Evaluation of aerodynamic and structural design to enhance solar energy absorption for e-Cars

Abstract

The integration of photovoltaic (PV) systems into electric vehicles (EVs) offers a promising solution for extending driving range and reducing dependence on grid-based charging. However, vehicle-integrated PV systems are limited by aerodynamic drag, structural integration challenges, thermal losses, and inefficient energy management. This study presents a multidisciplinary simulation framework to evaluate aerodynamic and structural optimization strategies for enhancing solar energy absorption in EVs. Computational fluid dynamics (CFD) was used to analyze airflow and reduce aerodynamic drag, while finite element analysis (FEA) assessed structural integrity and weight optimization after PV integration. PV energy flow and thermal models were also developed to evaluate power generation, battery charging behavior, and temperature-dependent efficiency losses. The optimized design reduced the drag coefficient from 0.310 to 0.236, a 23.7% improvement, while maintaining a structural safety factor above 1.75 through lightweight composite materials. The optimized PV configuration increased solar conversion efficiency from 17.6% to 22.3% and daily energy generation from 2.91 kWh/day to 3.75 kWh/day, corresponding to a 28.9% increase in harvested energy. Thermal management strategies lowered average PV operating temperature by about 12 °C, improving efficiency by an additional 5%–7%. Unlike existing studies that examine aerodynamic, structural, or PV performance separately, this work provides a unified framework that evaluates their combined impact on solar energy harvesting in EVs. The proposed integrated design approach demonstrates that coordinated aerodynamic, structural, thermal, and energy-management optimization can substantially improve the practicality and energy contribution of solar-assisted EVs in high-irradiance environments.