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)
 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)

ii
 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.

iii
 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

iv
 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

————————————————–

v
 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.

vi
 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

vii
 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

viii
 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 6.1: work done by each member 35

Table 6.2 partial brain storming 36

Table 6.3 general morphological matrix 37

Table 6.4 idea generator 38

Table 7.1: work done by each member 40

Table 7.2 function for customer needs 41

Table 8.1: work done by each member 43

Table 9.1: work done by each member 47

Table 10.1: work done by each member 50

Table 10.2 DFA guidelines 51

Table 10.1 cost estimation/ analysis 55

Table 11.1: work done by each member 56

Table 12.1: work done by each member 63

Table 12.2 component list 64

Table 13.1: work done by each member 68

ix
Table 13.2 design of experiments 69

Table 13.3 bill of materials 72

Table 14.1: work done by each member 74

x
 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

xi
Chapter 1

INTRODUCTION

1
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.

2
 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

3
 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
An ability to apply knowledge of mathematics, science, and
A 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.

4
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.

5
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

6
 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 Design Problem

number statement
1 SUBHANKAR DASH 1241019177
2 NISHA KUMARI 1241013049 DESIGN AND
3 SIDDHARTH S.PATI 1241013256 ANALYSIS OF SOLAR
4 KUMAR SANKET 1241013253 PV SYSTEM(SOLAR
STREET LIGHTING)

Signature of IDP with

date

7
 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

8
 Chapter 2

CUSTOMER NEEDS RECOGNITION

9
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 Task assigned date Task completed on
performed
1:SUBHANKAR Questionnaire & 10.02.2016 12.02.2016
DASH & NISHA interview Form
KUMARI

2:NISHA KUMARI Affinity Diagram 12.02.2016 13.02.2016

3:SIDDHARTH Priority table 12.02.2016 13.02.2016
S.PATI

4:SUBHANKAR Problem statement 12.02.2016 13.02.2016

DASH & KUMAR with requirements
SANKET and constraints

Signature of Team Members:

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

10
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

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

12
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

13
2.3 Interview method

Table 2.3: Interview Form for Product

Customer Name: Ramesh Chandra swain Interviewer: SUBHANKAR DASH

(GM CESU) Date:28.02.2016
Address: IDCO TOWER ,BBSR

Questions Customer response to Interpreted need statement Importance

question by interviewer rating assigned
by customer
What are the uses of i)Production of Electricity generation Must
the current product electrical energy
or similar product? using solar energy
ii)Hybrid vehicles Solar electric cars Good

iii)Day to day basic Solar water heater,

use Solar cooker, Solar street Good
light, Solar Charger etc
Questions that expose
the LIKES of the
product
1 Less pollution Eco-friendly Must
3 User-friendly Can be used as Roof or Good
ground mounted
according to needs
5 Continuous Power Uninterrupted Power Must
supply Supply
7 Tracking System Single or Dual axis Good
tracking system
9 Generally used for Supply power to remote Should
small loads areas
Questions that expose
the DISLIKES of the
product
1 Setup and
Maintenance cost is
high
2 Non-availability of Use of Hybrid system Must
solar energy
3 Battery causes Use of bio batteries Should
pollution
Suggestions for i)Use bio batteries of Should be stressed upon Should
improving the compact size batteries that don’t cause
current product pollution
ii)Conventional Input Hybrid system installation
i.e Power from grid which increases the Must
stability to supply power
to loads

14
2.4. Organising and prioritising of customer needs

Fig2.4 Affinity Diagram

15
Table 2.5. Prioritised customer need

Priority Table

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

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 FUNCTIONAL REQUIREMENT/CONSTRAINTS TEST/VERIFICATION
WISH
D Provides solar energy for electricity generation. Conservation of energy principle

D Provides protection against overcurrent,over- Verify with passing high current

charging and under-charging of battery 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.

16
 Chapter 3

FUNCTION DECOMPOSITION

17
3.1 Task distribution and monitoring

Table 3.1: 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 Task assigned date Task completed on
performed
1:SUBHANKAR 16.02.2016 18.02.2016
DASH & NISHA Function tree by
KUMARI FAST method

2:SUBHANKAR Function tree by 17.02.2016 19.02.2016

DASH Subtract and Operate
Procedure
3:SIDDHARTH Function tree by 20.02.2016 21.02.2016
S.PATI & KUMAR energy diagram
SANKET
Signature of Team Members:
Member 1:SUBHANKAR DASH Member 2:NISHA KUMARI

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

18
 3.2 Function tree by FAST method

TAPPING OF
GENERATE SOLAR LIGHT LIGHT
SOLAR
PANELS ENERGY TO
ELECTRICIT ENERGY BY ENERGY
ARRAY EE
Y ENERGY(DC) SOLAR

STORES EE IN DC FLOW MAXIMUM

BATTERY AS CONTROL BY POWER
BACKUP HYBRID POINT
CHARGE
TRACKING

DC LED LOADS
ACTUAL
POWER

Fig3.2 Fast Method

19
 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 No control to No way to No way to No way

convert light current flow convert store the to
energy to and charging Convention electrical regulate
electrical of battery al AC energy the
energy power to output
Cause DC power No backup power
No electricity damage during
generation and power
decrease failures or
in night hours
lifecycle
of
battery.

20
 Loads Power output

Used as
backup at
Store adverse Provides
Battery charge conditions electrical output

Converts Conventional
AC supply to
Dc Supply
RECTIFIER
S

SOLAR PV
Controls the
Current flow and
charges the
battery

Hybrid Charge
Controller

Converts light
Solar Panel energy into electrical
Array energy

21
 3.4 Function structure by energy diagram

CONVERT SOLAR TO ELECTRICAL DC POWER

SOLAR ENERGY
(Energy from sun rays) ENERGY(DC) BY PV PANELS
AC POWER

DC POWER CONVERT AC GRID

ENERGY FLOW CONTROLLER
BATTERY SUPPLY TO DC POWER
BY CHARGER CONTROLLER
SUPPLY BY SUPPLY
CKT
SMPS

SUPPLY POWER TO LOADS

DC POWER
ADVERSE CONDITIONS
(Power generation failure)

3.5. FUNCTION STRUCTURE BY ENERGY DIAGRAM:

22
 Chapter 4
PRODUCT TEARDOWN & ENGINEERING SPECIFICATION

23
4.1 Task distribution and monitoring

Table 4.1: 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 Task assigned date Task completed on
performed

1:SUBHANKAR 23.02.2016 24.02.2016

DASH & SOP, House of
SIDDHARTH S.PATI quality

2:NISHA KUMARI Force flow 23.02.2016 24.02.2016

&Qualitative
Specification Vs
Quantitative

3:SUBHANKAR Product hierarchy & 24.02.2016 26.02.2016

DASH Specification Sheet

4:KUMAR SANKET Bill of materials

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

24
4.2 Product teardown

DEDUCED
ASSEMBLY/ PART DESCRIPTION EFFECT SUBFUNCTION(S) AND
PART N.O OF REMOVAL AFFECTED CUSTOMER
NEEDS

A1 ELECTRICAL POWER
GENERATION MECHANISM
No conversion of energy, Convert light Energy
1 Solar PV panels No electricity generation to Electrical energy

No conversion of Ac Converts Conventional

3 RECTIFIER CIRCUIT power to Dc power Ac power to Dc power
ELECTRICAL POWER
A2 STORAGE,CONVERSION AND
WORKING MECHANISM

Over current flow

A2.1 Hybrid charger Controller No Control over current protection, Protection
flow to loads and against Overcharging
Battery charging. and undercharging of
battery
4 IC 555 No frequency of Controls the charging
operation and charging and discharging of
and discharging of battery by giving high
battery can not be and low output.
controlled
5 ZD1 IC 555 May suffer from Designed to protect
over voltage situation. the 555 from an over
voltage situation.
6 ZD2 Battery overcharges Over charge protection
beyond 15V purpose
7 D1,D2,D3 Reverse current may Causes reverse current
flow from battery to protection.
panel or power circuit

25
8 C3,C4 Cannot charge the Charge the battery
battery effectively effectively

9 NPN Transistor No control over charging Charges battery by

control capacitors

10 No stabilization of Stabilize the operating

R1,C1 operating voltage voltage of the
oscillator.

No frequency can be set Set up the frequency

11 R2,R3,C2 to operate the IC 555 of operation

No switching from Switches battery

12 Relay colis battery power to power to conventional
conventional Ac power Ac power and vice
and vice versa versa
13 LED No indications, Provides the
No information indications
representing the status
14 No dusk to dawn Provides Dusk to dawn
LDR operation operation.

26
 4.3 Post-teardown reporting

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

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

Date

Functional Analysis DFM Cost Analysis

Part Name Qty Function Flows in Flows out Manuf. Materials

Process
1. PV PANELS 1 Absorbs light Silicon
energy and
converts to Light Electrical Factory
electrical energy
.
HYBRID 1 Provides the
4. CHARGE battery from
CONTROLLER over and deep Soldering Electronics
(Components) discharging. Electrical Electrical &Fabrication

5. BATTERY 1 Stores energy, Electrolyte

Used as backup
in adverse Electrical Electrical
conditions
1 Electrical and Fabrication Resister,LEDs
6. LOAD Provides output Electrical mechanical Mounted board
power assembled

27
4.4 Engineering specification

SPECIFICATION SHEET TEMPLATE

(Solar PV system)
DEMAND OR FUNCTIONAL REQUIREMENT/CONSTRAINTS TEST/VERIFICATION
WISH
D Provides solar energy for electricity generation. Conservation of energy
principle

D Provides protection against overcurrent,over- Verify with passing high

charging and under-charging of battery 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.

28
 SOLAR PV SYSTEM DESIGN, QUALITATIVE SPECIFICATIONS VS QUANTITATIVE

Specification type Specifications Quantifications

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

29
4.5. HOUSE OF QUALITY:

30
 Chapter 5

PRODUCT ARCHITECTURE

31
5.1 Task distribution and monitoring

Table 5.1: 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 Task assigned date Task completed on
performed
1:SUBHANKAR Basic Clustering 27.02.2016 29.02.2016
DASH,NISHA
KUMARI &
SIDDHARTH
S.PATI
Signature of Team Members:
Member 1:SUBHANKAR DASH Member 2:NISHA KUMARI
Member 3:SIDDHARTH S.PATI Member 4:KUMAR SANKET

32
 5.2 Modular design by basic clustering
SOLAR PV PART

Solar Falling of light Conversion of Supply

Energy energy on solar light energy to electricity(DC)
pv panels electrical energy

TRANSMISSION AND PROTECTION SYSTEM

Chapter 6
Over-charging and under
Store energy(EE) by Battery charging of the battery by Conversion of
CONCEPT GENERATION
charge controller circuit AND conventional AC Conventional
Conversion of Dc power to AC supply to Dc by Supply
also performs dusk to dawn
power by Inverter RECTIFIER CIRCUIT
operation.

LOADS CONNECTED
Supply to power
loads

Working of DC
LOAD

33
6.1 Task distribution and monitoring

Table 6.1: 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 Task assigned date Task completed on
performed
1:SUBHANKAR Brainstorming 02.03.2016 03.03.2016
DASH
2:NISHA KUMARI Morphological 02.03.2016 03.03.2016
analysis
3:SIDDHARTH Idea generators 02.03.2016 03.03.2016
S.PATI & KUMAR
SANKET
Signature of Team Members:
Member 1:SUBHANKAR DASH Member 2:NISHA KUMARI
Member 3:SIDDHARTH S.PATI Member 4:KUMAR SANKET

34
 6.2 Brainstorming

Analysis of rated charging

NIGHT
SOLAR POWER current before designing
INDICATOR
INDICATOR

LED Conventional power ANALOGIES

Day

INDICATOR
VERO Nickle-
DESIGN Lead-acid
board,Switch, COMPONENTS & cadmium
CHARGE
Connector MATERIALS Backup at
CONTROLLER
REQUIRED adverse condItion
TYPES

Electronics STORE CHARGE

Transistor, Nickle-Iron
DESIGN OF
Diode BATTERY
PV SYSTEM
IC 555

ZENER DIODE ANALOGIES

Capacitor

Analysis of Ah
Ceramic Electrolytic requied

CHARGE CONTROLLER
CIRCUIT Dusk to dawn load
LOADS
control ckt

LAYOUT OF
6.3THE
C-sketch
CKT / 6-3-5 ANALOGIES

SWITCHING CIRCUIT USING RELAY Rating of the load WATT-HR

BETWEEN SOLAR AND
CONVENTIONAL PV PANEL

Product of load
ANALOGIES rating and total
time usage in a
day
Size & power of the
PV module,ratings
35
 6.3 Morphological analysis

SL.NO SUBFUNCTION CURRENT ALTERNATIVE SOLUTION

SOLUTION
1 2
1 Conversion of Solar energy to Use of
Electrical energy Solar PV panel ---------- ----------
2 Maximum Power generation Use of
-------------- Solar Tracker ----------
3 Over-current protection and
protection against Use of solar charge Use of hybrid
Overcharging and controller Solar Charger ----------
Undercharging of Battery Controller
, IGBT, Thyristors
3.1 Switching operation Relay Mosfet,Diodes, (SCR)
BJT(NPN type),
Two way Switc
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 Battery ---------- ----------
Adverse Condition)
5 Conversion of conventional
Ac supply to Dc supply Use of Rectifier SMPS Converter

36
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?

37
 Chapter 7
CONCEPT SELECTION

38
7.1 Task distribution and monitoring

Table 7.1: 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 Task assigned date Task completed on
performed
1:SUBHANKAR Function to customer 05.03.2016 06.03.2016
DASH ,NISHA needs
KUMARI
Signature of Team Members:
Member 1:SUBHANKAR DASH Member 2:NISHA KUMARI
Member 3:SIDDHARTH S.PATI Member 4:KUMAR SANKET

39
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 Associated flow(s) Associated

need rating(1-5) subfunction(s)
Large-scale usage 4 Solar energy, Convert solar to
(Powerful) Electricity electricity
Maximum power 3 Electricity MPPT system
generation
Protection against 5 Electricity Protection system
the faults in PV
Uninterrupted 5 Electricity Hybrid System
Power Supply
Long lasting 5 Electricity Stores electricity,
Battery Backup
Light weight& 1 Human force Load analysis
Small size
Maintenance free 1 System
Maintenance

40
 Chapter 8
PRODUCT EMBODIMENT

41
8.1 Task distribution and monitoring

Table 8.1: 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 Task assigned date Task completed on
performed
1:SUBHANKAR Layout 07.03.2016 08.03.2016
DASH & NISHA
KUMARI
2:SIDDHARTH System modelling 07.03.2016 08.03.2016
S.PATI & KUMAR
SANKET
Signature of Team Members:
Member 1:SUBHANKAR DASH Member 2:NISHA KUMARI
Member 3:SIDDHARTH S.PATI Member 4:KUMAR SANKET

42
8.2 Refining geometry and layout

Conventional
AC power
through
RECTIFIER
CIRCUIT

DUSK TO DAWN
SPV MODULE
SWITCHING OPERATION CIRCUIT
CIRCUIT BETWEEN USING RELAY
SOLAR & TRANSISTOR PAIR AND
CONVENTIONAL USING LDR
RELAY & TRANSISTOR
LED

LOAD

CHARGE
CONTROLLER

CIRCUIT
BATTERY

43
 8.3 Systems modeling

Product- Solar PV system

SOLAR ENERGY

ENERGY TRANSFORM
MATERIAL

HEAT ENERGY KINETIC ENERGY

SOLID

PV panels, Rectifier circuit, Controller, Battery

ENERGY TRANSFORM HEAT

ELECTRICAL ENERGY MATERIAL

SOLID
MATERIAL
Silicon Material

SOLID

Solar Pv Cells

44
 Chapter 9
PRODUCT METRIC MODEL

45
9.1 Task distribution and monitoring

Table 9.1: 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 Task assigned date Task completed on
performed
1:SUBHANKAR Model selection by 08.03.2016 09.03.2016
DASH,NISHA performance
KUMARI,SIDDHARTH specification
S.PATI
Signature of Team Members:
Member 1:SUBHANKAR DASH Member 2:NISHA KUMARI
Member 3:SIDDHARTH S.PATI Member 4:KUMAR SANKET

46
9.2 Model selection by performance specifications

WEIGHTED SUBFUNCTION VALUES FOR THE SOLAR PV SYSTEM

Subfunction Associate customer Weighted customer

need ratings need rating
Generate & supply 5,4,3,4 16
electricity
(Convert Solar to
electricity)
Protection system 5,4,4 13
Hybrid system 4,5,3 12
Store Electricity 5,4,1 10
Regulate Electricity 5,5,4 14

47
 Chapter 10

DESIGN FOR MANUFACTURE ASSEMBLY AND ENVIRONMENT

48
10.1 Task distribution and monitoring

Table 10.1: 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 Task assigned date Task completed on
performed
1:SUBHANKAR MANUFACTURING 10.03.2016 12.03.2016
DASH ,KUMAR & COST ANALYSIS
SANKET,NISHA
KUMARI
2.NISHA KUMARI APPLYING DESIGN 10.03.2016 12.03.2016
& SIDDHARTH GUIDELINES
S.PATI
Signature of Team Members:
Member 1:SUBHANKAR DASH Member 2:NISHA KUMARI
Member 3:SIDDHARTH S.PATI Member 4:KUMAR SANKET

49
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.

50
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.

51
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.

52
 Chapter 11

ANALYTICAL AND NUMERICAL MODEL

SOLUTTIONS

53
11.1 Task distribution and monitoring

Table 11.1: 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 Task assigned date Task completed on
performed
1:SUBHANKAR Product concept 13.03.2016 15.03.2016
DASH coordination
2.NISHA KUMARI Calibration And 13.03.2016 15.03.2016
Validation
3.SIDDHARTH Worksheet 13.03.2016 15.03.2016
S.PATI
4.KUMAR SANKET Worksheet 13.03.2016 15.03.2016
Signature of Team Members:
Member 1:SUBHANKAR DASH Member 2:NISHA KUMARI
Member 3:SIDDHARTH S.PATI Member 4:KUMAR SANKET

54
 INPUT PROCESS
OUTPUT

55
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 HR/DAY WATT-

RATING HR
1. LED 1 16 WATT 2 32
ASSEMBLY
TOTAL WATTAGE 16 WATT
TOTAL DAILY 32
ELECTRICITY
DEMAND(WH)
TOTAL DAILY .32
ELECTRICITY
DEMAND (KHR)

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

56
 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

57
 Chapter 12

PHYSICAL PROTOTYPE

58
12.1 Task distribution and monitoring

Table 12.1: 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 Task assigned date Task completed on
performed
1:SUBHANKAR Prototype Planning 16.03.2016 18.03.2016
DASH & NISHA and Design
KUMARI
2:SIDDHARTH Assembly creation 16.03.2016 18.03.2016
S.PATI
Signature of Team Members:
Member 1:SUBHANKAR DASH Member 2:NISHA KUMARI
Member 3:SIDDHARTH S.PATI Member 4:KUMAR SANKET

59
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.

60
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:

61
2. Fig 12.2.DUSK TO DAWN CIRCUIT:

3. Fig 12.3.SWITCHING CIRCUIT BETWEEN CONVENTIONAL AND

SOLAR POWER:

4.

62
1. Fig 12.4.POWER CIRCUIT USING TRANFORMER & RECTIFIER
CIRCUIT:

63
 Chapter 13

PROTOTYPE TESTING AND IMPROVEMENT

64
13.1 Task distribution and monitoring

Table 13.1: 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 Task assigned date Task completed on
performed
1:SUBHANKAR Performance matrix 19.03.2016 20.03.2016
DASH
2:NISHA KUMARI Performance matrix 19.03.2016 20.03.2016
3:SIDDHARTH S. Bill if the material 19.03.2016 20.03.2016
PATI & KUMAR
SANKET
Signature of Team Members:
Member 1:SUBHANKAR DASH Member 2:NISHA KUMARI
Member 3:SIDDHARTH S.PATI Member 4:KUMAR SANKET

65
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.

66
 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.

67
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 5W,15V 2 20
DIODE(1N5352)
3 CAPACITOR(CERA 47nF 1 3
MIC)
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

SL.NO COMPONENTS SPECIFICATION QUANTITY NET PRICE

(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 4 8
LED

68
3. PV MODULE,BATTERY,LOAD

SL.NO COMPONENTS SPECIFICATION QUANTITY NET PRICE

(RS)
1 PV MODULE 12V,20W 1 1700
2 BATTERY 12V,7AH 1 650
3 LED LOAD 12V,16W 1 120
ASSEMBLY
TOTAL 2922.00

69
Chapter 14

FINAL PRODUCT

70
14.1 Task distribution and monitoring

Table 14.1: 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 Task assigned date Task completed on
performed
1:SUBHANKAR Final product 22.03.2016 01.04.2016
DASH Fabrication and the
process involved
2:NISHA KUMARI Final product 02.04.2016 10.04.2016
Fabrication and the
process involved
3:SIDDHARTH Product Fabrication 11.04.2016 14.04.2016
S.PATI
4:KUMAR SANKET Product Fabrication 11.04.2016 14.04.2016
Signature of Team Members:
Member 1:SUBHANKAR DASH Member 2:NISHA KUMARI
Member 3:SIDDHARTH S.PATI Member 4:KUMAR SANKET

71
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.

72
Fig14.1. Solar Pv System

73
.

Fig.14.2 . 7Ah,12v Battery

74
Fig14.3-Charge Controller circuit

75
Fig 14.4. Step-down transformer with rectifier circuit

76
Fig 14.5-Dusk to Dawn operation

77
Fig 14.6-switching circuit between conventional and solar power

78
Chapter 15

CONCLUSION

79
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.

80
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.

81
APPENDIX

1. Pin diagram of 555 timer:

Pin description:

82
2 . LIGHT DEPENDENT RESISTOR:

83