UNIVERSITI KUALA LUMPUR MALAYSIA FRANCE INSTITUTE

WPB 49806 FINAL YEAR PROJECT

HYBRID POWER SUPPLY USING SOLAR CELLS AND LI-ION BATTERY FOR ZERO ENERGY ROBOTICS APPLICATION
Presented By :- Khairoul Afeeq Bin Jamaludin 50213108284 Nor Ilham Bin Mat Yaacob 50213108261 Supervised By :- Mr Mahadzir Bin Abdul Ghani

INTRODUCTION

What is Hybrid Power?

Hybrid power describes the combination of a power producer and the means to store that power in an energy storage medium. In our project:

Power producer is Solar Cells Storage Medium is Li-Ion Battery

INTRODUCTION

What is Zero Energy Concepts?

Zero Energy is a concept introduced by NASA for its MARS Rover Project. Mars rover is an automated motor vehicle which propels itself across the surface of the planet Mars after landing. Mars rover use renewable energy to operate in Mars. (Solar Cell to generate electricity before being stored into battery)

Picture of NASA Mars rover

INTRODUCTION

What is Solar Cell?

Solar cell is a device that converts the energy of sunlight directly into electricity by the photovoltaic effect. Solar is the best renewable energy but solar cells is an expensive device

Figure of 12V 2W Solar Cell

INTRODUCTION

What is Lithium-Ion Battery?

Rechargeable Lithium Ion (Li-ion) cells have a negative electrode (anode) made from lithium compounds. This leads to higher energy densities for the Li-ion cell. Also known as lithium-polymer. They are one of the most popular types of battery for portable electronics, with one of the best energy-to-weight ratios, higher end energy and a low discharge rate when not in use.

Why Lithium-Ion?

Picture of Li-ion Battery

PROJECT SCOPE

This Hybrid Power Supply is built to empower certain robotics application to enable the equipment to work under Zero-Energy Concepts. For the beginning, this hybrid power supply is build to power medium size robot application. (Such as outdoor robotics application, i.e. Rover)

PROJECT OBJECTIVES

To design an electrical equipment ( Hybrid Power Supply using solar and Li-ion battery with customized circuitry of DC to DC enabling the equipment to work according to zero-energy robotics concepts). To implemented the concept of zero energy using solar and battery To analyze the constraint and requirement of such Power Supply for zero energy concepts. To suggest future features to improve the concept

PROJECT BACKGROUND

How we come out with the idea?

The hybrid power supply system come from our supervisor, Mr Mahadzir Bin Abd Ghani.Then, we decide to apply the Zero Energy Concept that has been highlighted by our Head of Campus. After taking few consideration, we have finalize our project title, which is HYBRID POWER SUPPLY USING SOLAR CELLS AND LI-ION BATTERY FOR ZERO ENERGY ROBOTICS APPLICATION

PROJECT BACKGROUND

Solar cells are connected to form a solar array (Combination of solar cell by series or parallel is called the solar array or solar module). The electricity from the solar cells is stored in the battery for immediate or later use. The role of the charge controller is to regulate the voltage and current from the solar cells before it is stored in the battery. The charger circuit is used to charge the Li-ion battery.

PROJECT BACKGROUND
Relay Module Solar Panel or External Source

LCD Display

PIC Microcontroller

5V Regulator

Charger Circuit (Bq2057)

Battery

DC Load (Motor)

System block diagram

PROJECT METHODOLOGY

Hardware Development
Controller Circuit (Develop PCB)
1. 2.

3. 4.

5. 6.

PCB layout is designed using Protel DXP 2005. After PCB layout is generated, use printer to print the design before make a copy in transparency. Cut PCB size according to the printed layout size. Expose the printed layout on the top of PCB to the UV light (Pendaflour light) for 30 minute to create the PCB Etching. Wash the PCB using PCB developer (alkaline) for 5 min. After PCB is developed, put it in Ferric Chloride liquid. Add in water (80C) and shake the water until the unused part is washed and left only the tracks. It takes about 30min for this process. Wash the PCB with thinner to get rid off the green coating

7.

PROJECT METHODOLOGY

Hardware Development
Controller Circuit (Develop electronic devices)
1. 2.

3.

Take the PCB and the drills the hole to the desired location. Use drill bit of size 0.8mm, 1.0mm and 1.2mm that suitable to the electronic devices. Place the electronic devices one by one, then solder the component using soldering iron until the circuit is complete.

PROJECT METHODOLOGY

Top view of the completed controller circuit

Bottom view of the completed controller circuit

PROJECT METHODOLOGY

Hardware Development
Charger Circuit
1.

2. 3. 4. 5. 6.

Designed using old method (draw schematic on PCB using small tip marker pen). Wash the PCB using PCB developer (alkaline) for 5 min. Wash the PCB with thinner to get rid off the green coating. Drill the button hole using 0.8mm drill bit. Place the component in each position and solder it. SMD component (Surface Mount Device) such as IC and Transistor is soldered using flood and suck technique.

PROJECT METHODOLOGY

PROJECT METHODOLOGY

1. 2. 3. 4. 5. 6. 7.

Software Development
Open PCW C-Compiler. Then create a new File Save the file as filename.c , e.g. myprog1.c. Then create the program. Save program before compile. Compile the program by pressing F9. Check for errors in program when compile the codes.

PROJECT METHODOLOGY

1. 2.

Program Development using Winpic800

Connect PIC developer to computer via serial port / USB port Insert PIC into the programmer socket.

3. 4.

Look for Winpic800.exe in the folder.

Double click Winpic800.exe to start the application.

PROJECT METHODOLOGY
5. Select proper PIC name in the top right combo box.

6. 7.

Open the .hex file which you want to download into PIC e.g. if your .c filename is abc.c, suppose you need to download abc.hex into PIC. Go to Device -> Program All to start download program into your PIC.

PROJECT ACTIVITIES
Search for suitable solar cell

Construct Controller circuit

Build charger circuit

Assemble all components

Troubleshooting

Testing

MILESTONES
Week Expected No. progress
1 2 Hardware preparation Hardware construction Hardware construction Hardware construction & Hardware assembly Hardware construction & Hardware assembly

Actual progress Description

Research on project devices Perform research on selecting Solar cells, batteries and LCDs.

Research on Perform online research on project schematic schematic circuit, type of ics to be used. Final research on Conclude the desired devices and project devices components and components Perform online survey for project devices and components Search for project devices and components at Electronic store Survey on Farnell.Newark website for desired electronic components

Go to Jalan Pasar searching for project components (Couldnt find Li-ion Battery and Bq2057 ic)

MILESTONES
6 Hardware construction & Hardware assembly Hardware construction & Hardware assembly Hardware assembly

Construct Controller circuit

Continue on constructing controller circuit Generate program codes and Test-Run the Controller circuit Troubleshooting and ordering components for charger circuit Construct charger circuit

Developing PCB, drilling and soldering components onto developed PCB.

Continue on developing controller circuit

Write

program codes (using C language), compile and debug. Connect LCD Display Test run Perform troubleshooting on controller circuit and perform online order at Farnell.Newark website for Ics and Transistors Developing PCB ,drilling and soldering components for charger circuit onto developed PCB

Hardware assembly

10

Hardware assembly & Troubleshooting

MILESTONES
11 Troubleshooting Troubleshoot

the charger circuit and ordering Li-ion Battery

12 Troubleshooting Combine circuit

Perform troubleshooting on the charger circuit and buy online for li-ion battery

Connects all the components of the project (Solar cells, controller circuit, charger circuits and li-ion battery) Write report and prepare plastic prospect for hardware display. Continue on writing report. Preparing presentation slides for Final presentation. Final testing and final alteration on hardware (mount hardware onto plastic prospects).

13 14 15 16

Documentation Documentation Documentation Final testing

Prepare report Prepare report Prepare slides Testing and Troubleshooting

MILESTONES
During our project, we have found that:

Week 9 week 12 is most critical and vital period during our project because :

The BQ2057 ICs is hard to find and we have to wait almost 1 week to acquire the ICs. Developing the charger circuit is quite challenging because it consist of soldering surface mount devices (IC and transistor). We have made few mistake during developing the circuit. More over, the components we used is quite small.

OUTCOME
At the beginning of our project, we have split the task in developing the project part by part. After all parts have been successfully developed, then we combine it to form a complete finished project.

OUTCOME

Solar cell connected in series (7.2V 1W / pc)

OUTCOME

Controller circuit

OUTCOME

LCD Display

OUTCOME

Charger circuit

OUTCOME

Li-ion battery (7.4V,860maH)

PROJECT SCHEDULE

Gantt Chart of project scheduling

CONCLUSION
By the end of this project, our project has met the desired main objective which is to allow the equipment to work under zero energy concepts. The controller has successfully communicated with the charger circuit to charge the specified li-ion battery.

RECOMMENDATION
For future development, we have enlisted a few items that need to be carry on in order to achieve a better result.

Need to use more efficient PV cell which produce much more power (usually more expensive). Develop the MPPT (Multiple Power Point Tracking System) to reduce power lost while charging.