It’s a wrap!
A converted warehouse.
It sits in the middle of nowhere, amid a patchwork of fallow open lands and construction sites.
The site, located about ten miles outside the Ann Arbor campus, is patrolled by stray cats, and strewn with wild shrubs, rubble and car carcasses.
But don’t let the looks fool you.
The site is home to a veritable temple of technology: this is where the University of Michigan’s solar cars are designed, built, tested, and shipped.
As I stepped out of the cab, the sound of nail guns mixed with the drone of jigsaws to break the bucolic silence.
Inside the garage, amid gaping engine compartments and hulking pieces of automotive hardware, a couple of students/engineers sat on the pavement floor tightening screws, working up a sweat trying to solve what appeared to be thorny technical problems.
The floor was cluttered with debris: yellow and blue duct tape, an empty soda cup from Taco Bell, a tattered diagram of what seemed to be a brake balance assembly, half-empty Sam’s choice water bottles, a torn yellow duffel bag, and glasses missing a lens.
The workshop was crammed with floor-to-ceiling racks of tools, toolboxes, equipment and heaping stacks of open cartons; the walls were covered with blowups of their work and posters of past solar cars and their developers.
Makeshift tables were overflowing with schematic drawings, technical reports, pictures, financial information, budget sheets, planning materials, and more.
It was your typical car garage without the pungent smell of oil.
Americans drive more than 5 billion miles a day, which accounts for about 40 percent of US oil consumption and 20 percent of the country’s greenhouse-gas emissions.
Michigan solar car effort is partially sponsored by Ford and GM. The giant automakers invested time and money because they see the project as a proving ground for solar technologies that might one day contribute to the effort to help the environment.
Sabina and I visited this warehouse to meet with some University of Michigan students, part of the team that helped design, develop, finance, and race the university’s new solar car, Infinium.
Infinium is scheduled to race in two upcoming competitions.
The first is the 2009 World Solar Challenge, a grueling 1,800-mile race across the Australian outback, considered to be the premiere solar car race in the world.
The second competition is the 2010 North American Solar Challenge, a college-only race that covers 2,500 miles of urban and rural highway through America and the Canada.
Infinium is the latest model for a Michigan program that has won five of the nine North American challenges since 1990.
The solar car is a BIG deal here at University of Michigan: the team is made up of more than 100 students, and faculty and alumni help as much as possible.
Immediately upon entering the garage, my eyes locked on the carbon-fiber custom-built car: Infinium.
One word to describe it?
Sexy.
It is an ultra-light, 16-hp, three-phase, in-wheel electric motor kit, a closed-cockpit marvel of precision engineering, power, and speed (in the 90-mile range).
Its most striking feature is an aerodynamic, wind-dodging shape, made to optimize the impact of airflow, wind resistance and aerodynamic drag, but also allowing aerodynamic efficiency to guide aesthetics.
Solar cars are made from more than 200 components, almost all of them custom-made. Students on the team design the car’s wheels, brakes, battery pack and hubs. Every aspect is aerodynamically designed, from the body to the narrow-windowed fairings.
Beneath the sun/energy-absorbing shell lies a web of nifty electrical engineering. That’s all I’m going to say about that, partly because I’m not sure I know what I’m talking about here, but mainly because it is confidential/classified info ( this is, after all, a multimillion-dollar competition).
In fact, we learned that some of the engineers’ biggest challenges was to come up with inexpensive methods for producing a lightweight, high-strength body that could withstand the rigors of the Australian outback and still be molded into the crazy shape they envisioned.
It’s this last point - that a winning vehicle has to be safe and ready to be manufactured at a reasonable cost - that separates the fantasy cars from those that actually take part in the competition.
The team has been trying a number of options, from streamlined versions of existing technologies to completely novel contraptions.
Ford and other behemoth automakers are sure to be watching carefully for interesting technologies. If the team designs, say, a clever hybrid engine that could improve the electric range of a Chevy Volt, it could sell the design to GM and emerge a big winner regardless of whether it does well in the race.
Steve Hechtman, for his part, is playing to win. Steve, who graduated in the Spring of 2009 with a major in electrical engineering, has been an integral part of the University of Michigan’s solar car “dream team” for four years, helping them capture last year’s North American Solar Challenge championships. This year, as the project manager, he oversees the round-the-clock operations: designing, engineering, building, checking, testing, developing, and running the solar car.
Of course, savvy engineering isn’t the only way to get an edge in this fiercely competitive world.
The program is made of four divisions: Business, Operations, Engineering, Strategy. They all work hand in hand.
It also helps to know what the weather will be like, for example. Consequently, the team routinely gets the help of student meteorologists to get an edge.
Steve was accompanied by Chris, an engineer and a sophomore at U of M. His corn-fed, all-American good looks can be misleading. He is in fact one of the many intensely competitive, die-hard students who shape their college careers almost exclusively around the solar car, so dedicated to the project that he didn’t think twice about taking last spring semester off in order to fully help the team build the 2009 car.
The students gave us a tour of the workspace. They showed us the ‘office’ where engineers and designers would spend days hunched over drawing boards, sketching a faster, smoother solar car - one that could help the university capture its first ever World Championship (the team has finished as high as 3rd three times) or at least nibble into the Dutch unassailable dominance (they have never been defeated in the World Championship!).
And sometimes most of the day is spent discussing the nuts and bolts of creating a winning solar car.
Like Steve, Chris is convinced that the three-wheeled car they’ve built has a legitimate shot.
As we finish our tour, more students pour through the doors, mobile phones pressed to their ears, empty backpacks flapping on their shoulders.
They looked smart, organized, and restless.
The students, most of them engineers, dropped their backpacks and immediately get to work, producing renderings and computer models of the solar car, discussing validation of the math-based analysis and physical testing, tweaking in their laptops last-minute diagnostic software for an upcoming test run.
These like-minded wide-eyed dreamers create technology the old-fashioned way: by locking up the doors behind them and sweating and bleeding until the job is done right. It’s a routine that never ends.
But again, they don’t want it to end.
And it’s hard not to get caught up in the team’s enthusiasm.
The place is pulsing with opportunity, full of inspired creators and devoted workers. The mood is egalitarian; there are no special treatments for team leaders or older team members. They are free to choose which aspect of the project they work on and whom to partner up with on it.
In this democracy, all are young and equal college students.
They symbolize what tomorrow could be like: shiny and happy, a clean, lucrative and electric force that could reverse the auto industry’s decline.
In Michigan, the future has never looked so green… Or should I say blue?