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Bahir Dar University

Institute of Technology

School of Electrical and Computer Engineering

Design of Hybrid Solar Vehicle

By

Heran Hailemariam

Mengistu Yaregal

Mesay kifle

Mintwab Yohannes

Advisor

Mr. Tewoderos G.

February 20/2015
HYBRID SOLAR VEHICLE

ACKNOWLEDGMENT

First of all, our hearty thanks go to Almighty God for His blessing-full knowledge, inspiration
and diligence. We highly indebted to our advisor Mr Tewoderos Gera for his guidance,
suggestions, encouragement and constant supervision as well as for providing necessary material
and information regarding the semester project. Without which this work could have not been
completed.

In addition we would like to thank our University for the fulfilment of necessary materials.
Finally we would like to extend our sincere thanks to all of them who support us.

Contents
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List of Figure.............................................................................................................................................iv
List of Table...............................................................................................................................................v
List of Acronyms.......................................................................................................................................vi
ABSTRACT..............................................................................................................................................vii
CHAPTER ONE........................................................................................................................................1
INTRODUCTION.....................................................................................................................................1
1.1 Background Information....................................................................................................................1
1.2 Statement of the problem...................................................................................................................2
1.3 Objective...........................................................................................................................................2
1.3.1 General objective.............................................................................................................2
1.3.2 Specific objective............................................................................................................2
1.4 Methodology.....................................................................................................................................2
1.4.1 Design of HSV................................................................................................................3
1.5 Project Scope and limitation..............................................................................................................4
1.5.1 Project scope....................................................................................................................4
1.5.2 Limitation........................................................................................................................4
CHAPTER TWO.......................................................................................................................................5
BACKGROUND THEORY AND LITRATURE REVIEW..................................................................5
2.1 Literature Review..............................................................................................................................5
2.2 Background Theory...........................................................................................................................6
2.2.1 Applications of PV Power...............................................................................................6
2.2.2 Advantages and disadvantage of solar electricity...........................................................7
2.2.3 The PV Power System.....................................................................................................7
2.2.4. Types of PV panels.......................................................................................................10
2.2.5 Solar system battery......................................................................................................11
2.2.6 Charge controllers.........................................................................................................16
2.2.7 EM.................................................................................................................................17
2.2.8 HSV Components..........................................................................................................18
CHAPTER THREE.................................................................................................................................24
METHODOLOGY..................................................................................................................................24
3.1 Data of solar resource of Bahir Dar.................................................................................................24
3.2 Determination of solar resources.....................................................................................................24
3.2.1 Load determination........................................................................................................25

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3.2.2 Design of PV system.....................................................................................................25


3.2.3 Design of Battery system..............................................................................................28
3.2.4 Selection of charge controller........................................................................................30
3.2.5 Wire Selection...............................................................................................................31
CHAPTER FOUR...................................................................................................................................32
RESULTS AND DISCUSSIONS............................................................................................................32
4.1 Result...............................................................................................................................................32
4.2 Discussion.......................................................................................................................................32
CHAPTER FIVE.....................................................................................................................................34
CONCLUSION AND RECOMMENDATION.....................................................................................34
5.1 Conclusion.......................................................................................................................................34
5.2 Recommendation.............................................................................................................................34
Reference..................................................................................................................................................35

List of Figure
Figure 1 Breakdown of incoming solar energy...............................................................................8

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Figure 2 Crystalline structures of silicon and intrinsic conductivity...............................................9


Figure 3 Energy transferred from light to consumer.....................................................................10
Figure 4 Flexible thin-film PV array.............................................................................................11
Figure 5 Series connected batteries...............................................................................................14
Figure 6 Parallel connected batteries.............................................................................................14
Figure 7 Series and Parallel connections.......................................................................................15
Figure 8 MPP controller, graphical representation of the DC to DC transformation....................16
Figure 9 Main components of HSV...............................................................................................18
Figure 10 A general Transmission system of hybrid solar............................................................20
Figure 11 For Auto Rickshaw 4 stoke Bajaj data..........................................................................27
Figure 12 Equivalent Circuit of PV Cell.......................................................................................28

List of Table
Table 1 Monthly average radiation of Bahir Dar...........................................................................24
Table 2 Load profile......................................................................................................................25

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Table 3 Auto Rickshaw 4 stoke Bajaj data....................................................................................27


Table 4 battery voltage selection as the load demand...................................................................29
Table 5 load profile........................................................................................................................31
Table 6 Result of the designed photovoltaic system for car is listed below..................................32

List of Acronyms
AGM- Absorbent Glass Mat battery
BCC- Battery Charge Controller
BLDC-Brushless Direct Current motor

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DC – Direct Current
EM- Electrical Motor
HSV-Hybrid Solar Vehicle
LED- Light Emitting Diode
PV - Photovoltaics
MPP-Maximum Power Point

ABSTRACT
Solar energy is a renewable energy source and clean. It is being used to produce electricity by
using solar panel. With the help of this technology we aim to design solar photovoltaic (PV)

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system for transportation system with low emission. This work is a development of an
indigenous technology hybrid solar vehicle (HSV) that harnesses the renewable energy from Sun
to generate electricity. We designed the PV module, battery sizing of the system, and selection of
voltage controller, sizing the cross sectional area and selection of electrical motor. The solar
energy directly connected to the electrical motor (EM ) through voltage regulator and stored in
the batteries thus its supply light appliance in the vehicle, the EM & gas engine drive the vehicle
during day time the system operate using PV panel whereas the battery and gas engine operate
during night time. During shortfall the diesel engine drive the vehicle and also in case the battery
fail or empty that’s why HSV.

OUTLINE OF THE PROJECT

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This thesis consists of five chapters. Chapter 1 Discuss about background of project, objective of
the project, Project scope and limitation, and problem statement.

Chapter 2 Contains background theory and literature review, a detailed description of solar PV
system. It will explain about the concept of solar PV system, the application, advantage and
disadvantage of this system.

Chapter 3 Includes methodology. The design of solar PV system. It will explain how the project
is organized and the sizing of PV module, and battery of this project. Also in this topic the
selection of MPP is contained.

Chapter 4 contains the result and discussion of the design of PV system. The last chapter
contained the detailed description about conclusion and recommendation. This chapter will
conclude the whole project and give a future recommendation to make this project perfect.

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CHAPTER ONE

INTRODUCTION
1.1 Background Information
The PV technology converts sunlight into electricity. It is one of the fastest growing sectors of
the renewable energy industry and it is already well established in many countries and looks set
to become one of the key technologies of the 21st century. The market is being driven by
concerns about carbon emissions, energy security and the rising price of fossil fuels.Solar PV
system or solar power system is one of renewable energy system which uses PV modules to
convert sunlight into electricity. The electricity generated can be stored or used directly. Solar
PV system is clean source of electricity that can suit a wide range of applications such as
residence, industry, agriculture, livestock, transportation etc. In our project the application of
solar energy in transportation system will be discussed the generation of energy in our modern
industrialized society is still mainly based on a very limited resource. As the world's energy
demands rise and new sources for petroleum become scarce, the search for alternative energy
resources has become an important issue for our time. A large amount of research has been done
in the area of unlimited energy sources such as wind power generation and solar energy
transformation. Significant projects have been realized and others are still in planning. Most of
these new systems are used to generate electrical power which is fed into the public electrical
grid to provide energy for businesses and private homes.

In transportation systems, another important element of our industrialized society generates a


considerable demand for petroleum based energy. Since the combustion of carbon based
petroleum derivatives generates the infamous greenhouse gas carbon-dioxide (CO2), the
continually increasing traffic significantly contributes to global warming and is the main source
of air pollution in big cities.
This has led to programs and efforts to design low emission and zero emission vehicles.
Research is being done in highly efficient combustion engines, fuel cell technology, hybrid
vehicle combining conventional propulsion techniques with electrical drive systems, and
electrical vehicle powered either by diesel or by a solar energy conversion system.

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A solar vehicle is powered by PV cell arrays which allow for direct conversion of solar radiation
into electrical energy. Since space and weight are very limited with any vehicle, it is desired that
the maximum possible amount of energy be obtained from the employed photovoltaic cells. In
order to give as much energy as possible to the vehicle, the array needed to first collect as much
light as possible. This is best achieved when the panels are facing directly towards the sun. After
obtaining electricity through the electrochemical reactions in the panels, this source of energy
must be delivered to the power system for future management.

1.2 Statement of the problem


The main sources of energy for car is natural gas (oil, petroleum) which are not renewable
sources because they are exhaustible, or not reproducible and release carbon emissions to the
environment. This results in global warming which is the result of bad environmental condition
for living things and high running cost. There are also imported fuels in case of our country, and
there may be depletion of non-renewable resources (fuels) on a worldwide basis. This has
necessitated an urgent search for alternative energy sources to meet up the present day demands.

1.3 Objective
1.3.1 General objective
The objective of this project is to design of HSV with environmental friendly resource and free
power for the vehicle.
1.3.2 Specific objective
The specific objective of the project:

 To size solar PV module for vehicle.


 To size battery bank for the system.
 To select voltage controller for the system.
 To Selection appropriate wire.
 To Selection appropriate EM.

1.4 Methodology
This project is focused on sizing of solar PV module, battery, selecting appropriate charge
controller and design sizing cross sectional area of wire.

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1.4.1 Design of HSV


The PV modules are made up of silicon cells. The silicon solar cells which give output voltage of
around 0.7V under open circuit condition. When many such cells are connected in series or
parallel we get a solar PV module.

 Determination of solar resources


Insolation is the total amount of solar radiation energy received on a given surface area
during a given time.
Since the systems need to track maximum radiation, the solar panels are adjusted
perpendicular to the sun light.
 Load determination
The motor used in solar cars typically than the other appliance. And we will estimate the
power usage of each appliance of the vehicle.

 Sizing PV module
Different size of PV modules will produce different amount of power. To find out the
sizing of PV module, the total peak watt produced needs. The peak watt produced
depends on size of the PV module and climate of site location.
 Sizing charge battery storage
In most appliences an energy-storage is needed to bridge times of no sunshine. A Battery
stabilizes the System and gives Energy whenever the Solar Energy Supplied is not
enough. In case the solar battery empty the switching lunch the diesel and the vehicle
can use it until the solar battery store electricity.
 Sizing charge controller
The voltage at which PV module can produce maximum power is called ‘maximum
power point’ (or peak power voltage). Maximum power varies with solar radiation,
ambient temperature and solar cell temperature. The controller protects the battery
overcharging and discharging from the energy that comes from PV module and we select
the appropriate charge controller.
 Wire selection
In practice bare conductors, whether single or stranded together are termed as Wire. Can
be determined that it connected to PV array to battery then tap to other appliance.

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1.5 Project Scope and limitation


1.5.1 Project scope
This project is focused on sizing of solar PV module, battery, selecting appropriate voltage
controller and selecting EM and also the simulation.
Therefore, this design will cover the scope as shown below.
 PV module
 Battery bank
 MPP
 Using EM.
1.5.2 Limitation
a. Lack of journal on HSV.

b. Lack of appropriate software for simulation and materials to implement the project.

c. Controlling voltage fluctuation - As stated before, the sun cannot give us a constant voltage
all day long. There might be cloud, movement of earth; movement of sun etc. can change the
voltage level rapidly which we call fluctuation. As we all know, voltage fluctuation is always a
threat to any electrical device, but there is no such way defined here to solve this problem in this
plan.

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CHAPTER TWO

BACKGROUND THEORY AND LITRATURE REVIEW


2.1 Literature Review
Dr. Samih Al Jabi [1] has Study, Design and Construct an Electrical solar Car and his paper is
presented as follows.

HSV represents one of the modes in which solar energy is used to back up the generation of
clean photo voltaic electric power supplied to the electric motor which is used instead of internal
combustion engines, which leads to less pollution by reducing emission of toxic gases.

He designed for a pickup truck and all the components and parts including solar panels, batteries,
Direct Current (DC) motor, car control unit, battery charge controller (BCC), power circuits and
control circuits were installed on the truck. Nine solar modules were framed on the top of the
truck, each 4 were connected in series to produce 58 V output and 200 W power. 2 groups of 4
modules were connected in parallel. The power and output voltage of the solar panel modules
were supplied to DC motor of 48 V or to 4 batteries each of 12V and 105Ah and connected in
series through the charging control unit. The DC motor used is of series excitation type and was
modified that it can change the direction of rotation by the separation of exciting circuit from
induction circuit and the change of polarity.

Batteries were fixed on the back of the car and connected to the EM through the central control
circuit. Also been linked to solar panels by the charging unit. This vehicle goes at speed of up to
80 kilometers per hour for a distance of 200 km, depending on energy savings to 10 hours of
charging from the solar panel. The vehicle moves without any noise and with small toxic gas
emission, it is a friend of the environment.

Ranjeet Singh and Manoj Kumar Gaur [2] focused on an idea about hybrid solar car technology
which solves the major problem of fuel and pollution in present days. Determine how feasible
help them to reduce their carbon emission and is also widespread change to hybrids would
be in future with all information taken into account, concluded that hybrids have several
advantages as fuel efficient, low pollution. But those ideas have their own limitation
because they made hybrid with electricity and solar and that’s the car recharge go back every
battery discharge or need power transmission line every road.

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2.2 Background Theory


About half the incoming solar energy reaches the Earth's surface. The Earth receives 174 peta
watts (PW) (1015 watts) of incoming solar radiation at the upper atmosphere. Approximately
30% is reflected back to space while the rest is absorbed by clouds, oceans and land masses.
Earth's land surface, oceans and atmosphere absorb solar radiation, and this raises their
temperature. Sunlight absorbed by the oceans and land masses keeps the surface at an average
temperature of 14 °C. By photosynthesis green plants convert solar energy into chemical
energy, which produces food, wood and the biomass from which fossil fuels are derived.

In 1839 a French physicist A. E. Becquerel first recognized the photovoltaic effect. In 1954 Bell
Laboratories, experimenting with semiconductors, accidentally found that silicon doped with
certain impurities was very sensitive to light. Dary Chapin, Calvin Fuller and Gerald Pearson,
invented the first practical device for converting sunlight into useful electrical power. Resulted in
the production of the first practical solar cells with a sunlight energy conversion efficiency of
around 6%. In 1958 first spacecraft to use solar panels was US satellite Vanguard.

2.2.1 Applications of PV Power


Here are the examples of application of photovoltaic power or solar power.
a. PV in transport
Photovoltaic power has been used for auxiliary power in space. Photovoltaic power is rarely used
to provide motive power in transport applications, but is being used increasingly to provide
auxiliary power in boats and cars.
b. PV power in standalone devices
Photovoltaic power has been used for many years to power calculators and novelty devices.
Improvements in integrated circuits and low power liquid crystal displays make it possible to
power a calculator for several years between battery changes, making solar calculators less
common. In contrast, solar powered remote fixed devices have seen increasing use recently, due
to increasing cost of labor for connection of mains electricity or a regular maintenance
programmed. For examples are parking meters, emergency telephones, and temporary traffic
signs.

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2.2.2 Advantages and disadvantage of solar electricity


a. Advantage of solar electricity
 Minimizes the energy absorption by the earth to reduce warming.
 Solar power is pollution free during use. Production end wastes and emissions are
manageable using existing pollution controls. End of use recycling technologies are under
development.
 Facilities can operate with little maintenance or intervention after initial setup.
 Solar electric generation is economically superior where grid connection or fuel transport
is difficult, costly or impossible. Examples include satellites, island communities, remote
locations and ocean vessels.
 When grid-connected, solar electric generation can displace the highest cost electricity
during times of peak demand (in most climatic regions), can reduce grid loading, and can
eliminate the need for local battery power for use in times of darkness and high local
demand; such application is encouraged by net metering. Time of use net metering can be
highly favorable to small photovoltaic systems.
 Grid connected solar electricity can be used locally thus reducing transmission or
distribution losses.
 Once the initial capital cost of building a solar power plant has been spent, operating
costs are extremely low compared to existing power technologies.
b. Disadvantages of solar electricity.
 Solar electricity is not available at night and is less available in cloudy weather
conditions. Therefore, a storage or complementary power system is required.
 Limited power density.
 Solar cells produce DC which must be converted to AC (using a grid tie inverter) when
used in currently existing distribution grids. This incurs an energy loss of 4-12%.

2.2.3 The PV Power System


The Earth receives 174 petawatts (PW) (1015watts) of incoming solar radiation at the upper
atmosphere. Approximately 30% is reflected back to space while the rest is absorbed by clouds,
oceans and land masses. Earth's land surface, oceans and atmosphere absorb solar radiation, and

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this raises their temperature. Sunlight absorbed by the oceans and land masses keeps the surface
at an average temperature of 14 °c.

Figure 1 Breakdown of incoming solar energy


There are various elements of such a photovoltaic power system and derive the cell as a
semiconducting device that absorbs light and converts it into mathematical models necessary to
represent its behavior in a complete system simulation.
2.2.3.1 How a solar cell works
The way, in which solar cells work is shown below, taking crystalline silicon cells as an
example. Highly pure silicon with a high crystal quality is needed to make solar cells.
The silicon atoms form a stable crystal lattice. Each silicon atom has four bonding electrons
(valence electrons) in its outer shell. To form a stable electron configuration, in each case in the
crystal lattice two electrons of neighbors’ atoms form an electron pair bond. By forming electron
pair bonds with four neighbors, silicon achieves its stable noble gas configuration with eight
outer electrons. An electron bond can be broken by the action of light or heat. The electron is
then free to move and leaves a hole in the crystal lattice. This is known as intrinsic conductivity.

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Figure 2

Crystalline structures of silicon and intrinsic conductivity

2.2.3.2 Design and functioning of a crystalline silicon solar cell


The classic crystalline silicon solar cell comprises two differently doped silicon layers. The layer
that faces the sun's light is negatively doped with phosphorus. The layer below it is positively
doped with boron. At the boundary layer, an electrical field is produced that leads to the
separation of the charges (electrons and holes) released by the sunlight. In order to be able to
take power from the solar cell, metallic contacts need to be fitted on the front and back of the
cell. Screen printing is normally used for this purpose. On the back of the solar cell it is possible
to apply a contact layer over the whole surface using an aluminum or silver paste. The front, by
contrast, must let as much light through as possible. Here, the contacts are usually applied in the
form of a thin grid or a tree structure. Sputtering or vapor depositing a thin film (anti-reflective
coating) of silicon nitride or titanium oxide onto the front face of the solar cell reduces light
reflection. Positively charged doping atoms remain in the n-region of the transition and
negatively charged doping atoms remain in the p-region of the transition. An electrical field is
created that is opposed to the movement of the charge carriers. If connecting the negative (_ve)
and positive ( +ve) terminal by a load (in Figure 3, a light bulb, computer ,speaker etc.) current
flows .

Photo + voltaic = convert light to electricity

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Figure 3 Energy transferred from light to consumer


2.2.4. Types of PV panels
PV arrays comprise varying numbers of modules connected together. The modules fall into
several categories:

• Mono crystalline silicon


This is the most oldest and expensive type of PV panel. But right now, it is the most
efficient types of solar panels. In other words, when sunlight hits these PV cells, more
of it turns into electricity than the other types below. This is more expensive because their high
silicon content and this type of solar panel is best for the roof. The efficiency of this panel on
averages 10% to 12%. Life expectancy is typically 25-30 years.
• Poly crystalline silicon
“Poly” panels have lower silicon levels than “mono” panels. So that it makes them less
expensive to produce, but they’re also slightly less efficient. But because of construction design
t is not that much less efficient and it is also good for roofs. The efficiency of it on averages
0% to 11%. Life expectancy is around 20-25 years.

• String Ribbon
This is a refinement of polycrystalline production; there is less work in production so costs are
even lower. Module efficiency averages 7% to 8%.

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• Thin film (amorphous silicon, cadmium telluride, copper indium gallium (di) selenide)
Thin films can be rigid or flexible, is the most inexpensive material using in solar panel and
because of this thin film these are the cheapest panels in the world. Another advantage of the
panel is it produces almost no heat and that’s why it is so cool and can be produced in various
colours, giving great versatility for different applications and sites. But still now it is very
inefficient, which means its efficiency averages 5% to 7%.

44.4% efficient solar cells by Sharp. Notably, these world-leading solar cells by Sharp are in
the concentrator triple-junction solar cell category. Such solar cells are complicated and are not
used in residential or commercial application, because they are bloody expensive. They are used
in space applications by the likes of NASA.

Figure 4 Flexible thin-film PV array


2.2.4.1. Selecting of solar panel
Mono  crystalline  and  polycrystalline  panels’  efficiency  is  very  high  but  these  are  much 
expensive. But we are always concern about the design. As we are designing a 
system which runs the whole vehicle with solar energy so our supply to battery should 
large  and  from  the  real  vehicle  study  we  don’t  get  much  space  for  implementing  solar 
panel. In this circumstances considering the facts we have decided to use flexible thin-film PV
array 44.4% efficient solar cells,  which will  be too costly but efficient.

2.2.5 Solar system battery


A battery is a device that converts chemical energy into electrical energy and vice versa. This
summary provides an introduction to the terminology used to describe, classify, and compare
batteries for hybrid, plug-in hybrid, and electric vehicles. It provides a basic background, defines

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the variables used to characterize battery operating conditions, and describes the manufacturer
specifications used to characterize battery nominal and maximum characteristics.
In solar system batteries are charged and discharged randomly. Life time  of  battery  is 
depends  on  charging  and  discharging  of  battery.  The charging capacity of the battery 
measured with Amp‐hour. Battery ratings are depended according to cycle. In vehicle there 
is  used  shallow  cycle  battery  which  means  battery  have  cycles  between  10% ‐ 15%  of 
batteries total capacity. But in solar system there is used deep cycle batteries which have 
up to 50% ‐ 80% of total battery’s capacity. This type of battery is best for solar project.

2.2.5.1 Available types of batteries


There are many variety of batteries found in the market but only four types of batteries are 
usually used in solar system. 
• Marine type deep cycle battery
Marine type deep cycle battery is basically used in boats and camps where small load is used to
get powered. These types of batteries do not have capacity for continuous service with charger or
discharger.

• Lead acid battery
Lead acid batteries can be used in solar energy storage. These types of batteries are deep cycled
and have long life time for charging and discharging. Typical life time of lead- acid batteries is
3- 5 years. Life time of Battery actually depends on the charging and discharging cycle. Lead
acid batteries releases some gas while charging. That’s why these batteries are needed to be kept
outside or cross ventilated place, where air circulation is good enough.

• Absorbent Glass Mat (AGM) battery

The full meaning of AGM battery is absorbed glass material battery. It allows the electrolyte to
be suspended in close proximity with the plate’s active material. The AGM batteries are
expensive batteries and typically cost twice as much as a premium wet cell battery. However
they store very well and do not tend to sulfate or degrade as easily as wet cell. There is little
chance of a hydrogen gas explosion or corrosion when using these batteries. The larger AGM
batteries are typically good deep cycle batteries and they deliver their best life performance if
recharged before allowed to drop below the 50% discharge rate. When Deep Cycle AGM
batteries are discharged to a rate of no less than 60% the cycle life will be 300. AGM batteries
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are used in airplanes and hospitals where large charging time is needed.
• Gel battery
Gel Cell battery is similar to the AGM battery because the electrolyte is suspended, but different
because technically the AGM battery is still considered to be a wet cell. The recharge voltage on
this type of cell is lower than the other styles of lead acid battery. This is probably the most
sensitive cell in terms of adverse reactions to over-voltage charging. Gel Batteries are best used
in very deep cycle application and may last a bit longer in hot weather applications. If the
incorrect battery charger is used on a Gel Cell battery poor performance and premature failure is
certain.

2.2.5.2 Selection of Battery

Among the four types of battery all are not suitable for solar system and some are much
expensive. So, for selecting a type of battery for a solar driven bajaj, we always have
to concern about less expensive, contradict the above comparatively light in weight and high
energy supply and consumed battery. Considering the economic factor and availability in our
country we will be using Lead ion batteries because of light Wight which is 20 kilogram, which
are being widely used as a solar system storage device. These batteries are comparatively cheap,
efficient in power storing and have a life time of 3 – 5 years. Though these types of batteries
release some hydrogen gas while charging and needs some maintenance but still for large solar
energy storage system lead acid battery is very popular. In our project we use two 72v-420Ah
lead acid batteries.

a. Connecting Batteries in Series

Batteries connected in a series circuit have only one path for the current to flow. Batteries are
arranged in series by connecting the negative terminal of the first battery to the positive terminal
of the second battery, the negative of the second battery to the positive of the third battery, and
so on for as many batteries or cells in the series string. For similar batteries connected in series,
the total voltage is the sum of the individual battery voltages, and the total capacity is the same
as for one battery. If batteries or cells with different capacities are connected in series, the
capacity of the string is limited to the lower battery capacity. Figure 5 illustrates the series
connection of two similar batteries.

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Figure 5 Series connected batteries


b. Connecting Batteries in Parallel

Batteries connected in parallel have more than one path for current to flow, depending on the
number of parallel branches. Batteries (or series strings of batteries or cells) are arranged in
parallel by connecting all of the positive terminals to one conductor and all of the negative
terminals to another conductor. For similar batteries connected in parallel, the voltage across
the entire circuit is the same as the voltage across the individual parallel branches, and the
overall capacity is sum of the parallel branch capacities. Figure illustrates the parallel
connection of two similar batteries.

Figure 6 Parallel connected batteries

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C. Series vs. Parallel Battery Connections

In general, battery manufacturers recommend that their batteries be operated in as few


parallel strings as possible. If too many parallel connections are made in a battery bank,
slight voltage differences between the parallel strings will occur due to the length, resistance
and integrity of the connections. The result of these voltage differences can lead to
inconsistencies in the treatment received by each battery (cell) in the bank, potentially
causing unequal capacities within the bank. The parallel strings with the lowest circuit
resistance to the charging source will generally be exercised to a greater extent than the
parallel groups of batteries with greater circuit resistance to the charging source. The
batteries in parallel strings which receive less charge may begin to sulfate prematurely. The
battery capacity requirements and the size and voltage of the battery selected dictate the
series and parallel connections required for a given PV application. For PV systems with
larger capacity requirements, larger cells, generally in nominal 2-volt cells for lead-acid, may
allow the batteries to be configured in one series string rather than in several parallel strings.
When batteries must be configured in parallel, the external connection between the battery
bank and the PV power system should be made from the positive and negative terminals on
opposite sides of the battery bank to improve the equalization of charge and discharge from
the bank

Figure 7 Series and Parallel connections

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2.2.6 Charge controllers


Constantly solar power systems will need a charge controller. The purpose of measures the
battery voltage and protects the battery against overcharging, by diverting power away from it
once it is fully charged. This is achieved by:

 switching out the PV array when the charge cut-out voltage is exceeded, as happens with
series controllers; or
 short-circuiting the PV array with a shunt controller; or
 Adjusting the voltage with an maximum power point tracker (MPPT) charge controller.

Solar charge controllers are specified by the system voltage they are designed to operate on and
the maximum current they can handle. The system voltage is 48 Volts.

2.2.6.1 MPP charge controllers


The MPPT controller will adjust its input voltage to harvest the maximum power from the solar
array and then transform this power to supply the varying voltage requirement of the battery plus
load. Thus, it essentially decouples the array and battery voltages.

Figure 8 MPP controller, graphical representation of the DC to DC transformation


Since the battery voltage determines the operating point on the PV characteristic curve and,
therefore, the PV array is often not operating at the MPPT point, series and shunt charge
controllers do not always make optimum use of the available solar energy. These power losses

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HYBRID SOLAR VEHICLE

can amount to between 10 per cent and 40 per cent, depending upon battery voltage, irradiance
and temperature. This can be avoided by using an MPPT tracker. An MPPT tracker essentially
consists of a regulated D C / D C converter. Regulation is performed by an MPPT tracker, which
approximately every five minutes passes along the current/voltage characteristic curve of the PV
array and determines the MPPT power. Then the D C / D C converter is set so that it takes the
optimum power from the PV array and adjusts it to the charge voltage of the battery.

2.2.7 EM
Motors used in Electric cars most of them are DC motors. The major reasons of using DC motor
are these motors are cheap and the making procedure of controller for DC motor is simple than
AC motor. There are 2 main types of DC Motors used in Electric Cars. One is Brushed DC
Motors and another is Brushless DC Motors (BLDC Motors).

a. Brushed DC Motors

The brushed DC electric motor generates torque directly from DC power supplied to the motor
by using internal commutation, stationary magnets, and rotating electrical magnets. Advantages
of this motor are low initial cost, high reliability, and simple control of motor speed and
disadvantages are high maintenance and low life-span for high intensity uses.
b. BLDC Motors

BLDC motors use a rotating permanent magnet or soft magnetic core in the rotor, and stationary
electrical magnets on the motor housing. A motor controller converts DC to AC. This design is
simpler than that of brushed motors because it eliminates the complication of transferring power
from outside the motor to the spinning rotor. Advantages of brushless motors include long life
span, little or no maintenance, and high efficiency. Disadvantages include high initial cost, and
more complicated motor speed controllers.

2.2.7.1 Motor selection


As our greatest concern on designing a cost effective solar car, among the two types of DC 
motor BLDC motor is most suitable for us because of its long life span, almost zero 
maintenance cost and high efficiency. Motor that is used in the project would be 800 watt - 48v
BLDC motor. 

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HYBRID SOLAR VEHICLE

2.2.8 HSV Components


Generally our project solar hybrid vehicle is consisted of eight main parts: PV panel, gas engine,
electric motor, battery, inverter, voltage controller, and power split device, gear box and
differential. A diagram of the hybrid solar vehicle can thus be illustrated in Figure.

PV panel

Gas engine

Main parts of Electric motor


hybrid solar
Bajaj Battery

Voltage controller

Gear box

Differential

Figure 9 Main components of HSV


(1) PV panel convert sunlight into electricity, which is stored in batteries. Then its energy will be
utilized for hybrid vehicle propulsion.

(2) Gas engine has been employed for driving of hybrid solar car which can be used during a
night or minimum electric energy (shortfall) of solar vehicle. (Petrol operated 4-stroke engine)

(3)Electric motor has, generally, been employed for driving the hybrid solar vehicle. However,
we can observe that the BLDC motor is often operated in the solar vehicle over the classical DC
motor due to long lifetime operation, high speed and also high torque.

(4) Battery is an important component for the solar vehicle. It has been generated DC for
supplying to the electric motor and also electronic devices in the solar vehicle.

(5) Voltage controller have a purpose of measures the battery voltage and protects the battery
against overcharging, by diverting power away from it once it is fully charged. Solar constantly
power systems will need a charge controller.

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HYBRID SOLAR VEHICLE

(6) Gear box (reduction gear) is an arrangement by which an input speed can be lowered for a
requirement of slower output speed, with same or more output torque. Reduction gear assembly
consists of a set of rotating gears connected to a wheel work. The high speed incoming motion
from the wheel work is transmitted to the set of rotating gears, wherein the motion or torque is
changed. The number of gears used in the reduction gear assembly depends on the output speed
requirement of the application. The reduction gear assembly is usually known as reduction gear
box.

(7)Differential is a particular type of simple planetary gear train that has the property that the
average of the angular velocities of its sun and annular gears. The motion obtain at the gear box
output shaft through different gear arrangements is transferred to the differential. From
differential, power is transmitted finally to both the road wheels according to the speed
requirement.

 To aim the engine power at the wheels.


 To act as the final gear reduction in the vehicle, slowing the rotational speed of the
transmission one final time before it hits the wheels
 To transmit the power to the wheels while allowing them to rotate at different speeds
(This is the one that earned the differential its name.)

2.2.8.1 Transmission system


In this hybrid solar vehicle, we are design transmission system of hybrid solar vehicle can thus
be illustrated in Figure below.

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HYBRID SOLAR VEHICLE

Figure 10 A general Transmission system of hybrid solar


2.2.8.2 Operational Concepts of the HSV
Hybrid solar vehicle use a solar as the primary source of the power, a gas engine and battery are
additional power needed. The configuration of solar hybrid system is analyzed for various
photovoltaic array sizes with respect to a diesel engine to operate in tandem with the battery
system.

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HYBRID SOLAR VEHICLE

The main objective of solar hybrid system is to reduce the cost of operation and maintenance and
cost of logistic by minimizing diesel runtime and fuel consumption. To achieve this the gas
engine only runs as needed on when system operate during shortfall period. It is started when the
battery reaches a preset discharge level and is run at full capacity until the battery is fully
recharged and then shut down. A schematic of normal daily operation of a typical solar hybrid
system can be shown in a series of diagram in Figure below.

a. During day time


Solar is the first choice and only source of energy while the gas engines off. The charge
controller has a purpose of measures the battery voltage and protects the battery against
overcharging and give to that of DC electric motor and for other appliance. The extra power
produced is stored in battery system.
b. During night time

The solar hybrid solar vehicle system makes use of the solar PV to produce electricity that can be
supplemented by diesel engine and battery. Battery is the only source of energy while the gas
engine and solar PV are both off. The battery will supply the load to its maximum discharge
level.
c. During shortfall
Shortfall normally happens at night time. During shortfall, the battery reaches its maximum
discharge level and therefore, the gas engine is on. At this time, the gas engine serves the load as
well as charges the battery. The battery charge rate is adjusted to maintain the generator at full
output.

2.2.8.3 Mechanical Operation of Hybrid Solar Bajaj

Gas Engine Clutch and fly wheel Gear box Differential

A. Gas engine

Power prodce from the engine is converted in to reciprocating motion of the piston.The
ricprocating motion is converted in to rotating motion of the crankshaft using connecting roads.

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HYBRID SOLAR VEHICLE

B. Clutch and fly wheel

Thus rotating motion is transmitting to the fly wheel which is attached to the crank shaft output
shaft. When the clutch pedal is pressed the hydrolic pressure from the clutch reservior forces the
preure forces the pressure plate to move againest the rotating fly wheel.

When the pressure plate moves away from the clutch plate, the power from the engine gets
disconnectes. When clutch pedal is released the pressure plate moves towards the clutch plate
and power from the engine gets connected

C. Gear box

When the pressure plate engages again the power from the fly wheeltransfered to the gear box
input shaft using cluching mechanism.atypical outhomative gera box consists of main shaft,lay
shaft dog clutch and selector mechanism.

Gear on the main shaft are directly engage to the gear on the lay shaft and rotate with them.the
main shaft gear do not transmite the power to the main shaft as they are mounted over the
bearings.The power transmission is done using dog clutches ,which are directly mounted on the
main shaft and are able to move left or right to engage with different gear on the main shaft and
attain the motion accordingly.

D. Differential

Diferential torque or speed variations are obtained by engaging the gears on the main shaft using
selector mechanism. When 1st gear is selected using the selector mechanism the dog clutch shaft
towards its left engaging with the 1st gear.

The power is thus transmitted from the gear box input shaft to the layshaft 1st gear,and from there
to the 1st gear on the main shaft and finally to the gear box out put shaft.

Since the diameter of the 1st gear is comparatively bigger,the speed of the engine reduce but
torque is increased.

In 2nd gear the dog clutch shaft to its right engagin with the second gear on the main shaft and
thus another gera ratio is obatian with increasing in speed and redution torque.

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HYBRID SOLAR VEHICLE

To achive the 3rd gear the 2nd dog clutch is shafted to its left inorder to mesh with the 3rd gear on
the main shaft .in this condition the speed increates further while torque reduce.

In reverse position the 3rd dog clutch shifts towards its right to engage with the reverse gear that
rotate in reverse direction using ideal gear,and those rverese motion is transferred to the gear box
out put shaft.

The selecter 2 mechanism select the operation condtion which is either PV or EM. The first dog
clutch is shaft towards its right to engage with the EM gear on the main shaft. first dog clutch is
shaft towards its lift to engage with the gas engine gear on the main shaft.

The motion obtained at the gear box out put shaft through differential gearing arrangements is
then transfered to the differential. From the differential power is transmitted finnaly to both fully
road wheels accordingly to the speed requirments

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HYBRID SOLAR VEHICLE

CHAPTER THREE
METHODOLOGY

3.1 Data of solar resource of Bahir Dar

Table 1 Monthly average radiation of Bahir Dar

Total Bahir Dar Solar radiance per day


kWh/m2/day =
12

70.98
kWh /m2/day =
12

kWh/m2/day =5.92

3.2 Determination of solar resources


Insolation is the total amount of solar radiation energy received on a given surface area during a
given time. It is also called solar irradiation and expressed as "hourly irradiation" if recorded
during an hour or "daily irradiation" if recorded during a day.

These data is available from solar electricity handbook, is available via the internet.
www.solarelectricityhandbook.comsolar-irradiance.html

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HYBRID SOLAR VEHICLE

3.2.1 Load determination


Table 2 Load profile

Appliance Quantity Wattage HR/day WHR/day


EM 1 800 6 4800
Head LED lamp 1 10 0.5 5
Fog LED lamp 1 6 0.33 1.98
Turn Signal LED lamp 2 6 0.25 3
Stop and Tail LED lamp 2 8 0.25 4
TOTAL 4813.98

System Voltage = 48v (operating voltage of Electrical motor)

Watt hour 4813.98


Ampere hour= = =100.29
System voltage 48

3.2.2 Design of PV system


The PV system design is based on the size and capacity of load. The energy from PV panels can
be obtained summing the Contributes of during parking (p) and driving (d) periods (for
simplicity, we are assumed that both parking and driving occur during daytime). While in the
former case it is reasonable other obstacles. Therefore, the energy captured during driving can be
reduced by a factor α<1, that of course depends on the specific route. In order to estimate the
fraction of daily solar energy captured during driving hours (hd), it is assumed that the daily
solar energy is distributed over hsun hours (hsun =10). Anyway, this hypothesis does not affect
the total energy to the PV panel, which is provided on a daily basis.

We take into account the efficiency of the devices (i.e. inverter, cables) to produce AC current,
but do not consider the further degradation due to charge and discharge processes in the battery.
A factor β<1 is then introduced to account for this effect for energy taken during parking. The
incident solar energy is computed considering the previously described options for panel
positions: horizontal, tracking, vertical. The net solar energy available for propulsion taken
during parking and driving modes can therefore be expressed as:

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HYBRID SOLAR VEHICLE

1. Driving time

The energy produced during a running period of a car is calculated by the formula.
pv∗esun∗hsun−hp
Ed=η∗A ∗α … … … … … … ..equation 1
hsun
BAct−BAdt
But , α = … … … … … ….. equation 2
BAct

2. Parking time - The energy produced during the parking period of a car is calculated by the
formula

pv∗esun∗hsun−hp
Ep=ELDT +η∗A ∗β … … … … … … .. equation3
hsun

BAct−BAdt
But , β = … … … … … ….. equation 4
BAct

ELDT =62.4 %∗Ed … … … … … … .. equation5

Where:
ηpv – PV Panel efficiency (44.4%)
Apv- PV Surface Area (2.6m2)
esun – Average energy enough by solar panel captured in Bahir Dar (5.92 KWh/m2/day).
hsun – Solar energy captured during a sun at (7 AM to 6 PM)
hp – Solar energy during a parking time. (2)
BAct - Battery Charging time.(6)
BAdt - Battery Discharging time.(0.5)

ELDT - Energy loss during driving time.

α - Solar energy reduction due to shadow during daytime driving


β - Energy degradation due to charge and discharge process

Energy of PV = Driving time + Parking time

Epv=Ep+ Ed

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HYBRID SOLAR VEHICLE

Figure 11 For Auto Rickshaw 4 stoke Bajaj data


Table 3 Auto Rickshaw 4 stoke Bajaj data

Auto Rickshaw Wheel base Overall width Overall length Overall height
4 stoke Bajaj 2000mm 1300mm 2635mm 1692mm

A pv=¿2000*1300

2
Apv=2.6 m

Maximum panel area can be estimated as function as:

A pv , H , Max=l∗w−0.3∗W −0.05∗l∗w

A pv , H , Max=3.2 m2

6−0.5
α= =0.91
6

0.444∗2.6∗5.92∗(10−2)
Ed= ∗0.9
10
Ed=¿4.87 KW

6−0.5
β= =0.91
6

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HYBRID SOLAR VEHICLE

0.44∗2.6∗5.92∗(10−2)
Ep=(0.62∗4.87)+ ∗0.9
10
Ep=¿ 3.01+4.87=7.88kw

Epv=Ep+ Ed

Epv=7.88+ 4.87

Epv=12.7 kw

Figure 12 Equivalent Circuit of PV Cell


Where:

Ipv – PV Current in Amps.


Vpv – PV Voltage in Volts.
ID - Diode current in Amps.
IRP – Parallel Resistance current in Amps.
IRS – Series Resistance current in Amps.

3.2.3 Design of Battery system


In most appliances an energy-storage is needed to bridge times of no sunshine. A Battery
stabilizes the System and gives Energy whenever the Solar Energy Supplied is not enough. The
most common type of batteries being used in stand-alone PV Systems are rechargeable lead-
acid-batteries. The storage battery can be calculated using the following equation. Battery
voltage or the system voltage selection depends on the total load demand of the system according

28
HYBRID SOLAR VEHICLE

to Table below. The analysis will take into account the user input on the days of storage needed
and also battery DOD.

Table 4 battery voltage selection as the load demand

Total daily load(kwh) Battery voltage(Volt)


<1 12
1–2 24
2–3 36
3–4 48
>4 60 –120

Therefore we choose 420Ah in 72v because of total load is 4.14 Kwh so which is greater than 4.

Battery bank capacity ( Brc ) in Ampere hour (AH) is given by:

( Ah )∗Ds
Brc=Ec
DODmax

Ds 2
But, DOD= Ds+1 = 3 =0.667

DOD=66.7%

Ec ( Ah )=
Ds∗pl ( day
wh
) = 2∗4813.98 =300.72
Vs∗DOD 48∗0.667

300.72∗2
Brc= =901.71
0.667

Were:

DOD - Battery depth of discharge


Ds - battery autonomy or storage days
Ec (Ah) - energy or load is given by Ampere in hour

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HYBRID SOLAR VEHICLE

Batteries in parallel

Brc 901.71
Bp= =
Bsc 420
=2.14

Where: Bsc - capacity of selection battery (Ah)

Batteries in series

Vn 72
Bs= = = 1.5
Vs 48

Where: Vn - nominal voltage of battery


Vs - nominal voltage of system

Total battery bank of the system

BT=Bp*Bs

BT=2.14*1.5 = 3.21

So that we have 4 batteries each having 420Ah.

3.2.4 Selection of charge controller


Charge controllers or also known as power conditioners are used to protect batteries from over
charging, under charging and also to maintain flow of electricity to the load. Output voltage of
the charge controller must be the same with the battery voltage. The following equation is used
to calculate the charge controller size in amps for the hybrid solar vehicle.

P
Cs= Where:
Vb
Cs - Solar charge controller current rating (A)
Vb - battery voltage (v)

4813.98
Cs= =68.77 A . Therefore we need one charge controller.
72

3.2.5 Wire Selection


The Cross-Section of the different DC-Cables can be calculated with the Formula:

30
HYBRID SOLAR VEHICLE

L∗P
A= 2
3 %∗V ∗K

Where: A - cable cross section (mm²), L - cable length (m)

P - Power transfer in cable, V - System voltage (V)

K=conductivity copper (cu=5.96*107 /Ωm), 3% = percentage of cable loss.

Table 5 load profile

Cable b/n the Length in m Component Connected Calculated A Selected A


following (+ve + -ve load in in in
cable) W mm2 mm2
PV array and 2 PV array 12700 6.1 8
Battery
Battery and EM 2 Motor 800 0.4 1
Battery and head 2 Head lamp 10 0.005 0.2
lamp
Battery and fog Front 1.5 Fog lamp 6 0.002 0.2
lamp
Battery and fog Rare 1 Fog lamp 6 0.0015 0.2
lamp
Turn signal lamp Front 2 Turn signal 12 0.0058 0.2
and battery
Turn signal lamp Rare 1 Turn signal 16 0.0039 0.2
&battery
Stop and tail 1.5 Tai lamp 16 0.0058 0.2
lamp and battery

CHAPTER FOUR
RESULTS AND DISCUSSIONS

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HYBRID SOLAR VEHICLE

4.1 Result
Table 6 Result of the designed photovoltaic system for car is listed below

Solar resources 5.92 kwh/m2/day


Total Load 4.81 Kwh
Total power of PV module 12.7 Kw
Size of battery(Ah) 420 Ah
Battery in parallel 2.14
Battery in series 1.5
Total No. of battery 4

4.2 Discussion
Since the designed system assumes the Bajaj to travel for ten hours per day, a 2.6 m2 area PV
panel that have 12700W maximum power is needed. Those panels are more efficient and can
supply all the loads.

The designed systems also use a battery to store energy for consumption at night and cloud time.
There are four batteries that are connected in parallel and in series to increase the voltage and to
have the same voltage with the designed system.

Since it is required to transmit power from the source to the load that the appropriate cable size
must be select, the designing uses the formula of cable selection for each device.

Hybrid solar vehicle use a solar as the primary source of the power, a gas engine and battery are
additional power needed.

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HYBRID SOLAR VEHICLE

The principle of driving HSV is that the PV energy pass through voltage regulator to EM. The
selecter mechanism select the operation condtion which is either PV or EM. If the first dog
clutch is shaft towards its right to engage with the EM gear on the main shaft output through
differential gear arrangements is transferred to the differential. Then the system run by PV panal.
First dog clutch is shaft towards its lift to engage with the gas engine gear on the main shaft
output shaft through different gear arrangements is transferred to the differential. Then the
system run by Gas Engine. From differential, power is transmitted finally to both the road
wheels, else pushing clutch pedal and connect the gas engine in the system.

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HYBRID SOLAR VEHICLE

CHAPTER FIVE

CONCLUSION AND RECOMMENDATION

5.1 Conclusion
In this paper, a new implementation of HSV reduced Fuel consumption (IC Engine). Also HSV
technology is proposed and investigated and it solves many problems related to the environment
and is the best pollution free method.

This multi charging Bajaj can charge itself from solar power and IC Engine (reduced fuel
consumption). HSV technology is continuous running during all intervals. The Bajaj is by adding
its Gas engine with an 800 watts BLDC Electrical Motor, 12.7 kilowatts PV Panel, four 72 V/
420 Ah Battery.

The battery stores electricity for use at night or for meeting loads during the day when the
modules are not generating sufficient power to meet load requirements. The Gas engine used for
shortfall condition meeting loads during the day when the modules are not generating sufficient
power and when the battery is empty to meet load requirements. Maximum Power Point is a
charge controllers used for extracting maximum available power from PV module under certain
conditions.

In our project we are able to size the PV module, maximum power point tracker and battery
depending up on the motor rating of car and others lighting loads.

5.2 Recommendation
In future this type of Bajaj have lot of marketing value because it will be used nonrenewable
resource and renewable energy. This type of Bajaj does create a little pollution so it is also have
a lot of positive point toward nature. Only the manufacturing cost is high but maintenance cost is
almost zero. Hence this Bajaj is economic and environmental friendly. We believe that if this
project is implemented practically, it helps in so many ways and is for sure profitable as the idea
is interesting and purely innovative. Also it will be used for research work and education
purpose.

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HYBRID SOLAR VEHICLE

Reference
[1] Dr. Samih Al Jabi,”Study, Design and Construction of Electrical solar Car,” Beijing
International Conference on Wind Energy, Beijing, 2007.

[2] Ranjeet Singh, Manoj Kumar Gaur and Chandra Shekhar Malvi “A Study and Design Based
Simulation of Hybrid Solar Car” Mechanical Engineering Department, MITS Gwalior-474005
Madhya Pradesh, India, January 2013.

[3] Soroush Seif, Mahshid Hashemi, and et al, “SEEDS SOLAR VEHICLE,” UBC Social
Ecological Economic Development Studies (SEEDS) Student Report , University of British
Columbia, April 2012.

[4] Ranjeet Singh, Manoj Kumar, Chandra Shekhar, “A Study and Design Based Simulation of
Hybrid Solar Car,” MITS Gwalior-474005 Madhya Pradesh, vol.3, No.1, pp685-691, 2013

[5] J. Rizk, and Y. Chaiko, “Solar Tracking System: More Efficient Use ofSolar Panels,” World
Academy of Science, vol.41, No.2, pp312-315, 2008

[6] Electronics hub, “Solar Tracking System”, available on-line at


http://www.electronicshub.org/top-electrical-mini-projects/, 2014.

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