Blue Sky Solar
Roll Cage Design
Back Roll Cage Final Design
Specifications
• Volume = 1.1017e-003 m³
• Mass = 8.648 kg (Back Cage) + 1.7681 kg (Front Cage) Total Mass= 10.4161 kg
• 4130 Steel Pipe Yield Strength ≈ 435 Mpa
Testing
• 6*force of gravity*mass of car ≈ 15000N• Apply 15000N force for the following
scenarios:– Car flips over and immediately the canopy gets
stuck sliding backwards– Car flips over and immediately the canopy gets
caught sliding forwards– Car flips over
Car Flips and Canopy gets Stuck Sliding Backwards
Force applied is shown as a purple arrow
Maximum von-Mises Stress3.9192e8 Pascals
Maximum occurs at weld point shown by red circle.
This is less than the yield strength.
Car Flips and Canopy gets Stuck Sliding Backwards
Maximum Deflection0.0027699 meters
Maximum occurs at top where force is applied. (Red section in
diagram )
Car Flips and Canopy gets Stuck Sliding Forwards
Force applied is shown as a purple arrow
Maximum von-Mises Stress3.9192e8 Pascals
Maximum occurs at weld point shown by red circle.
This is less than the yield strength.
Car Flips and Canopy gets Stuck Sliding Forwards
Maximum Deflection0.0027699 meters
Maximum occurs at top where force is applied. (Red section in
diagram )
Car Flips OverForce applied is shown as a
purple arrow
Maximum von-Mises Stress2.3277e8 Pascals
Maximums occur at weld point shown in red circle
This is less than the yield strength.
Car Flips Over
Maximum Deflection0.0015313 meters
Maximum occurs on arms where force is applied. (Red
section in diagram )
Front Cage• Force down on beam or pushing from the side has the same
stress analysis.• The maximum stress is: 3.886e8 Pascals• The maximum deflection is: 0.0011642 meters• Both are within the constraints and should survive the
impact the car flipping over or receiving a front end collision
Front Cage Stress Analysis
Front Cage Deflection Analysis
Results and Final Considerations
• All displacements and stress values are within acceptable ranges at 6 times the force of gravity
• Decapitation Factor – The bars in front of the driver should help to deflect the array if it is to move during driving.
Roll Cage inside Canopy
As can be seen the roll cage tightly hugs the canopy thereby
providing the most space possible for the driver. This will
keep the driver from coming into contact with the roll cage
in the event of an accident.