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Design of a Self-Sustained Photovoltaic Energy Harvesting System for Portable Applications

This project aims to develop a clean, self-sustained photovoltaic energy harvesting system capable of efficiently generating around 5W of power. The design will manage inputs from multiple energy sources, ensuring safe operation and component reliability. Key features include voltage stabilization for battery charging, data acquisition points for display design, and portability. It addresses challenges like energy source variability and includes comprehensive setup instructions, focusing on high efficiency and effective power management for diverse applications.

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Design of a Self-Sustained Photovoltaic Energy Harvesting System for Portable Applications

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  1. KGCOE MSD Technical Review P12407- Clean, Self-Sustained Photovoltaic Energy Harvesting System Josh Stephenson Mike Grolling Thomas Praderio

  2. Project Objective Utilize and properly manage energy from multiple sources to drive a load or charge a battery with high efficiency for portable applications

  3. Customer Requirements • Design will include safety and component failure • Ability to manage inputs from multiple power sources • Investigate and benchmark technologies, components and modules • System will integrate power management and load distribution. • Establish highly efficient energy conversion parameters and design • System must manage energy source variability • Provide data acquisition points for future team's display design • System must be portable • System must include instructions for set-up and use

  4. Project Specifications • Ability to generate ~5W of power • Voltage stabilization for battery charging (~15V ±0.05V) • Output voltage of 10V • Full solar delivery, provide a max output current of 0.5A • Energy Storage is ~5 A-h • Multiple solar panels • Benchmark given component's specifications • Calculate, design, measure each function • List DAQ points • Efficiencies for each function

  5. Phase 1: Preliminary Design • Incorporates single energy source

  6. (initial) Final Design

  7. Final design

  8. Maximum power point tracking (MPPT)

  9. SPV1020 MPPT IC

  10. Standard BBC Configuration

  11. Standard Battery Charger configuration

  12. Standard Power management configuration

  13. Lithium-ion batteries

  14. Risk Management

  15. Risk Management

  16. challenges • Winter in Rochester– Forced to rely on artificial light • Batteries used during experimentation were 12 years old and • did not hold charge very long • Flexible PV panels did not supply enough power • Buck/Boost did not maintain required voltage while charging • Learning curve on PCB layout software • Scheduling with PCB ordering during the Chinese New Year • Working with BGA footprint

  17. Challenges continued • Express PCB or Eagle CAD? • Proprietary vs. open standards • Licensing and version issues • Finding vendor footprints • Finding LGA footprints for the buck-boost • Board house selection • Price, capabilities, scheduling (Chinese new year) • Final decisions: • Eagle 5.7 for schematic and board layout • MyRo PCB for fabrication

  18. Microcontroller MSP430 Detail View

  19. Fractional Gain Amplifier for Voltage Sensing Both op amps are powered with a 3V button-cell CR2032

  20. Current Shunt Monitor INA193

  21. PCB layout

  22. Results

  23. Results continued

  24. Future Considerations • Troubleshoot analysis on PCB • Added display for real-time data capture • New batteries

  25. Questions?

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