Solar power is the energy from the sun that is converted into thermal or electrical energy. The uses of solar energy are now developing rapidly since it is the cleanest and renewable energy source available. This paper presents the design and fabrication of high-efficiency dual-axis solar tracking system. Moreover, the objectives of this paper is to make sure the designed dual-axis solar tracking system can move the solar panel to the direction of the light accurately. The project can be divided into two stages, which are the designing the structure of the solar tracker and the fabrication of the parts. In the design development, SolidWorks software is used to create the structure of the solar tracking system. To prove the structure is perfect for the solar tracking system, another software is used to test it. For the fabrication part, correct process is carefully chosen based on the machines and tools available in UMP. After the structure is completed, a solar panel, two linear actuators, sensors and batteries are assembled in the solar tracking system. The efficiency of the system has been tested and compared with static solar panel on several time intervals, and it shows the system react the best at the to-minutes intervals with consistent voltage generated. Therefore, the structure has been proven working for directing the solar panel towards the direction of light accurately so that it can capture maximum sunlight source for high efficiency solar harvesting applications

Muhammad Amir Syahiran, Muhammad Tarminzi

UMP Institutional Repository

PERPUSTAKAAN UMP Ill II II II II lll 0000119325 DESIGN AND FABRICATION OF DUAL AXIS SOLAR SYSTEM TRACKER MUHAMMAD AMIR SY AHIRAN BIN MUHAMMAD TARMINZI Thesis submitted in fulfillment of the requirements for the award of the degree of Bachelor of Engineering Technology in Manufacturing with Hons Faculty of Engineering Technology UNIVERSITI MALAYSIA PAHANG . PERPUSTAKAAN C:r UNIVERSITI MALAYSIA PAHANG DECEMBER 2016 No. Perolehan No. Panggllan 119325 FfeK. Tarikh ·• A-Lfb 1 6 AUG 2017 2-0lt-y l!,G.· IV SUPERVISOR'S DECLARATION I hereby declare that I have checked this project and in my opinion, this project is adequate in terms of scope and quality for the award of the degree of Bachelor of Engineering Technology in Manufacturing (Supervisor' s Signature) Full Name : DR. YASIR H. NAIF Position : LECTERUR FACULTY OF ENGINEERING TECHNOLOGY, UNIVERSITI MALAYSIA PAHANG Date : DECEMBER 2016 STUDENT'S DECLARATION I hereby declare that the work in this thesis is based on my original work except for quotations and citations which have been duly acknowledged. I also declare that it has not been previously or concurrently submitted for any other degree at Universiti Malaysia Pahang or any other institutions. (Student's Signature) Full Name :MUHAMMAD AMIR SY AHIRAN BIN MUHAMMAD TARMINZI ID Number : TA 13002 Date : DECEMBER 2016 v Vl ACKNOWLEDGEMENTS I would like to express the deepest appreciation to my supervisor, Dr. Yasir H. Naif, who has the attitude and the substance or a genius: he continually and convincingly conveyed a spirit of adventure in regard to research and an excitement in regard to teaching. Without his guidance and persistent help this senior design project would not have been possible. I wish to express my sincere thanks to Professor Dato' Dr. Zularisam Ab W ahid, Dean of the Faculty of Engineering Technology, for providing me with all the necessary facilities to complete the fabrication and testing of this senior design project. I am highly indebted and thoroughly grateful to my group project members, Harvindran AIL Kuppusammy and Nur lzaati binti Arshad for their help and support. We have created the best co-operation among ourselves deliberating over our problems and findings, but also happily by talking about things other than just our papers during this study. I would also like to thank both of my parents for their wise counsel and sympathetic ear all the time during my study here. My father, Mr. Muhammad Tarminzi bin Mustapha and my mother, Mrs. Norhayati binti Ali @ Mohd Ali. I cannot find the appropriate words that could properly describe my appreciation for their devotion, support and faith in my ability to attain my goals. Vll ABSTRACT Solar power is the energy from the sun that is converted into thermal or electrical energy. The uses of solar energy are now developing rapidly since it is the cleanest and renewable energy source available. This paper presents the design and fabrication of high-efficiency dual-axis solar tracking system. Moreover, the objectives of this paper is to make sure the designed dual-axis solar tracking system can move the solar panel to the direction of the light accurately. The project can be divided into two stages, which are the designing the structure of the solar tracker and the fabrication of the parts. In the design development, SolidWorks software is used to create the structure of the solar tracking system. To prove the structure is perfect for the solar tracking system, another software is used to test it. For the fabrication part, correct process is carefully chosen based on the machines and tools available in UMP. After the structure is completed, a solar panel, two linear actuators, sensors and batteries are assembled in the solar tracking system. The efficiency of the system has been tested and compared with static solar panel on several time intervals, and it shows the system react the best at the to-minutes intervals with consistent voltage generated. Therefore, the structure has been proven working for directing the solar panel towards the direction of light accurately so that it can capture maximum sunlight source for high efficiency solar harvesting applications. TABLE OF CONTENT SUPERVISOR'S DECLARATION STUDENT'S DECLARATION ACKNOWLEDGEMENTS ABSTRACT TABLE OF CONTENT LIST OF TABLES LIST OF FIGURES CHAPTER 1 INTRODUCTION 1.1 Introduction 1.2 Problem Statement 1.4 Significance of Research CHAPTER 2 LITERATURE REVIEW 2.1 Solar Power 2.1.1 History Of Solar Power 2.1.2 Technologies In Solar Tracking 2.2 Sun' s Position 2.2.1 Elevation Angle Page iv v vi vii viii xi xii 5 5 6 7 8 10 11 Vlll lX 2.2.2 Zenith Angle 11 2.2.3 Azimuth Angle 12 2.3 Solar Tracking System 12 2.3.1 Fixed Solar Panel 13 2.3.2 Passive Solar Tracker 14 2.3.3 Single Axis Solar Tracker 15 2.3.4 Dual-Axis Solar Tracker 17 2.4 Solar Panel 19 2.4.1 Monocrystalline Cell 20 2.4.2 Polycrystalline Cell 21 2.4.3 Amorphous Cell 22 2.5 Motor 23 2.5.1 DC Motor Brushed 23 2.5.2 DC Motor Brushless 23 2.5.3 Stepper Motors 24 2.5.4 Servo Motors 25 2.5.5 Linear Actuator 25 2.5.6 Comparison Between Motors 28 2.6 Light Dependent Resistor (LDR) 29 2. 7 Batteries (Load) 30 2.7.1 Lead Acid Battery 32 2.7.2 Rechargeable Alkaline Battery 33 2.7.3 Lithium-Ion Battery 34 2.7.4 Nickel-Metal Hydride Battery 36 2.7.5 Lithium-Ion Polymer Battery CHAPTER 3 METHODOLOGY 3.1 Introduction 3.2 Planning for Senior Design Project 3.3 Designing Structure Of Dual Axis Solar Tracker 3.4 Material Selection 3.4.1 Properties OfMild Steel 3.4.2 Comparing Mild Steels To Other Materials 3.5 Fabrication 3.5.1 Cutting Process 3.5.2 Welding Process 3.5.3 Joining Process 3.5.4 Finishing Process 3.6 Final Product 3.7 Cost Analysis 3.8 Gantt Chart 3.9 Ethical Consideration CHAPTER 4 RESULTS AND DISCUSSION 4.1 4.1 Project Outcomes 4.2 Design Analysis 4.2.1 Load Calculation 37 38 38 40 45 46 47 49 49 52 53 55 57 58 59 60 61 61 62 X 4.2.2 Stress And Defonnation Test 4.3 Solar Output CHAPTER 5 CONCLUSION 5.1 Conclusion 5.2 Recommendations REFERENCES APPENDIX A SAMPLE APPENDIX 1 APPENDIX B SAMPLE APPENDIX 2 63 64 67 68 69 72 75 XI Xll LIST OF TABLES Table No. Title Page Table 2.1 Types and the characteristics of actuators 27 Table 2.2 Motor actuation comparison table 28 Table 2.3 Light intensity measurement 29 Table 2.4 A table of all of the most commonly accepted rechargeable batteries on 32 the market today. Table 3.1 Design of dual axis solar tracker using SolidWorks software 43 Table 3.2 Properties of Mild Steel 46 Table 3.3 Comparison between mild steel, stainless steel and Aluminiwn 47 Table 3.4 The advantages and disadvantages of using mild steel 48 Table 3.5 Cost analysis 58 Table 4.1 Solar voltage output of PV panel in Fixed Mode for Sunny day 64 Table 4.2 Solar voltage output of PV panel in Tracking Mode for Sunny day 65 Table 4.3 Comparison of solar voltage output of PV panel in Fixed Mode and 66 Tracking Mode for Sunny day Xlll XlV LIST OF FIGURES Figure No. Title Page Figure 1.1 Movement for dual-axis solar tracker 2 Figure 1.2 Linear actuators of our project 3 Figure 2.1 Fix-mounted solar panel fixed on roof 9 Figure 2.2 Sun's position 10 Figure 2.3 The position for elevation, zenith and azimuth angles 11 Figure 2.4 Solar panel being fix-mow1ted on ground by solar mow1ting 14 structure Figure 2.5 Mechanism for passive solar tracking system 15 Figure 2.6 Principle of Single Axis Solar Tracking 16 Figure 2.7 Block Diagram of Single Axis Tracker System 16 Figure 2.8 Mechanism for dual-axis solar tracking system 17 Figure 2.9 Dual-axis solar tracking system 18 Figure 2.10 Monocrystalline solar panel 21 Figure 2.11 Poly crystalline solar panel 22 Figure 2.12 Amorphous solar panel 22 XV Figure 2.13 Working principle of PM stepper motor 24 Figure 2.14 The linear actuator system 26 Figure 2.15 LDR construction 30 Figure 2.16 Relationship between the lifetimes of each particular type of 34 battery Figure 2.17 Relationship between the cell capacity and number of discharge 35 cycles for a lithium ion battery Figure 2.18 The discharge temperature of the nickel metal hydride can be 37 related to the amount of capacity available within the battery itself Figure 3.1 Planning for senior design project 39 Figure 3.2 Finished design 44 Figure 3.3 2-inch x 2-inch mild steel 45 Figure 3.4 Stress strain curve for mild steel 48 Figure 3.5 Measuring tape 50 Figure 3.6 Faithful double end scriber and engineer square 50 Figure 3.7 Illustration how to use scriber and engineer square 51 Figure 3.8 Bosh cutting machine 51 Figure 3.9 MIG welding machine 52 XVl Figure 3.10 The figure shows how the linear actuator is assembled 53 Figure 3.11 The figure shows how the base part is joined to the upper part 54 by using brackets Figure 3.12 The base of linear actuator is fixed to a plate using bolt and nut 55 Figure 3.13 Bowl-type wire wheel wire brush used to remove rust 56 Figure 3.14 Tools to remove welding wear 56 Figure 3.15 Spraying 57 Figure 3.16 Final product 57 Figure 4.1 Simulation results on the main support 63 Figure 4.2 Solar voltage output by time of the day in Fixed Mode for sunny 64 day Figure 4.3 Solar voltage output by time of the day in Tracking Mode for 65 sunny day Figure 4.4 Graph of comparison solar voltages output in Fixed Mode and 66 Tracking Mode for Sunny day 1 CHAPTER 1 INTRODUCTION 1.1 INTRODUCTION According to National Center of Policy Analysis, solar power is the fastest growing means of renewable energy production with grid connected solar capacity increasing on average by 60% annually from 2004 to 2009 (D.Johnson-Hoyte et al, 2013). Unfortunately, solar energy only contributing a small part in energy work field. It is stated that the future of PV solar technologies looks promising considering favorable location and continued federal tax subsidies as well as state renewable standard protocol (S.J.Reichelstein and M.Yorston, 2012). According to paper, with the continued trend in decreasing cost of PV panels and government subsidies, PV Solar energy might become cost competitive in the next 10 years (subsidy-free), for commercial installations while for Utility-scale installations it will take longer. The latest solar energy production is by using the solar panel and solar tracker where the device is used to identify and track the light direction. The goal of this project is to build a Dual-axis Smart Solar Tracking System which is basically a device onto which sensors had been used to track the accurate direction of the sun across the sky to ensure maximum amount of sunlight strikes on solar panel throughout the day. The tracking system is continuously finding the sunlight by navigating through the path ensuring the best sunlight is detected. Our team members are divided to three major specializations which are manufacturing for design chassis part, electrical for controller and energy for solar panel and determine the experimental location. The design of the solar tracker requires many components. The design, construction and test of it could be divided 2 into five main parts, each with their main function. They are: 1. Design of tracker 2. Solar panel chosen, 3. Sensor and Sensor Controller, 4. Solar working mechanism with the sun, 5. Solar tracker efficiency. Dual-Axis solar systems allow for precise control of the elevation and azimuth angle of the panel relative to the sun. The tracking system is reported to be more accurately potentially double the energy output of a fixed PV Solar system which is about 48.982% (A.Catarius and M.Christiner, 2010). Meanwhile, if it is compared to the single axis solar tracker, it is also proven that dual axis solar tracker will give more energy output since they can rotate on two axes due to its two degrees of freedom that act as axes of rotation. They are primary axis, the axis that is fixed with respect to the ground and secondary axis, which is the axis referenced to the primary axis. These axes are typically normal to one another. There are several common implementations of dual axis trackers. They are classified by the orientation of their primary axes with respect to the ground. Two common implementations are tip-tilt dual axis trackers (TTDAT) and azimuth-altitude dual axis trackers (AADAT). So, the dual axis solar tracker can produce 40% more power compared to the single axis solar tracker (M.Scanlon, 2010). f'toflh Figure 1.1: Movement for dual-axis solar tracker 3 The design of the solar tracking system is completed by using SolidWorks software, which is one of the friendliest designing tools. The design is used to help the process of fabrication where the measurement of each part is precisely done in the drawing. After the design process, the construction process of the solar tracker it is done with the aids of many machines and tools. For example, saw machine, grinder and welding machine. At the end, the solar tracking system is tested practically under the sunlight. Compared to last year's, this project can ensure more precise direction since the solar panel is moved in two axes. Two linear actuators are used in order to move the solar panel in east-west and also north-south directions. With the used of these two linear actuator, it can increase the movement range of the solar panel. So, the solar panel are able to face any direction of the sunlight. Besides, with the aid of five sensors, it enhances the accuracy of the tracking system in order to trace the light intensity. By doing this, the solar tracking system are able to navigate to the best angle of exposure oflight from the sun. the sensors constantly monitor the sunlight and tilt the panel towards the direction where the intensity of sunlight is max1mum. Figure 1.2: Linear actuators of our project 69 REFERENCES Adrian Catarius and Mario Christiner (2010). Azimuth-Altitude Dual Axis Solar Tracker Alexandru C and Pozna C. Simulation of A Dual-Axis Solar Tracker for Improving the Perfonnance of a Photovoltaic Panel. Proc Inst Mech Eng, Part A: J Power Energy 2010;224(6):797-811 Dante Johnson-Hoyte, Melanie Li Sing How, Dante Rossi and Myo Thaw (2013). Dual-Axis Solar Tracker: Functional Model Realization and Full -Scale Simulations David Cooke (2011). "Single vs . Dual Axis Solar Tracking", Alternate Energy eMagazine, April 2011 David G. Vutetakis (2001). Batteries, Douglas Battery Co. by CRC Press LLC David Linden and Thomas B. Reddy (2001). HANDBOOK OF BATTERIES, 3rct Edition Deepthi.S, Ponni.A, Ranjitha.R, R Dhanabal, (20 13). Comparison of Efficiencies of Single-Axis Tracking System and Dual-Axis Tracking System with Fixed Mount Dijon Gumbs, James Lillie & Kaniel Martin, 2010, Solar Tracking Battery Charger Senior Design 1 Report Group 12 Dirk C. Jordan and Sarah R. Kurtz (2012). Photovoltaic Degradation Rates - An Analytical Review Energy.gov (20 15). Crystalline silicon photovoltaics. (Online) http://energy.gov/eere/stmshot/crystalline-silicon-photovoltaics-research (2 October 20 16) Freiburg (20 16). Photovoltaics report. (Online) https://www.ise.fraunhofer.de/de/downloads/pdf-files/aktuelles/photovoltaics-report-in-englischer-sprache.pdf (2 October 2016) George E. Dieter (1997). "Overview of the Materials Selection Process", ASM Handbook Volume 20: Materials Selection and Design 70 Hossein Mousazadeh, Alireza Keyhani, Arzhang Javadi, Hossein Mobli, Karen Abrinia and Ahmad Sharifi (2009). A Review of Principle and Sun-Tracking Methods for Maximizing Solar Systems Output International Energy Agency (2014). "Technology Roadmap: Solar Photovoltaic Energy" (PDF). lEA. Archived from the original on 7 October 2014. Retrieved 7 October 2014 Jaykant Gupta (2009). Mechanical and Wear Properties ofCarburized Mild Steel Samples John A. Duffie and William A. Beckman (2013). Solar Engineering of Thermal Processes, 41h Edition Joshua M. Pearce (2002). Photovoltaics -A Path to Sustainable Futures LaMar Alexander (2007). Simple Solar Homesteading: Off The Grid, SunPower Publishing: page 112 Mark Scanlon (2010). Dual-Axis Tracking Generates More Power. (Online) http ://www.renewableenergyworld.com/articles/print/pvw/volwne-2/issue-6/solar-energy/dual-axis-tracking-generates-more-power.html (14 September 20 16) Mehleri, E.D., P.L. Zervas, H. Sarimveis, J.A. Palyvos, and N.C. Markatos. "Determination of the Optimal Tilt Angle and Orientation for Solar Photovoltaic Arrays."Renewable Energy 35.11 (2010): 2468-475 Michael I. Current, 2010. Russell Ohl: The "Forgotten" Bell Labser. (Online) http://www.avsusergroups .org/ jtg pdfs/jtg2010 5current.pdf (23 November 2016) Narendrasinh .J. Parmar, Ankit .N. Parmar, Vinod .S. Gautam, (2015). Passive Solar Tracking System. Scott, By Andy, 2010 "Top Ten Stepper Motor & DC Motor Advantages and Disadvantages I DC Stepper Motor Benefits and Drawbacks." CNC Machine Tool Help I Learn CNC I CNC Programming I Learn Cnc I CNC Training Information and CNC Articles. 2003. http: //www.machinetoolhelp.com/ Automation/systemdesign/stepper dcservo.html (11 November 20 16) 71 Stefan Reichelstein and Michael Yorston (2012). The Prospects for Cost Competitive Solar PV Power Sue Bloomfied (20 16). Batteries and Solar Power: Guidance for Domestic and Small Commercial Consumers Sunpower Set Solar Cell Efficiency (2010). (Online) http://www .renewableenergyworld.com/artic les/20 l 0/06/sunpower -sets-so Jar-cell-efficiency-record-at-24-2.html (1 December 2016) Tamara A. Papalias and Mike Wong, (2007). Making Sense of Light Sensors Tania Ahmed, SyedaEshita Ashraf and MasruraTamanna (20 14 ). Performance and Evaluation OfMicrocontroller based Multilevel Sun Tracking Solar Photo Voltaic System Thomas Werner (2010). Integrating Distributed Energy Resources into Smart Grids with Virtual Power Plants Tiberiu Tudorache, Constantin Daniel Oancea, Liviu Kreindler (2012). Performance Evaluation of a Solar Tracking PV Panel Zhe Mi, Jikun Chen, Nuofu Chen, Yiming Bai, Rui Fu, Hu Liu (2016). Open-Loop Solar Tracking Strategy for High Concentrating Photovoltaic Systems Using Variable Tracking Frequency 

Design and fabrication of dual axis solar system tracker

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Design and fabrication of dual axis solar system tracker

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