project Intent / Objective

The Ford Mini Solar Electric Car was conceived from my passion for sustainable transportation and my admiration for Henry Ford, whose innovations reshaped the automotive world. This mini EV blends historical inspiration, modern electronics, and mechanical engineering into one compact, future-focused solar electric vehicle.

I am a university dropout (dropout in level 300) due to financial difficulties, but I refused to stop learning. Instead, I pursued self-directed education in mechanical engineering, electrical engineering, PCB design, and Fusion 360. This project stands as proof of what determination, creativity, and self-learning can achieve.

The goal is to demonstrate how a compact, two-passenger solar EV can operate efficiently while remaining practical. Core systems include:

. In-wheel QS FatWheel hub motors, one per rim, for high torque and space efficiency.

. Maytech VESC motor controllers for smooth control and regenerative braking.

. Texas Instruments MPPT for optimized solar energy harvesting.

. Libre Solar BMS (BQ76952) for safe cell management and protection.

The project also honors Dr. Alexandra Escoffery, who invented the first solar electric car in 1869, acknowledging the long history of renewable transportation.

In future iterations, this vehicle will incorporate self-driving capabilities through sensors and autonomous control systems. Ultimately, the Ford Mini Solar Electric Car merges history, sustainability, electronics, and engineering, built through perseverance and passion.

Key Highlights

. Two-Person Seating: Designed to comfortably carry two passengers.

. High-Quality Electronics: TI MPPT + Libre Solar BMS for professional-grade energy management.

. Mechanical Integration: Fully modeled chassis, suspension, in-wheel motors, and battery compartments.

. Energy Efficiency: Optimized solar input, battery protection, and motor performance.

. Forward-Thinking: Planned upgrade for self-driving functionality.

Technical Specifications

. Solar Panel Input / Max Current: ~60 V PV array, 15–20 A

. Battery Pack: 36–48 V, 20–30 A continuous

. MPPT: Texas Instruments MPPT IC

. BMS: Libre Solar BMS (BQ76952 IC)

. Cell Count: 10S Li-ion or LiFePO₄

. Balancing: Passive, via BQ76952

. Motors: QS FatWheel in-wheel hub motors (500 W – 1 kW)

. Motor Controllers: Maytech VESC (supports regen braking)

Component-by-Component Breakdown:

. Chassis

Completed: Full Fusion 360 chassis with motor mounts, suspension brackets, and PCB areas.

Pending: Join all subframes; complete seat mounting.

. Solid Axle Suspension Image Description

The image below showcases the Solid Axle Suspension designed for the Solar EV project. The suspension provides a robust and stable axle solution for small-scale electric vehicles, emphasizing both durability and simplicity.

Key Highlights Visible in the Image

. Solid Axle Design: Demonstrates a single, continuous axle for consistent wheel alignment and stability.

Mounting Points & Geometry: Clear view of suspension mounting locations and overall layout, useful for reference or educational purposes.

. Modularity & Flexibility: Components shown can be adapted or modified to fit various chassis designs.

. Open Design Intent: Created to be easy to understand and replicate, giving viewers an example of a practical EV suspension layout.

. Work in Progress: The steering system was not completed due to project complexity and computer performance limitations. This suspension focuses on the core axle and mounting design, which can be adapted for steering integration in future iterations.

This image serves as a visual reference, helping students, hobbyists, and engineers understand how a solid axle suspension is structured and integrated into a small EV chassis.

. Wheels & Tires

Completed: Fully modeled and integrated with the suspension and chassis

.

. Exterior Components

Completed: Designed grille, headlights, fog lamps, and simple boot belt molding for a clean automotive look.

. MPPT Schematic

Completed: TI-based MPPT schematic for solar charging and system protection.

. BMS Schematic

Completed: Libre Solar BMS (BQ76952) schematic for cell monitoring and balancing.

. MPPT PCB

Completed: Custom PCB with routed copper pours, connectors, and 3D renders.

MPPT Board – 4-Layer PCB Design Strategy (Image Description)

This MPPT board was designed as a 4-layer PCB to improve electrical performance, reliability, and manufacturability for a high-current solar EV application.

Layer Stack-Up & Component Placement Strategy

. Top Layer (User Interface & Power Entry):

All connectors and large electrolytic capacitors are placed on the top layer. This allows:

. Short, low-impedance paths for high-current input/output connections

. Easier soldering and inspection

. Cleaner mechanical integration into the vehicle enclosure

Bottom Layer (Control & Power Electronics):

All ICs and control circuitry are placed on the bottom layer. This helps:

. Separate sensitive control electronics from high-current interfaces

. Reduce electrical noise coupling

. Improve thermal spreading across the PCB

Inner Layer 1 – Solid Ground Plane:

One full inner layer is dedicated entirely to ground (GND).

This provides:

. A low-impedance return path

. Improved EMI/EMC performance

. Stable reference ground for analog and digital sections

Inner Layer 2 – High-Power Distribution Layer:

The second inner layer is dedicated to high-current power routing, carrying solar input and battery charging currents.

This approach:

. Minimizes voltage drop

. Reduces trace heating

. Keeps high-power paths short and well-controlled

Why This Layout Matters

This 4-layer architecture greatly improves:

. Electrical efficiency

. Noise immunity

. Thermal behavior

. Long-term reliability under continuous solar charging conditions

By separating power handling, grounding, and control electronics, the design remains robust, clean, and scalable, while still being DIY-friendly and manufacturable.

This PCB demonstrates proper professional power-electronics layout practices, making it well-suited for solar EV systems, educational research, and real-world renewable energy applications.

Key Features Highlighted in the Image

SM72295-based MPPT Controller: Core IC responsible for efficiently managing solar input and battery charging.

Input & Output Terminals: Clearly visible PV+ and PV- inputs from the solar panel, and VOUT+ and VOUT- outputs to the BMS.

Compact Layout: Components arranged for minimal trace resistance and efficient current flow.

Power Electronics Components: Capacitors, inductors, and MOSFETs are clearly visible, emphasizing high-current handling and reliability.

Educational Value: The image provides a clear view of component placement and board design, suitable for makers and students learning about solar power management.

This MPPT board images serve as a visual reference for the design, layout, and integration of a custom solar energy management system in a small-scale EV.

Rendered Image of MPPT Top Layer

Rendered Image of MPPT Bottom Layer

. BMS PCB

Completed: Custom PCB with multi-cell sensing lines and 3D visuals.

BMS Board – 4-Layer PCB Design & Component Placement Strategy

The Battery Management System (BMS) board was designed on a 4-layer PCB to ensure electrical stability, low noise, and safe power handling, while still keeping the layout simple and beginner-friendly.

Layer Stack-Up Overview

. Top Layer:

Primary component placement and signal routing

Houses almost all active components, including:

. Battery monitoring and protection ICs

. MOSFETs for charge/discharge control

. Voltage sensing networks

. Balancing circuits

. All connectors and interface components

Inner Layer 1 (Solid Ground Plane):

Dedicated continuous ground plane to:

. Minimize noise and EMI

. Improve signal integrity

. Provide a stable reference for sensitive analog measurements

Inner Layer 2 (Power Plane):

Reserved for high-current and power distribution paths, ensuring:

. Low resistance current flow

. Reduced voltage drops

. Improved thermal performance

. Bottom Layer:

Only a few passive components (resistors and small capacitors) are placed here, positioned close to their related circuits to:

. Shorten critical signal paths

. Support filtering and sensing functions

. Keep the main assembly layer uncluttered

Why This Placement Strategy Works

Even though the BMS uses a 4-layer stack-up, concentrating most components on the top layer provides several advantages:

. Simplifies assembly and soldering

. Makes visual inspection and debugging easier

. Improves manufacturability

. Reduces risk of assembly errors

. Keeps the design educational and DIY-replicable

The inner layers handle electrical performance, while the outer layers focus on usability and clarity.

Design Philosophy

This BMS layout reflects a balance between:

. Professional PCB engineering practices (ground plane, power plane, controlled routing)

. Practical real-world usability for hobbyists, students, and experimental EV projects

The result is a robust, safe, and scalable 4-layer BMS design that remains easy to understand and reproduce.

Key Features Highlighted in the Image

. BQ76952-Based Protection IC: Handles cell balancing, monitoring, and safety management.

. Cell Connection Pads: Clearly labeled C1, C2, … showing where each cell connects to the BMS.

. Main Power Connections: BAT+, BAT-, PACK+, PACK-, and LD terminals are visible for battery integration and load distribution.

. Modular Layout: Components arranged logically for clarity, easy maintenance, and understanding of electrical flow.

. Educational Value: Offers a visual guide to BMS design, component placement, and safe battery management practices.

This BMS board image acts as a reference for safe battery integration, showing both the circuit architecture and the practical layout of protection components for small EV projects.

Rendered Image of BMS Top Layer

Rendered Image of BMS Bottom Layer

. Motors & Controllers

Completed: QS FatWheel hub motors + Maytech VESC integration.

Pending: Full wiring animation to PCBs.

. Wiring (Power & Signal)

Completed: Planned routing paths.

Pending: Realistic animation in Fusion 360.

Wiring Layout Description

The 2D wiring layout below clearly shows the complete power flow of the Solar EV using a simple and easy-to-follow structure. The connections are arranged in the exact sequence used in the project:

Solar Panel → MPPT → BMS → Battery → BMS → Load.

This layout highlights both the charging path (Solar Panel → MPPT → BMS → Battery) and the discharge path (Battery → BMS → Load). By routing the load through the BMS, the system ensures proper cell protection, overcurrent monitoring, and safe power delivery to the vehicle.

All components are represented with clean rectangular blocks and direct line connections so viewers can quickly understand how power enters, is managed, stored, and finally delivered. The clear separation of positive and negative wires also improves readability and makes the system architecture easy to interpret without referencing complex 3D models or animations.

This 2D wiring layout provides a professional and accurate representation of the electrical design, making it suitable for documentation, judging, and replication by others.

. Dashboard & Steering System

Pending: Not completed due to PC performance limitations.

. Seats & Interior Mounting

Completed: Two-seat layout placeholders.

Pending: Final mounting.

. System Integration

Completed: Major systems integrated (motors, suspension, chassis, PCBs).

Pending: Wiring animation + steering + seats + dashboard.

Work-in-Progress / Future Improvements

Some features — steering system, dashboard, wiring animation, seat mounts, and fully joined chassis — remain unfinished due to computer performance limitations as the project grew in complexity.

Planned upgrades:

. Full steering system

. Wiring harness and animation

. Dashboard and controls

. Enhanced battery system

. Self-driving mode with sensors and autonomous navigation

. Final mechanical refinements

CONCLUSION

This Solar EV project brings together efficient power electronics and practical design to demonstrate what small-scale clean mobility can achieve. The custom SM72295-based MPPT, BQ76952 BMS, and optimized wiring architecture work together to capture, regulate, and deliver solar energy with reliability and safety in mind. Each subsystem was modeled and developed with clarity and manufacturability as a priority.

The vehicle chassis has been intentionally left unthickened, allowing anyone to download the STEP file and customize the structure—from wall thickness and mounting points to part integrations and aesthetic changes. This open, adaptable approach makes the design accessible for students, hobbyists, and engineers who want to build on top of it.

Overall, this project aims to inspire curiosity and encourage more creators to explore renewable-energy engineering, rapid prototyping, and sustainable mobility solutions.

Contact

For inquiries, collaborations, or access to project files, you can reach me at:

Name: Kamal Deen

Email: mohammedkamaldeen2424@gmail.com

Feel free to contact me regarding improvements, customization requests, or any technical questions about the Solar EV project.