PERPUSTAKAAN UMP

IU I III IllI III III 0000086155

SINGLE AXIS ROTATION PV SOLAR PANEL TRACKING SYSTEM

ONG HORN LU

Report submitted in partial fulfillment of the requirements for the award of the degree of

Bachelor of Mechanical Engineering

F'

Faculty of Mechanical Engineering UNIVERSITI MALAYSIA PAHANG

. JtVij PERPUSTQN ' tJNVEm MALAYSIA PAHANG

N7Pan9gija--n- '15 !10 "

AO 13

2013

JUNE 13 rgMAy2ol4.

vi

ABSTRACT

A sustainable energy supply is required in Malaysia to meet the increasing electricity demand with rapid growing in population and economy. Photovoltaic solar panel is most suitable alternative way to generate electricity in Malaysia where most of its location receives large number of solar radiation throughout the year. However, fixed solar panel is more preferred than tracking panel because it is cost effective. In present work, the power output and efficiency of single-axis tracking solar panel is compared with fixed solar panel by experimentally in East Coast Malaysia. A single-axis tracking panel produces higher power output than fixed panel up to 28W. During this time, the average efficiency of tracking panel was about 66.70% and fixed panel was 39.96%. Hence, the percentage increment on average power output using tracking panel reached up to 66.92% compare to fixed panel during this period. The tracking panel module efficiency was higher than fixed panel for the same period and can reach up to 28.9% at 6.00p.m. In conclusion, single-axis tracking panel is more efficient than fixed panel in premeridian and postmeridian. Thus, it produces higher power output than fixed panel which means it utilize the most of available solar radiation effectively and this will reduce payback period of the initial investment cost.

VII

ABSTRAK

Satu bekalan tenaga yang berterusan diperlukan di Malaysia bagi memenuhi permintaan elektrik yang semakin meningkat berpunca dari penduduk dan ekonomi yang berkembang pesat. Panel solar Photovoltaic adalah cara alternatif yang paling sesuai untuk menjana tenaga elektrik di Malaysia di mana kebanyakan tempat menerima sinaran suria yang banyak sepanjang tahun. Walau bagaimanapun, panel solar tetap adalah lebih diutaniakan dari panel mengesan trek cahaya matahani kerana ia adalah kos efektif. Uji kaji dijalankan untuk membanding kuasa keluaran dan kecekapan panel solar tetap dengan panel solar yang pengesan trek cahaya matahari dalam paksi tunggal di Pantai Timur Malaysia. Panel solar pengesan trek cahaya matahari dalam paksi tunggal menghasilkan kuasa keluaran yang lebih tinggi daripada panel tetap sebanyak 28W. Pada masa iii, kecekapan purata panel solar pengesan trek cahaya matahari adalah sebanyak 66.70% dan panel tetap adalah 39.96%. Oleh itu, peratusan kenaikan purata kuasa keluaran panel pengesanan matahari mencecah sehingga 66.92% berbanding dengan panel tetap dalam tempoh yang sania. kecekapan modul panel mengesan matahari adalah lebih tinggi daripada panel tetap bagi tempoh yang sama dan mencecah sehingga 28.9% pada pukul enam petang. Kesimpulannya, panel pengesan matahari dalam paksi tunggal adalah lebih berkesan daripada panel tetap di premeridian dan postmeridian. Oleh itu, ia menghasilkan kuasa keluaran yang lebih tinggi daripada panel tetap punca dari sinaran suria digunakan dengan lebih berkesan dan mi akan mengurangkan tempoh bayar batik kos pelaburan awal.

viii

Page

TITLE PAGE

SUPERVISOR'S DECLARATION

STUDENT'S DECLARATION

DEDICATION

ACKNOWLEDGEMENTS

ABSTRACT

TABLE OF CONTENTS

LIST OF FIGURES

LIST OF TABLES xiii

LIST OF SYMBOLS xiv

LIST OF ABBREVIATIONS xvi

CHAPTER 1 INTRODUCTION

1.1 Background 1

1.2 Problem Statement 2

1.3 Objectives of Project 2

1.4 Project Scope 3

1.5 Gantt Chart 4

CHAPTER 2 LITERATURE REVIEW

2.1 Introduction 6

2.2 Malaysia Climate 6

2.3 Sun - Earth Relationship

2.4 Solar Energy 8

2.5 Declination Angle (5)

2.6 Hour Angle for Sunrise, Sunset, and Monthly Average of 11

Maximum Possible Sunshine Hour per Day

lx

2.7 Photovoltaic Technology 12

2.8 Solar Panel 12

2.9 Performance of Tracking and Fixed Panel 15

2.10 Type of Sun Tracker 15

2.11 Sun Tracking Method 16

2.11.1 Passive Trackers 16 2.11.2 Active Trackers 17

CHAPTER 3 EXPERIMENTAL DETAILS AND MODELLING

3.1 Introduction 22

3.2 Draft Design 25

3.3 Dimension of The Design 25

3.4 Material 28

3.5 Modeling 29

3.6 Motor 30

3.7 Gear Reduction 31

3.8 Control System 32

3.9 Electrical Component 34

3.9.1 Programmable Intelligent Computer (PlC) 34 3.9.2 Light Dependant Resistor (LDR) 35

3.10 LCD (16x2) 36

3.11 Circuit Diagram 36

3.12 Program PICl8F455O 38

3.13 Experiment Set-up and Procedure 38

3.14 Efficiency Calculation 40

CHAPTER 4 RESULT AND DISCUSSION

4.1 Introduction 41

4.2 Selecting the Suitable Material for Test Rig 41

4.2.1 Analytical simulation 41

4.3 Solar Radiation, Power Output and Energy Output 45

x

4.3.1 Performance of PV solar panel on sunshine day in UMP, 45 Pekan

4.3.2 Performance of PV solar panel on partly cloudy day in UMP 48 Pekan

4.4 Performance Evaluation 51

4.4.1 Performance comparison between tracking and fixed PV 51 solar panel on clear sky day and partly cloudy day

4.4.2 Calculation on number of PV panels requires to charge 24V 52 battery

4.4.3 Sample calculation of average power output and average 53 efficiency on clear sky day (22 March 2013)

4.4.4 Sample calculation of module efficiency of PV on clear sky 54 day (22 March 2013)

CHAPTER 5 CONCLUSION AND RECOMMENDATION

5.1 Conclusion 55

5.2 Recommendation 56

REFERENCES 57 APPENDICES 61

LIST OF FIGURES

Figure No. Title Page

2.1 Malaysia Solar radiation distribution 7

2.2 Sun positions in the northern hemisphere countries and the sun 9 path

2.3 Sun-Earth relationship 9

2.4 Variation of declination angle 5 with the nth day of the year 10

2.5 Maximum array tilt angles of varied seasons 11

2.6 Solar panel array configuration 13

2.7 Monocrystalline, Polycrystalline, and Thin film/Amorphous 14 Silicon Solar Panel

2.8 Plan View of an auxiliary bifacial solar cell 19

2.9 Photograph of the terrestrial tracker 20

2.10 Simulated example of the three variables (SMv, SEq, and CEq) 21

3.1 Flow chart of FYP progress 23

3.2 Draft design of PV solar panel bracket 25

3.3 Free body diagram of a portion of beam CC' 26

3.4 CAD drawing of Single-axis tracking PV panel 30

3.5 Proton Wira power window motor (right) 31

3.6 Flow chart of control system 33

3.7 PlC 18F4550 34

3.8 Tracking system working principle using LDR 35

3.9 LCD (16x2) 36

3.10 Circuit diagram for tracking system 37

xi

3.11 Circuit board of control system 37

3.12 Schematic diagram and actual photograph of PV Solar Panels 39

3.13 GT Power RC watt meter/Power Analyser 130A 39

4.1 Surface force and boundary condition on test rig 42

4.2 Maximum stress of test rig from three materials 42

4.3 Example solar radiation on sun shine day (Date 22 march 2013) 45

4.4 Power curve comparison between fix solar panel and solar 46 tracking system on date 22 March 2013in UMP, Pekan (Sunshine day)

4.5 Energy produces by fixed solar panel and solar tacking system 47 on date 22 March 2013 in UMP, Pekan (Sunshine day)

4.6 Example solar radiation on half sun shine day (Date 20 march 48 2013)

4.7 Power curve comparison between fix solar panel and solar 49 tracking system on date 20 March 2013 in UMP Pekan (half sunshine day)

4.8 Energy produces by fix solar panel and solar tacking system on 50 date 20 March 2013 in UMP Pekan (half sunshine day)

Al First view drawing of test rig 75

xii

LIST OF TABLES

Table No. Title Page

3.1 Mechanical properties of mild steel, aluminium alloy, and brass 29

3.2 Materials prices of dimension 2"square cut to 12"long 29

3.3 Motor specifications 31

3.4 Specification of PV Panel 39

4.1 Comparison maximum stress, ultimate tensile strength, and 44 safety factor between three materials

4.2 PV Solar Panel Efficiency 51

4.3 Module Efficiency (%) 51

4.4 Number of panels requires to charged 24V battery 52

Al Recommended average days for months and values of n by 70 months

A2 Calculation for Optimum Tilt Angle for PV solar panel in 73 UMP, Pekan

xli'

xiv

LIST OF SYMBOLS

(5

Declination angle,

(Os Hour angle, 0

Latitude, 0

NM

Monthly average of maximum possible sunshine hours per day, in hours

n

Leap year! Non leap year + Day

M

Bending moment, Nm

V

Shear force, F

X

Distance along x axis, m

y

Distance along y axis, m

W

Load, N

a1l

Allowable stress, Pa

o-u Ultimate stress, Pa

umax Maximum stress, Pa

I

Moment of inertia, m4

b

Base, m

h

Height, m

lip

Average PV solar panel efficiency

P0 Average power output from panel, W

Prnax

Maximum power output of the panel, W

11

Module efficiency

Area of PV solar panel, m2

G

Horizontal global irradiance, W/m2

/1

Angle made by the plane surface with horizontal

xv

L Length, m

M Mass, kg

F Force, N

R Reaction, N

t Thicknes, m

C Centroid, m

E Modulus of Elasticity

Le Effective length, m

Paii Allowed force, N

Pcr Critical force, N

g Gravity force, m/s

T Torque, Nm

N North

E East

H0 Monthly average of daily extraterrestrial radiation on a horizontal surface, kJ/m2.day

Hg Monthly average of daily global radiation on a horizontal surface, kJ/m2 .day

Hd Monthly average of daily global radiation on a horizontal surface, kJ/m2.day

Hb Monthly beam radiation, kJ/m2.day

a,b Regression coefficients which vary from site to site

flopt Optimum angle

LIST OF ABBBREVIATIONS

UMP Universiti Malaysia Pahang

PV Photovoltaic

FYP Final Year Project

SMA Shape Memory Alloy

Ni-Ti Nickel Titanium

CMOS Complementary Metal Oxides

IC Integrated Circuit

LDR Light Dependant Resistor

PlC Peripheral Interface Controller! Programmable Intelligent Computer

DC Direct Current

SMv Sun's Real Movement

SEq Progression of The Values Yielded by The Solar Equations

CEq Evolution Obtained After The Corrections

PSM Program Sarjana Muda

ASTM American Society for Testing and Materials

CAD Computer Aided Design

RPM Revolution Per Minute

EUSART Enhanced Universal Synchronous/Asynchronous Receiver/Transmitter

MCLR Master Clear

ADC Analog to Digital Converter

xvi

CHAPTER 1

INTRODUCTION

1.1 BACKGROUND

Population of human increased drastically in the past half century, and now the

human population is estimated to exceed 7 billion in the year 2012. A huge increasing

in human population cause the demand of electricity increase rapidly. However, energy

supply is far less than the actual demand in recent years as a result of industrial

development and population growth. In additional, the fossil fuel as the primary energy

source estimated drain in the future soon and global warming and pollution cause by

fossil fuel affect human health. As a result, scientists and engineers work hard to find an

efficient alternative energy such as solar, wind, ocean, geothermal, and nuclear to

replace fossil fuel now days. Among all the alternative energy, solar energy is one of the

most suitable green energy to replace fossil fuel due to its available constantly, naturally

replenished, safe to use, save space and easy to install. Nevertheless, several problems

annoying engineers and limit the popularity of the solar energy which are low efficiency

of the solar panel, losses in reflection of sunlight toward solar panel, and the high cost

to build the solar system.

Our earth rotates on its axis and equatorial plane is tipped 23.5° from the ecliptic

Plane, makes a slightly elliptical orbit surrounding the sun. Malaysia did not experience

four seasons like other countries in a year. However, the position of the sun is changing

everyday due to northern hemisphere tip towards or away from the sun and it affects the

performance of the solar panel.

2

This project calls "Single Axis Rotation PV Solar Panel Tracking System".

Solar energy is one of the most potential green energy to use to replace the current fossil

fuel energy in our country. This project helps to maximize the power generating by

solar system by setting the solar panel perpendicular to the sun ray. This project will use

an electrical motor to turn the gearing system, a gearing system that moves the surface

of the solar panel to be perpendicular to the sunlight to get the maximum intensity of

light. This system is easy to operate and suitable to move the solar panel smoothly to

increase the efficiency of solar energy.

1.2 PROBLEM STATEMENT

A solar system was installed as the main power source to charge the battery that

operates the pump that cycle the water between solar collector and water storage tank in

Universiti Malaysia Pahang (UMP) at Pekan, Pahang. However, the fixed solar panel

can't fully utilize, the most available solar radiation effectively and the desired amount

of solar panels to charge the battery and area of installation are increasing. In order to

maximize the advantage of solar energy and reduce the cost, the efficiency of solar

panel needs to be increased. Solar panel builds by monocrystalline material has higher

efficiency than thin film amorphous material, however, the cost to build the solar

system also increase dramatically. Nevertheless, a simple mechanism tracking system

may be the greatest solution to increase the efficiency of solar systems with relatively

low cost.

1.3 OBJECTIVE OF THE PROJECT

Below are the main objectives of "Single Axis Rotation PV Solar Panel

Tracking System" project.

(i) To develop a single axis rotation sun tracking system for PV solar panel.

(ii) Selecting the suitable material for tracker fabrication.

(iii) To design, fabricate, and evaluate test rig, control system and performance

between tracking and fixed panel.

3

1.4 PROJECT SCOPE

This project focused on design, fabricate, and evaluate a single axis rotation sun

tracking system for PV solar panel. Therefore, the tracking system will cover the scope

as follows.

(i) Conceptual design method of tracker.

(ii) System components and tracker fabrication using suitable and available

materials.

Compare and evaluate the output of solar panel with' and without tracking

system from time 9am to 6pm at UMP, Pekan.

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CHAPTER 2

LITERATURE REVIEW

2.1 INTRODUCTION

This chapter discusses the background of study related to this project This study

including sun-earth relationship, type of PV panel, types of sun tracker and methods of

tracking. Previously finding, rationale of the relevant study, methodology or research

methods and theoretical background of those studies will include in this chapter. Most

of the literature review and equations have been extracted from journals, books, and

wed site. Literature reviews from those information sources avoid the same mistake

happen like previous people done. Moreover, with these literature reviews, the project

can be run smoothly.

2.2 MALAYSIA CLIMATE

Direct sunlight also knows as beam radiation refers to the solar radiation

traveling in a straight line and reach the earth's surface without being scattered by the

earth's atmosphere. Diffuse radiation refers to the sunlight that reach the earth's surface

also but has been scattered by cloud in the sky. Meanwhile, total solar radiation or

global radiation is the sum of beam and diffuse radiation that reach the earth's surface

(Velautham, S. 2006). As cited in Monitoring results of Malaysian Building Integrated

PV Project in Grid-connected Photovoltaic system in Malaysia, the average daily global

solar irradiation in Malaysia is approximately 4.5 kWh/M2. Moreover, Malaysia

experience heavy rainfalls whole year, which between 2000mm to 2500mm per year.

Below is the average total daily solar radiation distribution in Malaysia. It is clearly

shown that the solar radiation distribution in Pekan is 15-16 MJ/m2.

13-14 El]

LII] 14-15

[III] 15-16

LIII 16-17

LII] 17-18

LII] 18-19

c 19-20

20-21

21-22

7

Figure 2.1: Malaysia Solar radiation distribution (Velautham, S. 2006)

2.3 SUN - EARTH RELATIONSHIP

Malaysia is a Tropical country which tropical region between 10 N and 70 N, and

1000 E and 1190 E. The weather of Malaysia remains relatively constant throughout the

year. As cited in The Performance of Three Different Solar Panels for Solar Electricity

Applying Solar Tracking Device under the Malaysian Climate Condition (Azhar

Ghazali et al, 2012), sunlight is available for more than ten hours per day and the

irradiation of direct sunlight is between 800W/M 2 and 1 000 W/m2 with approximate six

hour. Yet, as cited in Monitoring results of Malaysian Building Integrated PV Project in

Grid-connected Photovoltaic system in Malaysia, the annual average solar irradiation

was estimated to be approximately 1643 kWhIm 2/yr. From website index Mundi, the

Electric power consumption in Malaysia was 3613.53 kWh per capita in 2009,

according to a World Bank report, published in 2010. This means that energy from

approximately 3m2 of solar irradiation can support a Malaysian electrical consumption.

According to the Malaysia meteorological department, the monthly average maximum

direct sunlight that receives in Alor Setar is 8.7 hours while Kuching, on the other hand,

only receive an average of 3.7 hours of direct sunlight in extreme case. On the average,

Malaysia receives about 6 hours of sunshine per day.

2.4 SOLAR ENERGY

A sustainable energy supply is required in Malaysia to meet the increasing

electricity demand with rapid growing in population and economy. Solar energy is one

of the most potential renewable energy in Malaysia, whereby most of its location

receives abundant solar radiation yearly (AZhari,A.W. et al., 2008). The photovoltaic

(PV) solar panel is an alternative way to generate green electricity and becoming one of

popular technology in Malaysia. Typically in Malaysia, the stationary PV solar panel is

installed at fixed position at the rooftop of a building to harness energy from solar

irradiation during daytime throughout the year. Conversely, Ban, S. (2001) noticed that

not all Malaysian domestic consumers installed their PV solar panels at an optimum

orientation and tilt angle. Eventually, it reduces the incoming solar irradiation onto

panel to 10-35% less than properly installed solar panel. The optimum tilt angle of solar

panel is depending on seasons, location, month by month basis throughout the year.

However, the best position to receive irradiation of direct sunlight for the Northern

Hemisphere countries this is due south, for countries on the Southern Hemisphere this is

north. Thus, an optimum orientation and tilt angle can increase the yearly gains for

installed fixed solar panel.

However, the properly installed fixed panel is also operating less efficient at

some point compared to tracking panel due to the sun's motion on daily and yearly basis.

Therefore, employing a tracking panel will generate higher electricity and more efficient

as compared to fixed panel. (Chang, T.P, 2009; Lubitz,W.D., 2011; Ma, Y.,Li, G.,&

Tang, R., 2011)

8

NorthSouth

un's path )ecember 21

,ujijath \Ofl solstices

West

Sun's path

Figure 2.2: Sun positions in the northern hemisphere countries and the sun path (Mandi

E,J. et al. 2011)

2.5 DECLINATION ANGLE (ö)

Equatorial plane is tipped 23.5° from the ecliptic plane. As Earth revolves

around the sun, the orientation produces a varying solar declination. Declination () is

the angle subtended by a line joining the centers of the earth and the sun with its

projection on the earth's equatorial plane. Winter season happens when the northern

hemisphere tip away from sun meanwhile the summer season when the northern

hemisphere tip toward the sun.

N N 1 Tropic of Cancer 231/20 N 66'/211

Equator I 23Y20 ,Equator

- Sun's rays 231/20 ( Sun

23t I

lJ..UII

Axis perpendicular Tropic of \

l

\ to orbit plane 231/20 N S 22 Dec. winter solstice 21 June summer solstice

Tropics and northern hemisphere.

Figure 2.3: Sun-Earth relationship (Sharani,P., 2012)

+30

+20

+23.50

(1) ) +10

D) w

—10 C 0

10

The declination angle for an nth day may be calculated from the following

simple relationship given by Cooper (1969):

5 (in degrees) = 23 45 sin[ 284+n * 3601 (2.1)

365 -'

Where n is the total number of days counted from first January till the date of

calculation. The figure below descried the variation of declination angle 6 with the nth

day of the year. The graph clearly shows that the declination angle ô is a sine graph. The

zero declination angles 6 on March 22(fall) and September 22(spring). Besides that, the

minimum declination angle 6 change from value —23.5 December 22 to +23.5 ° on Jun

22.

—3Q I i- —23.5° I Sep, 22 Dec. 22 Mar. 22 Jun. 22 Sep. 22

Spring equinox Winter equinox Fall equinox Summer equinox Spring equinox

Time of the year

Figure 2.4: Variation of declination angle c with the nth day of the year (Sharani,P.,

2012)

Variations of the declination angle affect the optimum tilt angle of solar panel

toward the sunlight. During winter season, the solar panel should be mounted at a

greater tilt angle in order to get the maximum irradiation of sunlight. Furthermore, the

tilt angle of solar panel should be mounted at a smaller angle to achieve the optimum

performance. For spring and fall season, the declination angle is zero, in order to

maximize the energy production, the solar panel should mount at an angle between

winter and summer seasons. The figure below shows the relationship of the declination

angle of the varied seasons with the tilt angle of the solar panel.

Optimum Array Tilt Angles

11

tAntrrD

/ rir SUN PATH

TILT ANGLE CLOSE T0-V LATITUDE.

I __--TILT ANGLE

LESS THAN LATITUDE

MAXIMUM ANNUAL ENERGY PRODUCTION

1.1

/

MAXIMUM SUMMER MAXIMUM WINTER ENERGY PRODUCTION ENERGY PRODUCTION

Figure 2.5: Maximum array tilt angles of varied seasons (Sharani,P., 2012)

2.6 HOUR ANGLE FOR SUNRISE, SUNSET, AND MONTHLY AVERAGE

OF MAXIMUM POSSIBLE SUNSHINE HOUR PER DAY

Hour angle, the angular displacement of the sun east or west of the local

meridian due to rotation of the earth on its axis at 15 per hour; morning negative,

afternoon positive. The hour angle for sunrise, sunset are depend on the latitude and

declination angle of the location. In order to calculate the hour angle, we have to obtain

the information latitude and declination angle of the location. Hour angle can be

computed by the following equation as cited in Daily Global Solar Radiation Estimate

Based on Sunshine Hours (A.M. Muzathik et al, 2011):

cos co = - tan 0 tan 5

(2.2)

= cos 1 (- tan ct. tan cä)

(2.3)

Where Ji is the latitude (d) - slope (13) and 5 is the declination of the location. The

positive value of hour angle shows it is sunrise while negative values of hour angle to

show it is sunset. Sunlight is parallel to the sea level with a 900 of zenith angle which

means that the total hour angle between sun rise and sun set is 2co.

12

Since 150 of hour angle corresponds to one hour, monthly average of maximum possible

sunshine hour per day (NM) in hour can be calculated from the equation:

NM = Cos-] ( tan I tan 5) (2.4) is

2.7 PHOTOVOLTAIC TECHNOLOGY

Photovoltaic (PV) technology is a technology that converts the solar energy into

electrical energy. Photovoltaic did not request mechanical moving parts during the

convection. Unlike the Solar Collectors, flat plate and evacuated tube collector,

photovoltaic technology does not convert the solar energy to heat and generate

electricity but directly convert it to electric energy. Marliyani Binti Omar (2009)

explains the photovoltaic effect in a simple way, photon from sunlight strikes the PV

cell which is semiconducting material, such as silicon, energy transfer from photon to

electrons and knocked loose the electrons. Therefore electrons move into a higher state

of energy and cause holes to form in the atomic structure of the cell, other electrons can

move into the hole. If the PV cell connects to a positive and negative side, forming a

complete electrical circuit, thereby electricity is created.

2.8 SOLAR PANEL

In order to generate enough electrical energy to support electrical device, PV

cells are connect together and form a unit call photovoltaic module. Photovoltaic

module is a commercial component that users can buy it directly from the shop.

Moreover, combination of photovoltaic modules forms a photovoltaic array can future

improve the power that generate. The range of power output of a photovoltaic module is

about 10 watts to 300 watts which depending on the material. As cited in Renewable

Energy Powered Organic Rankine Cycle (Sanjayan Velautham, 2006), laboratory

experiment show that the efficiency of solar cell can reach approximately 30 %.

However, it only achieves around 18 % efficiency in commercial solar cells.