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.