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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

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blue sky solar

Blue Sky Solar

Roll Cage Design

specifications
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
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
Car Flips and Canopy gets Stuck Sliding Backwards

Force applied is shown as a purple arrow

Maximum von-Mises Stress

3.9192e8 Pascals

Maximum occurs at weld point shown by red circle.

This is less than the yield strength.

car flips and canopy gets stuck sliding backwards1
Car Flips and Canopy gets Stuck Sliding Backwards

Maximum Deflection

0.0027699 meters

Maximum occurs at top where force is applied. (Red section in diagram )

car flips and canopy gets stuck sliding forwards
Car Flips and Canopy gets Stuck Sliding Forwards

Force applied is shown as a purple arrow

Maximum von-Mises Stress

3.9192e8 Pascals

Maximum occurs at weld point shown by red circle.

This is less than the yield strength.

car flips and canopy gets stuck sliding forwards1
Car Flips and Canopy gets Stuck Sliding Forwards

Maximum Deflection

0.0027699 meters

Maximum occurs at top where force is applied. (Red section in diagram )

car flips over
Car Flips Over

Force applied is shown as a purple arrow

Maximum von-Mises Stress

2.3277e8 Pascals

Maximums occur at weld point shown in red circle

This is less than the yield strength.

car flips over1
Car Flips Over

Maximum Deflection

0.0015313 meters

Maximum occurs on arms where force is applied. (Red section in diagram )

front cage
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
results and final considerations
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
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.