After a six-year hiatus from the American Solar Car Challenge (ASC), the McMaster Solar Car Team made a return to the solar car racing scene. The team’s participation marked a significant milestone in the revival of a popular McMaster Engineering club.
While away from the competition, the team concentrated on developing a new multi-occupant solar powered vehicle. The COVID-19 pandemic posed significant challenges for the team, including restricted access to facilities. However, despite these obstacles, the team dedicated themselves to extensive work on both mechanical and electrical systems. Their perseverance paid off, and they successfully completed their vehicle in time to compete in the Formula Sun Grand Prix (FSGP), the pre-qualifier for the ASC.
The Formula Sun Grand Prix (FSGP), a track race that took place from July 11 to 19, hosted more than 30 student-run teams across the U.S. and Canada. including McMaster’s Solar Car Team. Teams were required to pass rigorous inspections and perform well in the FSGP races to secure a spot in the ASC. The challenge includes navigating city and highway driving while managing energy and adhering to road regulations.
While McMaster’s team did not move on to secure a spot in the final ASC competition, their time at the FSGP served as the ultimate lesson that the team plans to use as a foundation for building their future success.
Challenges faced and learnings applied
The team applied their academic knowledge to tackle the technical challenges they faced during competition. Insights gained from courses such as COMPENG 2DX3 and ELECENG 2EI4 were instrumental in developing the vehicle’s electrical systems. They utilized their understanding of microcontrollers and circuit design to enhance the car’s performance. Additionally, hands-on experience with carbon fibre work for the aeroshell proved highly relevant to the automotive and aerospace industries.
Attending the ASC was more than just showcasing their technical work, explains team members. It was an eye-opening experience that highlighted the supportive nature of the solar car racing community. The team faced challenges, including reliance on external manufacturing for key components like wheel rims and aeroshell molds. These hurdles were overcome through the camaraderie and generosity of other university teams at the competition, who shared their knowledge and assisted with assembling the McMaster solar car.
“The ASC not only strengthened our team, our knowledge and our confidence but also deepened our relationships with other teams,” says Mark Chen, Level 3 Mechanical Engineering, Solar Project Manager.
The team is particularly excited to bring home and integrate new manufacturing techniques for the aeroshell, effective mounting methods for the solar cells and improved electrical management strategies that they learned from other teams at the competition.
Memorable milestones
The competition was filled with moments that left a lasting impression on the team. For Valerie Stephens, Level 4 Mechanical Engineering, Mechanical Manager, mounting the aeroshell—the car’s exterior—at the competition was a particularly special moment.
“It really brought everything together and made it look like a real car. Additionally, seeing pieces that you’ve been working on for years finally come together is such a gratifying experience,” she says.
Chen recalls a pivotal moment just three days before the competition when the motors of the car were successfully tested for the first time.
“It gave me the confidence that we would be able to finish our vehicle in time for the competition. That confidence allowed me to push through and keep up the pace to work through all the tasks left before we could race,” he says.
Eyes on the road ahead
As they set their sights on the future, the McMaster Solar Car Team is focused on completing their car for the Formula Sun Grand Prix 2025.
“With the main components done, we can now refine details like wiring and the interior dash, waterproofing, mounting the rear brakes and more,” says Chen.
Beyond technical upgrades, the team is also enhancing documentation, training and leadership to ensure future success. Their journey to the American Solar Car Challenge has been marked by perseverance and growth, setting the stage for even greater achievements in the years ahead.
Learn more about the McMaster Solar Car Team at McMaster.