SOLAR STREET LIGHTING SYSTEM

DESIGN AND ANALYSIS OF SOLAR PV SYSTEM

(SOLAR STREET LIGHTING)

Major project report

Submitted by

SUBHANKAR DASH-1241019177

NISHA KUMARI-1241013049

SIDDHARTH S.PATI-1241013256

KUMAR SANKET-1241013253

(8TH Semester and Section-‘D’)

DEPARTMENT OF ELECTRICAL ENGINEERING

Institute of Technical Education And Research

SIKSHA ‘O’ ANUSANDHAN UNIVERSITY

Bhubaneswar, Odisha, India

(May 2016)

ii

CERTIFICATE

This is to certify that the project report titled “DESIGN & ANALYSIS

OF SOLAR PV SYSTEM (SOLAR STREET LIGHTING )” being submitted by

(SUBHANKAR DASH,NISHA KUMARI,SIDDHARTH S.PATI,KUMAR SANKET) to the

Institute of Technical Education and Research, Siksha ‘O’ Anusandhan University,

Bhubaneswar, Odisha, India for the partial fulfillment for the degree of Bachelor of

Technology in Electrical Engineering is a record of original work carried out by them under

my supervision and guidance. The project work, in my opinion, has reached the requisite

standard fulfilling the requirements for the degree of Bachelor of Technology. The results

contained in this thesis have not been submitted in part or full to any other University or

Institute for the award of any degree .

Dr Renu Sharma

(H.O.D)

( DEPT OF ELECTRICAL ENGG. ITER)

iii

ACKNOWLEDGEMENT

We would like to express our deep gratitude to our esteemed faculties who have

always been source of motivation and firm support throughout the project. We would also

like to convey our sincerest gratitude and indebtedness to all Lab faculties and staff of

Department of Electrical Engineering, ITER, who bestowed their great effort and guidance at

appropriate times without which it would have been very difficult on our project work.

An undertaking of this nature would have never been attempted without deriving

reference and inspiration from the works of others whose details are mentioned in references

section. We acknowledge our gratitude to all of them.

Further, we would like to express our feelings towards our parents and God who

directly or indirectly encouraged and motivated us during this undertaking.

iv

DECLARATION

We declare that this written submission represents our ideas in our own words

and where other’s ideas or words have been included,We have adequately cited and

referenced the original sources. We also declare that we have adhered to all principles of

academic honesty and integrity and have not misrepresented or fabricated or falsified any

idea in our submission. We understand that any violation of the above will be cause for

disciplinary action by the University and can also evoke penal action from the sources which

have thus not been properly cited or from whom proper permission has not been taken when

needed.

Date: ————– Signature of students

SUBHANKAR DASH

NISHA KUMARI

SIDDHARTH S.PATI

KUMAR SANKET

v

REPORT APPROVAL

This project report entitled ”DESIGN & ANALYSIS OF SOLAR PV

SYSTEM(SOLAR STREET LIGHTING )” by

1. SUBHANKAR DASH(1241019177)

2. NISHA KUMARI(1241013049)

3. SIDDHARTH S.PATI(1241013256)

4. KUMAR SANKET(1241013253)

is approved for the degree of Bachelor of Technology in Electrical

Engineering.

Date: ——————-

Place: —————— Examiners

————————————————–

————————————————–

————————————————–

HOD

————————————————–

vi

ABSTRACT

It is obvious that the rapidly growth of business and population are putting

such a pressure on world power resources as energy demand increases day by day. How to

reasonably utilize green energy and keep sustainable development is the most important

challenge now-a-days. As a huge green energy source generated from the sun, PV industry

will gain the best opportunity to grow up. We should grasp the opportunity to build the most

suitable environmental friendly PV power plant, and welcome a better tomorrow.

In this paper we are focusing on hybrid charge controller with charge

controller circuit which protects the battery by avoiding overcharge or excessive discharge

through the load, which can also extend the battery performance or life span. We also

demonstrate the dusk to dawn operation using light dependent resister, relay and other

circuitaries.

vii

TABLE OF CONTENTS

Certificate---------------------------------------------------------------------------------------------------------------- i

Acknowledgement----------------------------------------------------------------------------------------------------- ii

Declaration----------------------------------------------------------------------------------------------------------- iii

Report Approval------------------------------------------------------------------------------------------------------ iv

Plagiarism check Certificate---------------------------------------------------------------------------------------- v

Abstract------------------------------------------------------------------------------------------------------------------ vi

1 Introduction 1.1 The Board Statement Of Designing Problem 04 1.2 Student Outcome & Bloom’s Taxonomy 04 1.3 Design Check Point 05 1.4 Design Team Formation And Team Charter 07

2 Customer Needs Recognition 2.1 Task Listing And Monitoring 09 2.2 Questionnaire Method 10 2.3 Interview Method 13 2.4 Organizing And Prioritizing Customer Need 14 2.5 Problem Statement With Requirement And Constraint 15

3 Function Decomposition 3.1 Task Listing And Monitoring 18 3.2 Function Tree By FAST Method 19 3.3 Function Tree By Subtract And Operate Procedure 20 3.4 Function Tree By Energy Diagram 22

4 Product Tear 4.1 Task Listing And Monitoring 24 4.2 Product Teardown 25 4.3 Post Product Teardown Reporting 27 4.4 Engineering Specification 30

5 Product Architecture 5.1 Task Listing And Monitoring 32 5.2 Modular Design By Basic Clustering 33

6 Concept Generation 6.1 Task Listing And Monitoring 35 6.2 Brain Storming 36 6.3 Morphological Analysis 37 6.4 Assembly Sketches Concept Variants 38

7 Concept Selection

viii

7.1 Task Listing And Monitoring 40 7.2 Technical Feasibility By Applying The Knowledge Of Mathematics, 41 Science And Engineering

8 Product Embodiment 8.1 Task Listing And Monitoring 43 8.2 Refining Geometry And Layout 44 8.3 System Modeling 45

9 Product Metric Model 9.1 Task Listing And Monitoring 47 9.2 Model Selection By Performance Specification 48

10 Design For Manufacture, Assembly & Environment 10.1 Task Listing And Monitoring 50 10.2 Applying Design Guideline 51 10.3 Manufacturing Cost Analysis 52 10.4 Design For Environment 54

11 Analysis And Numerical Model 11.1 Task Listing And Monitoring 56 11.2 Spreadsheet Search 58

12 Physical Prototype 12.1 Task Listing And Monitoring 63 12.2 Mock Up Material And Processes 64

13 Prototype Testing And Improvement 13.1 Task Listing And Monitoring 68 13.2 Design Of Experiment 69

13.3 Improvement 72

14 Final Product 14.1 Task Listing And Monitoring 74 14.2 Final Product Fabrication 75

15 Conclusion 15.1 Conclusion 83 15.2 Group Learning 83 15.3 Individual Learning 83

16 Reference 84 17 Appendix 85

ix

LIST OF TABLES

Table 1.1: student outcomes 02

Table 1.2: learning levels 04

Table 1.3: course outcomes 05

Table 1.4: design checkpoints and student outcomes 06

Table 1.5: time line for design checkpoints 07

Table 1.6: team allocation and problem selection 07

Table 1.7: team charter 08

Table 4.2 Sop device worksheet 25

Table 4.3 bill of materials 27

Table 5.1: work done by each member 32


Table 6.2 partial brain storming 36

Table 6.3 general morphological matrix 37

Table 6.4 idea generator 38


Table 7.2 function for customer needs 41




Table 10.2 DFA guidelines 51

Table 10.1 cost estimation/ analysis 55



Table 12.2 component list 64


x

Table 13.2 design of experiments 69

Table 13.3 bill of materials 72


xi

LIST OF FIGURES

FIG 2.1 Affinity diagram 12

FIG 3.1 Fast diagram 16

FIG 3.2 Function tree 17

FIG 3.4 black box 22

FIG 4.1 House of Quality 30

FIG 5.1 Clustered function structure 33

FIG 8.2 Layout diagram 44

FIG 12.1 charge controller circuit diagram 62

FIG 12.2 Dusk to dawn circuit diagram 62

FIG 12.3 switching circuit diagram 63

FIG 12.4 power circuit diagram 64

1

Chapter 1

INTRODUCTION

2

1.1 .The broad statement of design problem

Present civilization is on a starve of energy for fulfilling their demand. So

there are much use of conventional energy occurs, which in turn creates the environment

pollution at a large scale and their quick extinction from the earth crust as much fossil fuels

are used. So by paying heed into this alarming effect and to reduce its impact, Renewable

Energy Sources are need to be used. So our objective is to implement & design the solar PV

cell in street lighting system

Background Theory:

The main objective of our project is to generate electrical energy

through solar panel from sun. For that the main components which are used in our project

are:

1. Solar Panel

2. Charge Controller circuit

3. Battery for storage

4. Transformer for power circuit

5. Light Dependent Resistor (LDR)

6. Light Emitting Device (LED assembly)

1. Solar Panel: Here we are using a solar panel of 12V, 20Watt. The main objective is

to generate electrical energy by absorbing heat energy from the sun. Solar panel

absorbs electrical energy (photons) from the sun and here PN- semiconductor

devices are used so by PHOTOVOLTAIC EFFECT electrical energy is generated

from the solar panel.

2. Charge Controller: A Charge controller optimally controls the charging of the

battery. The battery sometimes overcharges from its maximum value for which it

gets damaged also it gets corrode . A typical 12v battery can maximum charge upto

15v so beyond which the battery gets overcharged so a charge controller circuit

protects the battery from over charge phenomenon.

3

3. Battery: A battery is a device consisting of one or more electrochemical cells. A

battery has a positive terminal, called cathode, and a negative terminal, called anode.

The terminal with positive demarcation is at a higher electrical potential than the

negative. The terminal marked with negative is the source of electrons and it delivers

energy to an external load. Here battery is used for conservation of energy that could

be used when energy source is not present.

4. Transformer: In our project we have used conventional source so that we can

charge up the battery even there is inadequate amount of solar energy during rainy or

stormy weather. Like if it is a rainy day then we can charge up our battery through

the electrical grid. For this we need a transformer. Here we are using the step down

transformer so that it can step down the 230volt ac supply into the 12volt ac which is

required for our battery to be charged up. But the battery needs 12volt dc so we will

be using a rectifier which will be converting the 12volt ac into the 12volt dc.

5. Light Dependent Resistor: A Light dependent resistor (LDR) or a

photo resistor is a device whose resistivity varies with the variation of incident

electromagnetic radiation on it. So it is a light sensitive device. It is also called a

photoconductor. It is basically a photocell that works on the principle of

photoconductivity. The LDR basically consists of passive element resistor but its

resistance decreases to almost zero when light falls on it.

6. Light Emitting Device: A light emitting diode is a two lead semiconductor light

source. This is a PN junction diode which emits light when activated. When a

suitable voltage is applied to the leads, electron-hole recombination occurs within

the device, releasing energy in the form of photons.

1.2. Student outcomes and Bloom’s taxonomy of learning levels

• There are eleven student outcomes (a–k) for the Electrical Engineering B. Tech

program.

• There are six levels of learning as defined in the Bloom’s Taxonomy. Bloom’s

Taxonomy is a multi-tiered model of classifying thinking according to the six

cognitive levels of complexity. The levels have often been depicted as a stairway,

which encourages the students to “climb to a higher (level of) thought”. The lowest

4

three levels are: knowledge, comprehension, and application. The highest three

levels are: analysis, evaluation, and creation. The taxonomy is hierarchical, which

means, each level is subsumed by the higher levels. In other words, a student

functioning at the ‘application’ level has also mastered the material at the

‘knowledge’ and ‘comprehension’ levels.

Table 1.1: Student outcomes

Outcome Description

A An ability to apply knowledge of mathematics, science, and engineering.

B An ability to design and conduct experiments, as well as to analyze

and interpret data. C An ability to design a system, component, or process to meet desired

needs within realistic constraints such as economic, environmental, social, political, ethical, health and safety, manufacturability, and Sustainability. D An ability to function on multidisciplinary teams.

E An ability to identify, formulate, and solve engineering problems.

F An understanding of professional and ethical responsibility.

G An ability to communicate effectively.

H The broad education necessary to understand the impact of engineering

solutions in a global, economic, environmental, and societal context. I A recognition of the need for, and an ability to engage in life-long

Learning. J A knowledge of contemporary issues.

K An ability to use the techniques, skills, and modern engineering tools

necessary for engineering practice.

5

Table 1.2: Learning levels

Level Name Description

L-1 Knowledge Retrieving, recognizing, and recalling relevant knowledge from long-term memory. L-2 Comprehension Constructing meaning from oral, written, and graphic

messages through interpreting, exemplifying, classifying, summarizing, inferring, comparing, and explaining. L-3 Application Carrying out or using a procedure through executing, or

Implementing. L-4 Analysis Breaking material into constituent parts, determining how

the parts relate to one another and to an overall structure or purpose through differentiating, organizing, and Attributing. L-5 Evaluation Making judgments based on criteria and standards through

checking and critiquing. L-6 Creation Putting elements together to form a coherent or functional

whole; reorganizing elements into a new pattern or structure through generating, planning, or producing.

6

1.3. Design checkpoints

Table 1.3: Design checkpoints and student outcomes

Checkpoints A B C D E F G H I J K 1 Customer

needs recognition

√ √

2 Function decomposition

√

3 Engineering specification

√ √

4 Product architecture

√ √

5 Concept generation

√ √

6 Concept selection

√ √ √ √ √

7 Product embodiment

√ √

8 Product metric model

√ √ √ √

9 DFM, DFA, DFE

√ √ √ √ √

10 Analytical and numerical solution

√ √ √ √ √

11 Physical prototype

√

12 Testing and improvement

√ √ √

13 Final product and Final Report

√ √

7

Table 1.4: Time line for design checkpoints

Checkpoints Set time line

1 Customer needs recognition FILL THE SPECIFIED TIME

2 Function decomposition 10.02.2016-13.02.2016

3 Engineering specification 16.02.2016-21.02.2016

4 Product architecture 23.02.2016-26.02.2016

5 Concept generation 27.02.2016-29.02.2016

6 Concept selection 02.03.2016-03.03.2016

7 Product embodiment 05.03.2016-06.03.2016

8 Product metric model 07.03.2016-08.03.2016

9 DFM, DFA, DFE 08.03.2016-09.03.2016

10 Analytical and numerical solution 10.03.2016-12.03.2016

11 Physical prototype 13.03.2016-15.03.2016

12 Testing and improvement 16.03.2016-20.03.2016

13 Final product and Final Report 22.03.2016-14.04.2016

1.4 Design team formation and team charter

Table 1.5: Team allocation and problem selection

Name Registration number

Design Problem statement

1 SUBHANKAR DASH 1241019177 DESIGN AND ANALYSIS OF SOLAR PV SYSTEM(SOLAR STREET LIGHTING)

2 NISHA KUMARI 1241013049 3 SIDDHARTH S.PATI 1241013256 4 KUMAR SANKET 1241013253 Signature of IDP with

date

8

Table 1.6: Team Charter

Team ID:3(C) Section: D Semester: 8th

We are involved: (Name and Registration number of Team members)

Member 1: SUBHANKAR DASH 1241019177

Member 2: NISHA KUMARI 1241013049

Member 3: SIDDHARTH S.PATI 1241013256

Member 4: KUMAR SANKET 1241013253

Our objective: - Design and Analysis of Solar PV System(solar street lighting) Our goals:

� To do analysis that How much rating of PV panel and battery required according to the rating of the load.

� To design Hybrid charge controller circuit on vero board and assemble it & do testing . � To assemble the final whole design ( i.e PV panel, hybrid charge controller and load) on a

wooden board . Declaration: We, the members of the Design Team 3(C), Section ‘D’, Department of Electrical Engineering, ITER, Siksha ‘O’ Anusandhan University, hereby declare that we have created our own Team Charter, understood it, and agree to abide by it. Signature: Member 1: SUBHANKAR DASH

Member 2:NISHA KUMARI

Member 3:SIDDHARTH S.PATI Member 4:KUMAR SANKET

9

Chapter 2

CUSTOMER NEEDS RECOGNITION

10

2.1 Task distribution and monitoring

Table 2.1: Work done by each member

Work done by each member of Team ID 3(C) of Section ‘D’

Team leader: SUBHANKAR DASH

Team member Task(s) to be performed

Task assigned date Task completed on

1:SUBHANKAR DASH & NISHA KUMARI

Questionnaire & interview Form

10.02.2016 12.02.2016

2:NISHA KUMARI Affinity Diagram 12.02.2016 13.02.2016

3:SIDDHARTH S.PATI

Priority table 12.02.2016 13.02.2016

4:SUBHANKAR DASH & KUMAR SANKET

Problem statement with requirements and constraints

12.02.2016 13.02.2016

Signature of Team Members:

Member 1:SUBHANKAR DASH Member 2:NISHA KUMARI


11

2.2 Questionnaire method

Table 2.2: Questionnaire for the product

Q. 1 Do you have any idea about Solar PV MODULE? a) Yes b) No c) No idea Q. 2 Can Solar PV System be used for domestic purpose?

a) Yes

b) No

c) No idea

Q. 3 Do you think it should be mandatory for domestic users to have solar PV so as to reduce their dependency on conventional energy? a) Yes, can help meet energy demand and reduce pollution b) No, domestic users cannot afford it c) They should have the option to choose

Q. 4 4. What is the cost of a simple PV System you think?

a) Rs 38/watt

b) Rs 45/watt

c) Rs 55/watt

d) Rs 60/watt

Q. 5 How long do a PV system last according to you?

a) Less than 10 years

b) 20-60 years

c) More than 60 years

Q.6 Do you think it should be implemented in Bhubaneswar at the earliest given

its smart city status?

a) Yes, Bhubaneswar is a growing city should check pollution.

b) No, very costly

c) No idea

12

Q. 7 Should there be government subsidies for solar PV development?

a) No

b) Yes only to those who cannot afford it

c) No idea

Q. 8 According to you is it preferable as best i.e Roof mounted or Ground

mounted?

a) Roof mounted

b) Ground mounted

c) Both

d) No idea

Q. 9

Is it economic to use hybrid system in solar PV system?

a) Yes

b) No

c) To some extent Q. 10 According to you is it used as main source of power generation or backup?

a) As main Source

b) As Back up

c) Both

d) No idea

Q.11 What are the biggest obstacles in implementing Solar Pv system on a global

scale?

a) High installation cost

b) Reliability

c) Pollution

d) Lack of awareness

Q.12

Can we use solar PV system in dark/cloudy days?

a) Yes, battery as backup

b) No

c) No idea

13

Q.13

In what ways the solar battery charger protects the Solar PV?

a) Over-loading

b)Over-Voltage

b) Over-current

c) Both overloading & overcurrent

d) No idea

Q.14

Would you get an electric shock if you touch the PV panel?

a) Yes

b) No

c) Depending upon the moisture

d) No idea

Q.15 Is the implementation of the PV System harmful to the environment?

a) Yes

b) No

c) To some extent

d) Depending on the environment condition

Q.16 What is the maximum capacity Solar PV model can generate?

a) Enough for lighting a colony

b) Enough to light a house

c) Not enough for heavy loads (working)

c) No idea

14

2.3 Interview method

Table 2.3: Interview Form for Product

Customer Name: Ramesh Chandra swain (GM CESU) Address: IDCO TOWER ,BBSR

Interviewer: SUBHANKAR DASH Date:28.02.2016

Questions Customer response to question

Interpreted need statement by interviewer

Importance rating assigned by customer

What are the uses of the current product or similar product?

i)Production of electrical energy using solar energy ii)Hybrid vehicles iii)Day to day basic use

Electricity generation Solar electric cars Solar water heater, Solar cooker, Solar street light, Solar Charger etc

Must Good Good

Questions that expose the LIKES of the product

1 Less pollution Eco-friendly Must 3 User-friendly Can be used as Roof or

ground mounted according to needs

Good

5 Continuous Power supply

Uninterrupted Power Supply

Must

7 Tracking System Single or Dual axis tracking system

Good

9 Generally used for small loads

Supply power to remote areas

Should

Questions that expose the DISLIKES of the product

1 Setup and Maintenance cost is high

2 Non-availability of solar energy

Use of Hybrid system Must

3 Battery causes pollution

Use of bio batteries Should

Suggestions for improving the current product

i)Use bio batteries of compact size ii)Conventional Input i.e Power from grid

Should be stressed upon batteries that don’t cause pollution Hybrid system installation which increases the stability to supply power to loads

Should Must

15

2.4. Organising and prioritising of customer needs

Fig2.4 Affinity Diagram

16

Table 2.5. Prioritised customer need

Priority Table

2.6. Problem statement with requirements and constraints

Design and Analysis of Solar PV system(solar street lighting)

SPECIFICATION SHEET

(Solar PV system)

DEMAND OR

WISH

FUNCTIONAL REQUIREMENT/CONSTRAINTS TEST/VERIFICATION

D Provides solar energy for electricity generation. Conservation of energy principle

D Provides protection against overcurrent,over-

charging and under-charging of battery

Verify with passing high current

than rated one.(design)

CONSTRAINTS

D Size and cost of PV module. Verify during design analysis.

D Safe operation Prototype Testing

SAFETY

W No Partial Shading. Checking the physical condition.

D Ecofriendly Uses renewable sources.

CUSTOMER WANTS DEVICE USED

Uninteruppted Power Supply Hybrid system instllation i.e SMPS

Protection System Hybrid Charge Controller

Backup System Battery

Maximum Power Generation Solar Tracker

Output Power Regulation Loads

Solar Energy To Electricity(RES) PV Panels

17

Chapter 3

FUNCTION DECOMPOSITION

18



Work done by each member of Team ID 3(C) of Section ‘D’ Team leader: SUBHANKAR DASH Team member Task(s) to be

performed Task assigned date Task completed on

1:SUBHANKAR DASH & NISHA KUMARI

Function tree by FAST method

16.02.2016 18.02.2016

2:SUBHANKAR DASH

Function tree by Subtract and Operate Procedure

17.02.2016 19.02.2016

3:SIDDHARTH S.PATI & KUMAR SANKET

Function tree by energy diagram

20.02.2016 21.02.2016

Signature of Team Members: Member 1:SUBHANKAR DASH Member 2:NISHA KUMARI


19

3.2 Function tree by FAST method

Fig3.2 Fast Method

DC LED LOADS

MAXIMUM

POWER

POINT

TRACKING

ACTUAL

POWER

GENERATE

ELECTRICIT

Y

SOLAR

PANELS

ARRAY

LIGHT

ENERGY TO

EE

ENERGY(DC)

TAPPING OF

SOLAR

ENERGY BY

SOLAR

LIGHT

ENERGY

STORES EE IN

BATTERY AS

BACKUP

DC FLOW

CONTROL BY

HYBRID

CHARGE

20

3.3 Function tree by subtract and operate procedure

SUBTRACT AND OPERATE APPLIED TO SOLAR PV SYSTEM

PV PANELS CHARGER CKT RECTIFIERS BATTERY LOADS

� No way to

convert light

energy to

electrical

energy

� No electricity

generation

� No control to

current flow

and charging

of battery

� Cause

damage

and

decrease

in

lifecycle

of

battery.

� No way to

convert

Convention

al AC

power to

DC power

� No way to

store the

electrical

energy

� No backup

during

power

failures or

night hours

� No way

to

regulate

the

output

power

21

SOLAR PV

Solar Panel

Array

Hybrid Charge

Controller

RECTIFIER

S

Battery

Loads

Converts light

energy into electrical

energy

Controls the

Current flow and

charges the

battery

Converts Conventional

AC supply to

Dc Supply

Store

charge

Used as

backup at

adverse

conditions

Provides

electrical output

Power output

22

3.4 Function structure by energy diagram

3.5. FUNCTION STRUCTURE BY ENERGY DIAGRAM:

SOLAR ENERGY

(Energy from sun rays)

GRID

POWER

SUPPLY

ADVERSE CONDITIONS

(Power generation failure)

BATTERY

DC POWER

AC POWER

CONVERT SOLAR TO ELECTRICAL

ENERGY(DC) BY PV PANELS

ENERGY FLOW CONTROLLER

BY CHARGER CONTROLLER

CKT

CONVERT AC

SUPPLY TO DC

SUPPLY BY

SMPS

SUPPLY POWER TO LOADS

DC POWER

DC POWER

23

Chapter 4

PRODUCT TEARDOWN & ENGINEERING SPECIFICATION

24



Work done by each member of Team ID -3(C)of Section –‘D’


Team member Task(s) to be performed


1:SUBHANKAR DASH &

SIDDHARTH S.PATI

SOP, House of

quality

23.02.2016 24.02.2016

2:NISHA KUMARI Force flow &Qualitative

Specification Vs Quantitative

23.02.2016 24.02.2016

3:SUBHANKAR DASH

Product hierarchy & Specification Sheet

24.02.2016 26.02.2016

4:KUMAR SANKET Bill of materials




25

4.2 Product teardown

ASSEMBLY/

PART N.O

PART DESCRIPTION

EFFECT

OF REMOVAL

DEDUCED

SUBFUNCTION(S) AND

AFFECTED CUSTOMER

NEEDS

A1

ELECTRICAL POWER

GENERATION MECHANISM

1

Solar PV panels

No conversion of energy,

No electricity generation

Convert light Energy

to Electrical energy

3

RECTIFIER CIRCUIT

No conversion of Ac

power to Dc power

Converts Conventional

Ac power to Dc power

A2

ELECTRICAL POWER

STORAGE,CONVERSION AND

WORKING MECHANISM

A2.1

Hybrid charger Controller

No Control over current

flow to loads and

Battery charging.

Over current flow

protection, Protection

against Overcharging

and undercharging of

battery

4 IC 555 No frequency of

operation and charging

and discharging of

battery can not be

controlled

Controls the charging

and discharging of

battery by giving high

and low output.

5 ZD1 IC 555 May suffer from

over voltage situation.

Designed to protect

the 555 from an over

voltage situation.

6 ZD2 Battery overcharges

beyond 15V

Over charge protection

purpose

7 D1,D2,D3 Reverse current may

flow from battery to

panel or power circuit

Causes reverse current

protection.

26

8 C3,C4 Cannot charge the

battery effectively

Charge the battery

effectively

9 NPN Transistor No control over charging

control

Charges battery by

capacitors

10

R1,C1

No stabilization of

operating voltage

Stabilize the operating

voltage of the

oscillator.

11

R2,R3,C2

No frequency can be set

to operate the IC 555

Set up the frequency

of operation

12

Relay colis

No switching from

battery power to

conventional Ac power

and vice versa

Switches battery

power to conventional

Ac power and vice

versa

13 LED No indications,

No information

Provides the

indications

representing the status

14

LDR

No dusk to dawn

operation

Provides Dusk to dawn

operation.

27

4.3 Post-teardown reporting

Part Name Qty Function Flows in Flows out Manuf.

Process

Materials

1. PV PANELS

1 Absorbs light

energy and

converts to

electrical energy

.

Light

Electrical

Factory

Silicon

4.

HYBRID

CHARGE

CONTROLLER

(Components)

1 Provides the

battery from

over and deep

discharging.

Electrical

Electrical

Soldering

&Fabrication

Electronics

5. BATTERY 1 Stores energy,

Used as backup

in adverse

conditions

Electrical

Electrical

Electrolyte

6.

LOAD

1

Provides output

power

Electrical

Electrical and

mechanical

Fabrication Resister,LEDs

Mounted board

assembled

Functional Analysis DFM Cost Analysis

Date

Student(s) SUBHANKAR DASH,NISHA KUMARI,SIDDHARTH S.PATI,KUMAR SANKET

Project Name: DESIGN AND ANALYSIS OF SOLAR PV SYSTEM (SOLAR STREET LIGHTING)

Bill of Materials

28

4.4 Engineering specification

SPECIFICATION SHEET TEMPLATE

(Solar PV system)

DEMAND OR

WISH

FUNCTIONAL REQUIREMENT/CONSTRAINTS TEST/VERIFICATION

D Provides solar energy for electricity generation. Conservation of energy

principle

D Provides protection against overcurrent,over-

charging and under-charging of battery

Verify with passing high

current than rated one.(design)

CONSTRAINTS

D Size and cost of PV module. Verify during design analysis.

D Safe operation Prototype Testing

SAFETY

W No Partial Shading. Checking the physical

condition.

D Ecofriendly Renewable energy sources

such as solar energy is used.

29

SOLAR PV SYSTEM DESIGN, QUALITATIVE SPECIFICATIONS VS QUANTITATIVE

Qualitative

Functional:

Good Cabling System

Efficient Tracking System

Uninterrupted Power Supply

Constraints:

Size and Cost

Quantitative

Functional:

Solar PV panels Typically rated from 10W-

100W

(for Small loads )

Cabling System -------------------

Protection system Work voltage: 12V

(Hybrid charge controller)

Constraints:

Size And Cost Depends on area and n.o of

loads

Specification type Specifications Quantifications

30

4.5. HOUSE OF QUALITY:

31

Chapter 5

PRODUCT ARCHITECTURE

32



Work done by each member of Team ID -3(C)of Section-‘D’


Team member Task(s) to be

performed


1:SUBHANKAR

DASH,NISHA

KUMARI &

SIDDHARTH

S.PATI

Basic Clustering 27.02.2016 29.02.2016




33

5.2 Modular design by basic clustering

Chapter 6

CONCEPT GENERATION

Solar

Energy

Conversion of Dc power to AC

power by Inverter

SOLAR PV PART

Falling of light

energy on solar

pv panels

Supply

electricity(DC)

Conversion of

light energy to

electrical energy

TRANSMISSION AND PROTECTION SYSTEM

Store energy(EE) by Battery

Over-charging and under

charging of the battery by

charge controller circuit AND

also performs dusk to dawn

operation.

Conversion of

conventional AC

supply to Dc by

RECTIFIER CIRCUIT

Conventional

Supply

LOADS CONNECTED

Supply to power

loads

Working of DC

LOAD

34



Work done by each member of Team ID -3(C)of Section –‘D’ Team leader: SUBHANKAR DASH Team member Task(s) to be

performed Task assigned date Task completed on

1:SUBHANKAR DASH

Brainstorming 02.03.2016 03.03.2016

2:NISHA KUMARI Morphological analysis

02.03.2016 03.03.2016

3:SIDDHARTH S.PATI & KUMAR SANKET

Idea generators 02.03.2016 03.03.2016

Signature of Team Members: Member 1:SUBHANKAR DASH Member 2:NISHA KUMARI Member 3:SIDDHARTH S.PATI Member 4:KUMAR SANKET

35

6.2 Brainstorming

6.3 C-sketch / 6-3-5

DESIGN

CHARGE

CONTROLLER

BATTERY

COMPONENTS &

MATERIALS

REQUIRED

LAYOUT OF

THE CKT

ANALOGIES

Electronics

SWITCHING CIRCUIT USING RELAY

BETWEEN SOLAR AND

CONVENTIONAL

CHARGE CONTROLLER

CIRCUIT

Capacitor

VERO

board,Switch,

Connector

LED

NIGHT

INDICATOR SOLAR POWER

INDICATOR

Day Conventional power

Analysis of rated charging

current before designing

DESIGN OF

PV SYSTEM

STORE CHARGE

Backup at

adverse condItion

TYPES

Lead-acid Nickle-

cadmium

Nickle-Iron

ANALOGIES

Analysis of Ah

requied

PV PANEL

ANALOGIES

LOADS

ANALOGIES

WATT-HR

Product of load

rating and total

time usage in a

day

Rating of the load

Dusk to dawn load

control ckt

Transistor,

Diode

Ceramic

ZENER DIODE

IC 555

Electrolytic

INDICATOR

Size & power of the

PV module,ratings

36

6.3 Morphological analysis

SL.NO SUBFUNCTION CURRENT

SOLUTION

ALTERNATIVE SOLUTION

1 2

1 Conversion of Solar energy to

Electrical energy

Use of

Solar PV panel

----------

----------

2 Maximum Power generation

--------------

Use of

Solar Tracker

----------

3 Over-current protection and

protection against

Overcharging and

Undercharging of Battery

Use of solar charge

controller

Use of hybrid

Solar Charger

Controller

----------

3.1

Switching operation

,

Relay

IGBT,

Mosfet,Diodes,

BJT(NPN type),

Two way Switc

Thyristors

(SCR)

3.2 Amplifier

Transistor Opamp

--------

3.3 Voltage Stabilisation

Capacitor

----------

----------

3.4 Control of relay operation

Transistor pair Opamp

----------

3.5 Opposition to current flow

Resistors

----------

----------

3.9 Reverse current flow

protector

Use of diodes

Use of

Schottky device

----------

4 Store Charge

(backup During

Adverse Condition)

Battery

----------

----------

5 Conversion of conventional

Ac supply to Dc supply

Use of Rectifier

SMPS

Converter

37

6.4. Assembly sketching of concept variants

IDEA GENERATOR QUESTIONS OR APPLICATIONS

Make analogies 1 )Is there any product which can be analogous to Solar PV?

Wish & Wonder 2) What if Solar power Can be replaced by lunar power?

Eliminate &Minimize 1)What will happen if we remove the Battery?

2)If the size of PV panel is Small then what will happen?

3)Can we remove the inverter?

4)Can we split the Charge Controller?

What Can be substituted 1)What Can be Substituted instead of Charge Controller?

2)Is there any other process followed to protect the PV

panel?

3) Is there any favourable condition for installing Solar PV

in hilly areas?

Combine 1)Can we combine battery & charge controller to one

system?

2)What other units can be combined or merged with?

Adapt 1)What other device is like this i.e have same function?

2)What other ideas does this suggest?

Modify or Magnify 1)What can be made larger or extended or magnified?

More time? Stronger? Higher?

38

Chapter 7

CONCEPT SELECTION

39






performed


1:SUBHANKAR

DASH ,NISHA

KUMARI

Function to customer

needs

05.03.2016 06.03.2016




40

7.2 Technical feasibility by applying the knowledge of mathematics, science and engineering

By analyzing the customer needs also going through the constraints rating was

assigned on the basis of their importance. The circuit diagram required for our project was

decided during this stage and ratings of the components were selected very carefully such

that they can be designed within the timeframe and with the available resources. It was

made sure that the design selected is real.

FUNCTION TO CUSTOMER NEEDS CORELATION FOR THE SOLAR PV SYSTEM

Customer need Scaled customer

need rating(1-5)

Associated flow(s) Associated

subfunction(s)

Large-scale usage

(Powerful)

4 Solar energy,

Electricity

Convert solar to

electricity

Maximum power

generation

3 Electricity MPPT system

Protection against

the faults in PV

5 Electricity Protection system

Uninterrupted

Power Supply

5 Electricity Hybrid System

Long lasting

Battery

5 Electricity

Stores electricity,

Backup

Light weight&

Small size

1 Human force Load analysis

Maintenance free 1 System

Maintenance

41

Chapter 8

PRODUCT EMBODIMENT

42



Work done by each member of Team ID -3(C)of Section ‘D’



performed


1:SUBHANKAR

DASH & NISHA

KUMARI

Layout 07.03.2016 08.03.2016

2:SIDDHARTH

S.PATI & KUMAR

SANKET

System modelling 07.03.2016 08.03.2016




43

8.2 Refining geometry and layout

SPV MODULE

LED

LOAD

CHARGE

CONTROLLER

CIRCUIT

SWITCHING

CIRCUIT BETWEEN

SOLAR &

CONVENTIONAL USING

RELAY & TRANSISTOR

BATTERY

Conventional

AC power

through

RECTIFIER

CIRCUIT

DUSK TO DAWN

OPERATION CIRCUIT

USING RELAY

TRANSISTOR PAIR AND

LDR

44

8.3 Systems modeling

Product- Solar PV system

PV panels, Rectifier circuit, Controller, Battery

Silicon Material

Solar Pv Cells

SOLID

ENERGY TRANSFORM

MATERIAL

SOLAR ENERGY

KINETIC ENERGY

ELECTRICAL ENERGY

HEAT

MATERIAL

MATERIAL

SOLID

SOLID

HEAT ENERGY

ENERGY TRANSFORM

45

Chapter 9

PRODUCT METRIC MODEL

46






performed


1:SUBHANKAR

DASH,NISHA

KUMARI,SIDDHARTH

S.PATI

Model selection by

performance

specification

08.03.2016 09.03.2016




47

9.2 Model selection by performance specifications

WEIGHTED SUBFUNCTION VALUES FOR THE SOLAR PV SYSTEM

Subfunction Associate customer

need ratings

Weighted customer

need rating

Generate & supply

electricity

(Convert Solar to

electricity)

5,4,3,4 16

Protection system 5,4,4 13

Hybrid system 4,5,3 12

Store Electricity 5,4,1 10

Regulate Electricity 5,5,4 14

48

Chapter 10

DESIGN FOR MANUFACTURE ASSEMBLY AND ENVIRONMENT

49






performed


1:SUBHANKAR

DASH ,KUMAR

SANKET,NISHA

KUMARI

MANUFACTURING

& COST ANALYSIS

10.03.2016 12.03.2016

2.NISHA KUMARI

& SIDDHARTH

S.PATI

APPLYING DESIGN

GUIDELINES

10.03.2016 12.03.2016




50

10.2 Applying Design guidelines

TABLE 10.2 DFA Guidelines

SL.NO GUIDELINES

1 Minimize part count by incorporating multiple functions into single part

2 Modularize multiple parts into single subassemblies

3 Assemble in open space, not in confined spaces . never bury important

components

4 Make parts to identify how to orient them for insertion

5 Standardize to reduce part variety

6 Maximize part symmetry

7 Design in geometric or weight polar properties if non-symmetric

8 Eliminate tanglely part

9 Color code parts that are different but shaped similarly

10 Prevent nesting of parts

11 Provide orienting features on non-symmetries

12 Design the mating features for easy insertion

13 Provide alignment features

14 Insert new parts into assembly from above

15 Insert from the same direction or very few. Never require the assembly to be

turned over

16 Eliminate fasteners

17 Place fasteners away from obstructions

18 Deep channels should be sufficiently wide to provide Access to fastening tools.

No channel is best.

19 Providing flats for uniform fastening and fastening ease.

20 Proper spacing ensures allowance for fastening tool.

A product gets expensive depending on its manufacturing process. The

product designing approach that includes environment and the effects on it.

Design for manufacturing and assembly are now commonly refered to

as a single methodology. Thus the production uses most cost effective material & process.

This methodology shorten the product development cycle span.

51

10.3 Manufacturing cost analysis

10.4 Design for environment

We categorise the environment in global, economic, environmental and societal

context.

Engineering solutions always induce an impact towards the whole world.

Some cases it has positive impact as many we see the wonder of science & also have

negative impact in case of bombs having destructive power. So engineers usually concerned

towards safety and cost of their products.

Impact of engineering solution in global context

Our project aims to fulfill customer satisfaction and hence

fulfilling all the global aspects. The global impact of our project is as positive as it ensures

user safety and provides flexibility , at the same time it is ecofriendly as well as utilizing

green energy . It can be used anywhere in an effective and efficient way.

52

Impact of engineering solution in economic context

During the entire project, we have always kept the price

constraint in our mind. We have succeeded in designing our project that is affordable by its

fair performance. Hence, we can say that our project is economically effective.

Impact of engineering solution in environmental context

In our project we have utilized the most convenient source of

energy that is the energy that is harnessed from the sun. The sun gives enormous amount of

heat which is received by the solar panel and converts it into electrical energy. As we are

using the renewable source of energy it does not cause any kind of pollution and it is very

ecofriendly.

Impact of engineering solution in societal context

Our project has been designed for the benefits of the society. It helps in societal

development as it requires low cost. Initially we need somewhat high cost but the

maintenance is very low hence it benefits the society.

53

Chapter 11

ANALYTICAL AND NUMERICAL MODEL

SOLUTTIONS

54






performed


1:SUBHANKAR

DASH

Product concept

coordination

13.03.2016 15.03.2016

2.NISHA KUMARI Calibration And

Validation

13.03.2016 15.03.2016

3.SIDDHARTH

S.PATI

Worksheet 13.03.2016 15.03.2016

4.KUMAR SANKET Worksheet 13.03.2016 15.03.2016




55

INPUT PROCESS OUTPUT

56

11.2.MATHEMATICAL ANALYSIS –

1.ESTIMATION OF DAILY ELECTRICAL ENERGY REQUIRED BY LOAD:

The following table provides the load along with the power rating & approximate hours it will be used.

SERIAL NO LOAD NUMBER POWER RATING

HR/DAY WATT-HR

1. LED ASSEMBLY

1 16 WATT 2 32

TOTAL WATTAGE 16 WATT TOTAL DAILY ELECTRICITY DEMAND(WH)

32

TOTAL DAILY ELECTRICITY DEMAND (KHR)

.32

2. ESTIMATION OF SYSTEM VOLTAGE AND BATTERY REQUIREMENT:

• DECIDING THE SYSTEM VOLTAGE:

The system voltage depends on battery voltage, line current ,

allowable voltage drop and power loss in the cable. Here the terminal voltage of batteries used

in PV system is 12 volts. Therefore the PV system voltage should be 12 volts. If higher

system voltage is required then it should be multiples of 12v i.e 12v,24v,36v,48v etc. Higher

PV system voltage minimizes the current carried by the cable to minimize the power losses &

voltage drop in the cable. Here 12v system voltage has been considered for calculation.

• RATING OF THE BATTERY:

The selection of battery depends on two factors:

1. Depth of discharge of battery (DOD).

2. System voltage

In solar PV, the deep discharge batteries are used with DOD in the range of 60% and

considering 12v systems for this calculation.

Battery capacity(Ah)=

Battery capacity(Ah)= =2.67Ah

57

Actual battery capacity required=

Actual battery capacity required= =5.23Ah=6 Ah(approx)

(considering the battery efficiency =85% & Battery Depth of discharge=60%)

Here we are using 12v, 7Ah battery.

3. ESTIMATION OF PV MODULE REQUIREMENTS:

To design PV Module the following parameters are required:

• Available Voltage , Current and Wattage of the module in the market.

• Solar radiation at given location. • Temperature of the module.

• Dust level in the working Environment. The PV module capacity should be designed to supply the daily load demand.

Panel Watt-Peak Required=

Panel Watt-Peak Required==6.4wp

( considering global solar radiation for 5 hours)

Panel Watt-peak Required after considering the efficiency of the system &

module=

= =13.06 Wp=14Wp(approx)(considering total system efficiency=70% &

PV Performance efficiency=70%)

Here we are using 12v,20w panel as 12v,14w panel is not available in the market.

4. RATING & SIZE OF CHARGE CONTROLLER:

Solar charge controller voltage rating=system voltage=12v

Maximum charging current=total short circuit current of PV array=1.28A

58

Chapter 12

PHYSICAL PROTOTYPE

59






performed


1:SUBHANKAR

DASH & NISHA

KUMARI

Prototype Planning

and Design

16.03.2016 18.03.2016

2:SIDDHARTH

S.PATI

Assembly creation 16.03.2016 18.03.2016




60

12.1. Introduction to Physical Prototype

Prototype:-It is a physical instantiation of a product, made from a variety of materials i.e.

used to resolve issues during product development and how the product concept would

form. In general we can say it is a simplification of a product concept. It is mainly done so

as to test the Prototype under certain range of conditions to know about its performance,

how we can possibly control the variables in the test and finally know the empirical data so

that the development decision is done with high confidence, reduced cost and risk.

Prototyping:-It helps in communicating the visual layout and gives a product look.

Experimental Prototyping:-It helps in exploration, optimization and validation of a

mechanical hardware.

Final Hardware Prototyping:-It helps in fabrication and assembly issues .

12.2 Mock-up materials and processes

The instances where we have to choose substitute of the component as

depending upon component availability and cost. As of high cost, the conventional input

instead of SMPS we have designed a rectifier circuit with step down transformer which

provides a 12v or above as input to charger controller circuit.

12.3 Prototype planning and design

Planning -

1. To do analysis i.e find the ratings of PV panel and battery according to required load.

2. To study the components present in charge controller ckt diagram(i.e its functions and

connection)

3. To design charge controller

4 .After completion of design it is to be tested and final fit to board.

61

12.3.1 Prototyping process:

For building a prototype of a project that resembles the physical representation there are

various prototyping process involved. A number of techniques are available for producing

prototypes that ranges from hand working techniques to advanced precision equipment

technique.

In our project for prototype preparation we mainly focus on

1. Training

2. Testing

12.3.2 Assembly Creation: As shown below the assembly of the prototype is done using a

dc regulated power supply to give the circuit the wanted supply and in we use a LED in

output to know the exact output voltage.

CIRCUIT DIAGRAM-

1. Fig 12.1.CHARGE CONTROLLER CIRCUIT:

62

2. Fig 12.2.DUSK TO DAWN CIRCUIT:

3. Fig 12.3.SWITCHING CIRCUIT BETWEEN CONVENTIONAL AND SOLAR POWER:

4.

63

1. Fig 12.4.POWER CIRCUIT USING TRANFORMER & RECTIFIER CIRCUIT:

64

Chapter 13

PROTOTYPE TESTING AND IMPROVEMENT

65






performed


1:SUBHANKAR

DASH

Performance matrix 19.03.2016 20.03.2016

2:NISHA KUMARI Performance matrix 19.03.2016 20.03.2016

3:SIDDHARTH S.

PATI & KUMAR

SANKET

Bill if the material 19.03.2016 20.03.2016




66

13.1.2 Introduction:

The key issues in prototype fabrication and testing are how many to build,

what variables to vary, how to control noise and experimental uncertainties, and how to

formalize the results of testing. These issues give rise to the subject of design of

experiments. It provides a Statistical basis for monitoring and analyzing the inherent noise

in an experiment. Perform Experiments iteratively and bring out improvement in the

product.

13.2 Design of experiments

Designs of experiments are focused physical models where the empirical data is sought to

parameterize, lay out, or shape aspects of the product. This is fabricated from similar

materials and geometry as the actual product, with the design of experiments prototype

being just similar enough to replicate the real product’s physics, but otherwise made as

simply, cheaply and as quickly as possible.

13.2.1 Performance Matrix:

Performance metrics should be consistent with the performance objectives and

performance goals of the projects. Performance evaluation of projects should start with a

list of objectives. These objectives can be stated as questions about the performance.

Performance metrics should be selected to answer these questions. The performance

metrics must be directly related to the performance objectives. If the performance of the

project is to be tracked or improved, specific performance goals should be set and

performance metrics selected to measure progress toward the performance goals.

As demonstrated above our circuit is mainly divided into the following parts:

1. charge controller circuit: When the solar cell is creating a voltage much greater than

battery, the typical charge type situation ,then the circuit may be considered to

consist merely of solar cell and the battery. Current will flow from the solar cell into

the battery. All the other components are present solely because this situation does

not always pertain. For instance, it may well be that .because of night or cloud ,the

solar cell is actually not developing sufficient energy to charge. In this situation ,the

biggest danger is that the battery will discharge through the circuit or the solar cell.

67

D3 protects against this situation (refer fig12.1).At the opposite extreme ,the

battery might already be fully charged. It is necessary to have some form of voltage

clamp to ensure that battery is not damaged. This is achieved by ZD2,which

effectively stops the battery ever going over 15V.

A third problem is to ensure that when the solar cell voltage is below the

battery voltage, but not zero, the unit will still charge. The rest of the circuit is

designed to cover this eventuality. The heart of the circuit is voltage doubler built

around the 555,and the two capacitor c3 & c4. To see how it works , consider the

situation with pin 3, IC1 at VCC ,So that collector of Q1,and thus the negative plate

of C3 is effectively at ground. Then current will flow from the solar cell, through

D1onto the positive plate o C3. D2 is reverse biased by the battery.

When pin 3 IC1 goes low, the collector of Q1 goes high, pushing the

positive plate of the battery up to VCC .But C3 has VCC impressed across it already, so

new voltage is 2VCC .This switches off D1 and turns on D2. Current now floes into

C4. When Ic1, once again, causes the positive plate of C3 to drop to VCC ,D2 reverse

biases, thus providing C4 with one discharge path ,through battery. The 2VCC is less

than 15V as operation of ZD2.R2,R3 & C2 set up the frequency of operation of IC1.

ZD1 is designed to protect the 555 from an over voltage situation, and R1, C1 to

stabilize the operating voltage of the oscillator.

2. DUSK TO DAWN OPERATION: In this operation the 12.2 fig will be refered. The Q1

and Q2 transistors are operated in NOT logic . such that when LDR sense light its

resistance decreases so voltage decreases across Q2 so it went into break down

region but Q1 simultaneously goes high as more voltage drop occurs across 1k

resistor below LDR so current stops flowing through the coil of the relay so it de-

energies and load connected at NC contact trips to NO.

3. POWER CIRCUIT: In this the 12.4 fig will be refered. Here 230V is stepped down to

12V AC by step down transformer and by bridge rectifier circuit 12V AC is converted

to 12V DC.

4. SWITCHING CIRCUIT BETWEEN CONVENTIONAL AND SOLAR POWER SOURCE: In this

operation the fig 12.3 will be refered. Here when LDR sense the light Q1 goes on it

also off the Q3 transistor so the relay trips from conventional to solar.

68

13.3 Improvement

The protection system can be improved by microcontrolled based charge controller i.e The

values can be set by input(digitally) and the output value of each subcircuits can be seen ,so

that proper observations record can be maintained.

13.4 Product cost and bill of materials

1. CHARGE CONTROLLER CIRCUIT

SL.NO COMPONENTS SPECIFICATION QUANTITY NET PRICE

(RS)

1 CAPACITOR(ELEC) 33U,25V 1 3

2 ZENER

DIODE(1N5352)

5W,15V 2 20

3 CAPACITOR(CERA

MIC)

47nF 1 3

4 CAPACITOR(ELECT) 47uF/63V 1 3

5 CAPACITOR(ELECT) 220uF/35V 1 3

6 RESISTOR 1K 1 2

7 RESISTORS 10K 2 4

8 RESISTOR 56K 1 2

9 RESISTOR 1K 1 2

10 DIODE 1N4002 3 6

11 TRANSISTOR BC547 1 15

12 IC 555 1 30

13 IC SOCKET 8 PIN IC BASE 1 10

2. DUSK TO DAWN , SWITCHING CIRUIT,POWER CIRCUIT


(RS)

1 RELAY PCB RELAY 2 60 2 TRANSISTOR BC547 4 60 3

RESISTOR 1K 4 8

4 LDR 1 20 5 DIODE 1N4002 5 10 6 TRANSFORMER 230V/12V 1 180 7 CAPACITOR 47uF/63V 1 3 8 INDICATING

LED 4 8

69

3. PV MODULE,BATTERY,LOAD


(RS)

1 PV MODULE 12V,20W 1 1700 2 BATTERY 12V,7AH 1 650 3 LED LOAD

ASSEMBLY 12V,16W 1 120

TOTAL 2922.00

70

Chapter 14

FINAL PRODUCT

71



Work done by each member of Team ID -3(c)of Section –‘D’



performed


1:SUBHANKAR

DASH

Final product

Fabrication and the

process involved

22.03.2016 01.04.2016

2:NISHA KUMARI Final product

Fabrication and the

process involved

02.04.2016 10.04.2016

3:SIDDHARTH

S.PATI

Product Fabrication 11.04.2016 14.04.2016

4:KUMAR SANKET Product Fabrication 11.04.2016 14.04.2016




72

14.2 Final product fabrication

Fabrication is the process in which product is made from raw material or semi-finished

materials instead of being assembled from ready made parts.

14.2.1 Processes involved in fabricating the product:

• Drilling Process: It is a cutting process that uses a drill bit to cut a hole of circular

cross

Section in solid materials. The drill bit is a rotary cutting tool. Drilling in wood is

considered easier and faster than drilling in metal.

• Soldering Process: It is a process in which two or more items are joined together by

melting and putting a solder into joint, the solder metal having a lower melting point

than the adjoining metal.

• Assemble Process: It is the process that fit together the separate component parts

into a board.

73

Fig14.1. Solar Pv System

74

.

Fig.14.2 . 7Ah,12v Battery

75

Fig14.3-Charge Controller circuit

76

Fig 14.4. Step-down transformer with rectifier circuit

77

Fig 14.5-Dusk to Dawn operation

78

Fig 14.6-switching circuit between conventional and solar power

79

Chapter 15

CONCLUSION

80

15.1 Conclusions

A prototype of Solar PV system was designed and was tested. Charge

controller, Dusk to Dawn circuit, switching circuit between solar & conventional ,power

circuit were designed and were tested individually, then modeled.In this project ,at first the

analysis part was done ,then we gone for the planning and designing part. We focused first

on design of its protection system part with concept of uninterruptable power supply to the

load i.e charge controller We ensured the all component avaliabilty of the controller and

then studied each components(i.e specifications) .The design part included the soldering of

each protection circuits( explained in above chapter) according to the circuit diagram,each

circuits were tested and it gone successful. Then the whole system is modeled and the final

model tesing was done which included tesing the operation with a 16watt,12V led as

load.Thus,led bulb glown and the ckt functionality according to the theory was matched and

hence the project was successful.

15.2Group learning

The project was vast. It was a race against time to complete the project with

certain things like non availability of all the components ,that got substituted also the design

of subcircuits and whole circuit with testing. This project in a sense allowed us to know each

other in a more better way, know each other’s weakness and strengths and thus design and

plan in such a way that everyone was comfortable with the task assigned which ensured

timely completion of the project. Most importantly this project taught us to be team players.

15.3 Individual learning

Although the project as a whole was a group task but it had to be broken down

into parts for the timely completion. This breaking down ensured that each of us had some

new thing to explore and learn. Studing of each components(i.e specifications and

functionality), designing of circuit by soldering,etc gave the basic idea of knowing

hardware components functionality and hardware design projects.

81

References

[1] http://www.powermin.nic.in,www.vegakitindia.com

[2] Strategic Plan for New and Renewable Energy For the Period 2011-17, A Report by

Ministry of New and Renewable Energy, Government of India, February, 2011.

[3] B.Marion, J. Adelstein, K. Boylen and H. Hayden, “Performance parameters for

grid-connected PV systems”, 31st IEEE Photovoltaics Specialisits Conference and

Exhibition, Lake Buena Vista, Florida

[4] Performance Parameters for Grid-connected PV Systems, NREL Report, February,

2005

[5] S.M. Pietruszko, B. Fetlinski, M. Bialecki, “Analysis of the Perfromance of Grid

Connected Photovoltaic Systems”,photvoltaic Specialists Conference (PVSC),

Philadelphia,June 2009.

[6] Yuzuru Ueda, Kosuke Kurokawa, Takamitsu Itou, Kiyoyuki Kitamura, Yusuke

Miyamoto, Masaharu Yokota, Hiroyuki Sugihara, “Performance Ratio And Yield

Analysis Of Grid Connected Clustered Pv Systems In Japan”IEEE 4th World

Conference on Photovoltaic Energy Conversion, Waikoloa,May 2006.

[7] H. Haeberlin and Ch. Beutler, “Yield of grid connected PV systems in Burgdorf:

Considerably higher than the average yield in Switzerland”, 14th European

Photovoltaic Solar Energy Conference Barcelona (Catalunya), Barcelona Spain, 1997,

p1.

[8] SOLAR PV SYSTEM PERFORMANCE ASSESSMENT GUIDELINE, San Jose

University, California, January, 2012.

82

APPENDIX

1. Pin diagram of 555 timer:

Pin description:

83

2 . LIGHT DEPENDENT RESISTOR:

SOLAR STREET LIGHTING SYSTEM

Education

Transcript of SOLAR STREET LIGHTING SYSTEM