← All projects

Solar Array Hinging and Charging Setup

Designed fast, stable array hinges and supports for roadside camp charging.

Mechanisms · Solar · Operations · Regulations · Solar Racing
Array hinge detail in CAD
Carbon support poles and hardware
Array deployed for charging in the field

Outcomes

  • Improved array angle range for morning and afternoon charging.
  • Repeatable opening for repairs and installations.
  • Stable in wind.

New to Solar Racing? Read What is Solar Racing? for a quick overview. For how this interfaces to the car structure, see Carbon Bulkheads and Interfacing. The motion concept follows the Canopy Opening Mechanism for Driver Egress.

Requirements

Quick deploy, secure stays and safe handling in wind. Hinge axes were chosen to give useful tilt without fouling cables or the shell. Target opening was ~60° so early-morning and late-afternoon charging is worthwhile with our limited battery buffer.

Design

The hinge is a compact four-bar. The geometry hits the 60° target while maintaining clearance to the shell and wiring. Tilting reduces array incidence to the sun, increasing collected power at low sun angles.

Effect of tilt angle on collected solar irradiance

Effect of tilt angle on collected irradiance. Tilting at the ends of the day recovers power a horizontal array would miss.
Effect of tilt angle on collected irradiance. Tilting at the ends of the day recovers power a horizontal array would miss.

Top hinge mounts land on composite bulkheads bonded to the topshell. Bottom mounts pick up hard points on the main lower bulkheads. Space around the lower mounts is tight, so hardware is low-profile.

Bonding of the topshell bulkhead

Bonding a topshell bulkhead that carries the upper hinge. Adhesive bondlines are controlled and an overlaminate is applied.
Bonding a topshell bulkhead that carries the upper hinge. Adhesive bondlines are controlled and an overlaminate is applied.

Support poles are 24 mm OD carbon-fibre tubes. Ends are machined aluminium with brass tophat bushings to reduce friction. Countersunk bolts avoid fouling in the narrow bay.

Support pole CAD with end inserts

Support pole CAD. Grooved aluminium inserts increase bond area and resist pull-out.
Support pole CAD. Grooved aluminium inserts increase bond area and resist pull-out.

To bond inserts, grooves were machined into the aluminium to increase bond area. An aluminium plate jig kept the poles straight while the structural epoxy cured. Hole patterns were drilled with laser-cut acrylic jigs. Backing plates on the rear face of the top bulkheads distribute tension loads.

Front view of support poles

Front view — low-profile fasteners clear the bay.
Front view — low-profile fasteners clear the bay.
Rear view of support poles

Rear view — backing plates spread tension into the bulkhead.
Rear view — backing plates spread tension into the bulkhead.
Array open on the start line

Start-line open position for checks and comms access.
Start-line open position for checks and comms access.
Field deployment for charging

Field deployment at a stop with stays set to angle.
Field deployment at a stop with stays set to angle.

Two additional carbon poles act as stays to hold the array open at the desired angle.

Sunset charging at the track

Sunset charging at the track.
Sunset charging at the track.

Materials and notes

  • Four-bar links and mounts in aluminium with brass tophat bushings
  • 24 mm OD carbon-fibre tubes with bonded aluminium inserts
  • Structural epoxy with controlled bondline thickness and curing jigs
  • Laser-cut drill jigs for hole accuracy and repeatability
  • Low-profile, countersunk fasteners where clearances are tight

What I would refine next

  • Add more adjustability to ensure first-install fitment
  • Add opening assistance (e.g., gas struts) for drivers at control stops
  • Install before the solar array is fitted to improve access and reduce shell mass during setup