movement is done by the extrussor to avoid the filament to still going out of it. It is left as default. When the configuration it’s done the printing process starts. 6.1.2 Sail The sail manufacture is manufactured by the following sequence: - Cloth cutting - Sewing mast and boom edges - Mast, boom and battens cutting Cloth cutting First is drawed with apencil the perímeter of the sail and its rope holes with the dimensions of the blueprints on the cloth, then the cloth perimeter is cutted with the hand soldering iron and a metalic ruler following the lines drawed before and the holes for the rope are done with the same hand solder perforing the cloth with care to don’t make the hole too big. 111 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Sewing the mast and boom edges To sew the mast and boom edges it’s used the Singer sewer with the gutermann thread. For the thread preparation process is followed user manual in the annexes 3 page 41. To sew the borders, the borders are bended with the width wanted in the dorward and reverse directions with a linear pattern. The excess thread is cut with a scissors. Mast, boom and battens cutting The mast, boom and battens cutting it’s done with a cutter. The mast and the boom as comes with the final diameter it’s only needed to cutt it to the right dimensions following the blueprints. Fot the battens as they come with a width of 10x1000mm and are needed of 2mm and different dimensions are cuted for the wide and the lenght. As it’s carbon fiber to cut it longitudinally simply mark the width of 2mm with a pencil and with the cutter making pressure and cutting longitudinally is not needed even the ruler to cut it to perfection thanks to its distribution of the fibers. The rear axle is made with two dimensions of the flat carbon fiber rod that are made the battens. So they’re cutted as the blueprints in the same way as the battens. 6.2 Surface finishing Now that all the printed parts and sail components are finished it’s needed to perform a surface finishing to the parts. 6.2.1 ABS Printed parts For the abs pieces as they have threads at the end, the dimensions are not exact and the supports and fillings must be removed, first use the pack of files to remove and leave the pieces moderately flat. When the sanding is finished we proceed to the application of acetone for the surface finish. For the base this has a very good finish and does not need an application of acetone since the visible part is the lower part that is supported on the base at the time of printing so it has a flat finish. For the casing, the wheel rims, the wheel angles and the steering arm. This process has several variants, but the one that is best applied for small components is the dipping process and for large parts such as the housing the brushing process. For the casing, a brush dipped in acetone is used, which is passed over all parts of the part. As it is a thin piece, it is given a superficial layer and immediately washed with 112 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya water to stop the dissolution process. For the rest of the pieces, they are immersed in acetone for 1 minute and immediately washed with water. During the whole acetone process a mask and safety goggles are used to avoid irritation due to the steam given off by the process. Mast, boom and battens This three, as are made with carbon fiber, when they are cut, they leave visible filaments that can get stuck in the skin, so the edges are sanded with sandpaper. 6.3 Assembly For te assembly it’s divided in parts: - Sail - Steering system - Rear wheels and axle - Electronics 6.3.1 Sail For the sail, the battens and the boom are glued with adhesive to the sail. First the battens are positioned on the sail in a flat surface. Then the nylon adhesive is cutted longitudinally to 4 mm and with the length of the batten and subsequently placed in the center of the batten making pressure in the borders that make contact with the sail so it’s glued correctly without wrinkles. The exceed of nylon adhesive is cutted with a scissor. The process is repeated in all the battens. Then the boom is introduced in the boom sheath and closed witha bended nylon adhesive that surround the hole. To make sure that it has been well glued, it’s pressed firmly on the sides of the sheath. With this the sail is done. 6.3.2 Steering system The steering system is assembled achieving this process: Stering arm - wheel - First the front wheel rim is assembled with its cover syply inserting it in the rim. - The bearings are assembled with pressure in the both laterals of the weel rim axle. - Then the steering arm and the M2x16 screw are assembled from the exterior side and a nut is then threaded until it stops against the inner side of the steering arm. Then the wheel is assembled in the screw and another nut is positioned in the final of the screw to block the wheel. Note that the nut has to 113 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya be tight enough to don’t let the wheel balancing but lead a smooth roll. Steering arm - gear - A M2x30 screw is passed trough the steering arm and a nut is threaded til it blocks the steering arm. - Then it’s assembled all the direction form the screw trough the direction axle onthe base. - In the other side of the axle, a nut is threaded til it blocks the position of the screw and let it moves inside the base direction axis - In the end the gear is screwed and blocked with another nut Gear-gear - The other gear is assembled with the servo - The base bed of the servo is glued with termoplastic and the sevo it’s slided in it until it’s aligned with the other gear. 6.3.3 Rear wheels and axle Rear axle - For the rear axle formed by the two flat carbon fiber rods are positioned symetric in the base axle support by sliding them in the hole. - To fix the position it’s used the termoplastic gun in the interior of the axle hole Rear wheels and anglers - The wheel procedure is the same as the front wheel regarding to the wheel cover and the - Then the edges of the axle are inserted in the wheel anglers by pressure. - The M2x18 are passed trough the wheel anglers and a nut is threaded until the blocking. - Then the wheels and a nut are assembled to the screw to finish the asembly. 6.3.4 Electronics When all the mechanics are assembled it’s time to finish with the electronics. First the welding process is performed to have a better range of motion and welding accuracy. For the soldering process, tin filament and soldering iron are used. By joining the component and the cable at the soldering point and adding the tin filament, the soldering iron melts the tin, and when it cools down, it is already soldered. The connection is made according to product information and data sheet. All the components are positioned in it’s zone with the positioning regarding to the blueprints and gluing them with the thermoplastic gun to fix them in the position. With everything in its place, the product looks approximately like this: 114 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Figure 70. Model Source: Self made 115 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya 7. POJECT COST Finally, the set of costs involved in the development and creation of the RC landsailer throughout the project are shown. The cost will be divided into 3 parts: - Engineering costs - Component costs - Production costs 7.1 Engineering cost This project is an engineering project, where different engineers do all the process that has been carried out in the memory. In this case the work has only been done by one engineer, who is the author of the project. The design process carried out is divided into several elements summarized in the following table: Table 17. Engineering Cost. Source: Own elaboration. To simplify the price at the time of remunerating the different actions within the project these become 30 € / h which is an average price pulled upwards taking into account that the work is done by a student who will graduate in Industrial Design Engineering and Product Development, so really this cost is approximate. Although the hours showed in the table are the real hours spended in the realization of the project 116 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya processes. 7.2 Components and materials costs For the purchase of components and materials, all materials necessary for the realization of a single RC landsailer are taken into account. However, the initial costs incurred for the production will be shown first and then broken down according to their use. Therefore the electrical, mechanical, standardized and assembly elements listed and quoted below are taken into account: Table 18. Components costs. Source: Own elaboration. To obtain the costs of the components of the final product, it’s first broken down the costs of the components by cost of the product lot plus shipping, then by comparing the amount that comes in the lot and the units needed, the percentage of the lot spent with what together the total price of the lot it’s made to get the individual price spent for the manufacture of 1 unit, which added together gives the total cost of 1 product. The prices of the components are the actual purchase prices of the product, which have been searched among the different suppliers to find the best price and quality. 117 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya The ABS filament needed to print will be quoted in the production cost. 7.3 Production cost As for the production cost, the hours required to manufacture the product have already been quoted in the engineering costs section, which is the author of the project who manufacture and build the product. So what will be taken into account will be: - The cost of the material used by the 3D printer to print the parts - Machinery wear and tear - The electricity used during the process For these three aspects you can see your quotation from the following table: Table 19. Production costs Source: Own elaboration. As it can be seen in the tavle, fist to obtain the costs of the ABS used for the final product, it’s first accounted what costs 1 kg of ABS, then by comparing the real use of ABS can be get the percentage spent in each part with what together the total price of 118 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya the ABS used for the product is acquired. Then for the XYZ Da VInci Pro 1.0 is accounted what cost have and the warranty duration. Then comparing it with the printing duration the percentage of the printer that is used to print one product it’s obtained, which whith the machine price can be obtained the wear and tear. (Garantía del producto | Centro de ayuda | Impresora 3D - XYZprinting | Impresoras 3D | Modelos de impresoras 3D, s. f.) For the electricity cost the max consumption of the priner is taken, and combined with the time printing the total electricity consumption is obtained. Then with the current price of the electricity can be obtained the electricity cost to produce the printed parts for one product. (Precio de la luz: en mayo la factura sigue disparada, s. f.) 7.4 Final cost After having made all the cost analysis of the different aspects involved, the total cost of the sum of these can be obtained. Table 20. Total project cost Source: Own elaboration. As can be seen in the table above, the final cost of the project is 18.296€ although something must be taken into account, and that is that the engineering cost amounts to 18.120 € which is the vast majority of th eprice. To amortize the project taking in account the engineering cost leads to the need of an engineering process for mass production and sale. 119 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya Arjen van der Tol breaks the kite buggy world speed record with 133,4 km/h. (s. f.). Surfertoday. https://www.surfertoday.com/kiteboarding/arjen-van-der-tol-breaks-the-kite-buggy-world-sp eed-record-with-1334-kmh#:~:text=4%20km/h-,Arjen%20van%20der%20Tol%20breaks%2 0the%20kite%20buggy%20world,with%20133,4%20km/h Contributors to Wikimedia projects. (2008b, 30 de agosto). Wind-powered vehicle - Wikipedia. Wikipedia, the free encyclopedia. https://en.wikipedia.org/wiki/Wind-powered_vehicle Contributors to Wikimedia projects. (2009, 12 de agosto). High-performance sailing - Wikipedia. Wikipedia, the free encyclopedia. https://en.wikipedia.org/wiki/High-performance_sailing#cite_note-Bethwaite-2 Let's Begin At The Beginning... How Boats Sail. (s. f.). New Bern High School Naval Junior ROTC Sailing. http://nbnjrotc-sail.blogspot.com/2011/01/lets-begin-at-beginning-how-boats-sail.html Squatriglia, C. (2008, 21 de agosto). Riding the Wind Into the Record Book. Wired. https://www.wired.com/2008/08/wind-powered-ra/#:~:text=Instead%20of%20the%20conve ntional%20sail,the%20wing%20and%20the%20wheels. Breaking the speed sailing world record by standing inside a sail >> Scuttlebutt Sailing News. (s. f.). Scuttlebutt Sailing News. https://www.sailingscuttlebutt.com/2014/02/20/breaking-speed-sailing-world-record-standin g-inside-sail/#:~:text=The%20current%20overall%20speed%20sailing,highly%20engineere d,%20highly%20funded%20project. Instructables. (2012, 15 de mayo). The Complete Guide to RC Electronics. https://www.instructables.com/The-Complete-Guide-to-RC-Electronics/ ¿Qué es el voltaje y para qué sirve? Voltios, vatios y amperios. (s. f.). 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Kemp. https://www.kemp.es/metodologia/que-es-el-mind-mapping-o-mapas-mentales/ Performance RC Landsailers: Model Design Tools & Tips. (s. f.). Performance RC Landsailers - Home of the LS Radio Control Model Landyachts. http://www.rclandsailing.com/design.html Definition of RIGHTING MOMENT. (s. f.). Dictionary by Merriam-Webster: America's 126 Creation of a radio-controlled car powered by renewable energy Enrique Linares Moya most-trusted online dictionary. https://www.merriam-webster.com/dictionary/righting%20moment Performance RC Landsailers: Model Design Tools & Tips. (s. f.-b). Performance RC Landsailers - Home of the LS Radio Control Model Landyachts. http://www.rclandsailing.com/design.html PLA, ABS & PETG Shrinkage Compensation in 3D Printing – A How to | 3D Printerly. (s. f.). 3D Printerly. https://3dprinterly.com/pla-abs-petg-shrinkage-compensation-in-3d-printing/#:~:text=Shrink age%20in%203D%20printing%20is,material%20expands%20during%20this%20process Noble, H. (2019, 20 de diciembre). Fibers & Fabrics: A Sailor's Guide to Choosing Sailcloth | North Sails. North Sails. https://www.northsails.com/sailing/en/2019/12/fibers-fabrics-a-sailors-guide-to-finding-the-ri ght-materials Sail Cloth Material - Elvstrøm Sails. (s. f.). Elvstrom Sails - Elvstrøm Sails. https://elvstromsails.com/technology/sail-cloth Nylon vs Polyester - Difference and Comparison | Diffen. (s. f.). Diffen - Compare Anything. Diffen. Discern. Decide. https://www.diffen.com/difference/Nylon_vs_Polyester Noble, H. (2019b, 20 de diciembre). Fibers & Fabrics: A Sailor's Guide to Choosing Sailcloth | North Sails. North Sails. https://www.northsails.com/sailing/en/2019/12/fibers-fabrics-a-sailors-guide-to-finding-the-ri ght-materials What is Nylon and Polyester? (s. f.). Outlife Expert – Explore the Outdoors! https://outlifeexpert.com/nylon-for-tents/ Garantía del producto | Centro de ayuda | Impresora 3D - XYZprinting | Impresoras 3D | Modelos de impresoras 3D. (s. f.). https://www.xyzprinting.com/support/es-ES/Help/warranty Precio de la luz: en mayo la factura sigue disparada. (s. f.). www.ocu.org. https://www.ocu.org/vivienda-y-energia/gas-luz/informe/precio-luz#:~:text=Evolución%20de l%20precio%20de%20la,eleva%20a%2098,88%20euros 127