The University of Minnesota student-led Solar Vehicle Project team took first place in the Multi-Occupant Vehicle category in the 2022 American Solar Challenge, a biennial collegiate competition in which teams race solar-powered cars between 1,000 and 2,000 miles across North America. The students’ solar vehicle, named “Freya,” is a two-passenger car that can travel about 400 miles with a fully-charged battery. The 1,000-watt array of solar panels on the top of the car charge a lithium-ion battery that powers the vehicle. The U of M students were the only team at the competition who designed and built their own motors.
Electro-Matic provided Cable Assemblies for this project and will be providing TE Intercontec connectors for their next vehicle.
The 2022 winning project!
Cables and Connectors
Per the regulations of one of their races, they chose the very robust chainflex cabling, to double-insulate to account for the high voltage. While browsing different types of cabling and connector combos, they came across the 940 TE Intercontec speedtec connectors which met their current requirements.
The size of these connectors fit well in the design, as the vehicle being built was constrained by size. Additionally, the high-quality connection reliability, as well as the quick lock and unlock feature, was a highlight of the project.
Motor Controllers and TE Intercontec Speedtec Connectors
Their motor controllers, the wavesculptor 22’s, were connected to the cable by placing ring terminals on each phase wire, then connecting them with a bolt to the physical controller.
This design worked well because the singular wire helped reduce some of the wiring near the physical controller. The combined wire made it easier to pass from the wheel well to the high voltage compartment
Motor/Suspension Assembly
The TE Intercontec speedtec connector was on the backside of the motor, a location that can be difficult to reach and this connector gave them the flexibility to interchange motors on the fly, and even during the race in the event of motor failure.
Even junior members of the team and non-electrical engineers were able to interact with the motors and safely connect and disconnect them from power.
Custom built dynamometer to characterize custom motors
The compactness of the cables made it much easier to remove the motor from the car and transport it to the dynamometer, which they use to test and characterize their custom motors.
"These connector assemblies have definitely contributed to our success in the American Solar Challenge this past summer. We were able to place 1st in the Multiple Occupant Vehicle Class.
The reliability and safety that these connectors have allowed us to even be able to finish the race. We are so grateful for your sponsorship."
— University of Minnesota Solar Vehicle Project team
The U of M Solar Vehicle Project team has been competing in the American Solar Challenge since 1993, but this is the first time in history they’ve crossed the finish line first, after coming in second place in both categories seven times in the past.
Electro-Matic is proud to be able to sponsor the University of Minnesota student-led Solar Vehicle Project team, and looks forward to seeing what they do in the future!
