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DESIGN DOCUMENT
TEAM PEACOCK LANE
VER. 1.0
11/15/2013
Design Document
Sun Tracking Solar Panel
EE 480 SENIOR DESIGN PROJECT PREPARATION
Team Members:
Elise King (Fall Team Lead)
Caitlin Greeney (Spring Team Lead)
Beverly Raposa
Julius Jose Raposa
Faculty Advisors:
Dr. Zia Yamayee (Primary)
Dr. Robert Albright (Secondary)
Client:
Dr. Heather Dillon - University of Portland
Industrial Advisor:
Mr. Jeffrey Cook -Bonneville Power Administration
UNIVERSITY OF PORTLAND
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Revision History
Table 1: Revison History
Ver.
0.9
0.95
1.0
Date
5 November 2013
7 November 2013
14 November 2013
UNIVERSITY OF PORTLAND
Author
Reason for Changes
Elise King
Made final edits before submitting to
Dr. Yamayee.
Beverly Raposa
Edited content, grammar and added
step down circuit for measurements.
Caitlin Greeney
Edited minor grammar mistakes and
added content for stepper motors and
software component.
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Table of Contents
Revision History ............................................................................................................................................ 2
Table of Tables .............................................................................................................................................. 4
Table of Figures ............................................................................................................................................. 4
Introduction .................................................................................................................................................. 5
High-Level Architecture ................................................................................................................................ 6
Light Source: ............................................................................................................................................. 7
Photoresistors: .......................................................................................................................................... 7
Arduino: .................................................................................................................................................... 7
Stepper Motors: ........................................................................................................................................ 7
External Power Source: ............................................................................................................................. 8
Display: ...................................................................................................................................................... 8
Solar panel: ............................................................................................................................................... 8
Component Structure ................................................................................................................................... 8
Software Component ................................................................................................................................ 8
User Interface Component ..................................................................................................................... 11
Digital Systems Component: Breadboard ............................................................................................... 12
Control Systems Component .................................................................................................................. 14
Mechanical Component .......................................................................................................................... 15
Frame .................................................................................................................................................. 15
Motor .................................................................................................................................................. 18
System Test Plan ......................................................................................................................................... 18
Modifications of Functional Specifications Document ............................................................................... 19
Final Budget ................................................................................................................................................ 20
Conclusion ................................................................................................................................................... 22
References .................................................................................................................................................. 23
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Table of Tables
Table 1: Revison History................................................................................................................................ 2
Table 2: Final Budget................................................................................................................................... 20
Table of Figures
Figure 1: Sun Tracking Solar Panel ................................................................................................................ 5
Figure 2: Block Diagram of Device ................................................................................................................ 6
Figure 3: Sample Arduino coding ................................................................................................................ 10
Figure 4: LCD Display................................................................................................................................... 11
Figure 5: LabView User Interface ................................................................................................................ 12
Figure 6: Breadboard Layout ...................................................................................................................... 13
Figure 7: Step-down circuit and LabView Measurement............................................................................ 14
Figure 8: Negative Feedback Diagram ........................................................................................................ 14
Figure 9: Frame Design with Dimensions.................................................................................................... 16
Figure 10: Cone Configuration for Photoresistor Frame ............................................................................ 17
Figure 11: Cross Configuration for Photoresistor Frame ............................................................................ 17
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Introduction
The Sun Tracking Solar Panel is a system that aims to increase solar power production by
30-40% by tracking the sun (or other source of light). In this project, the device is designed for
small-scale demonstration purposes in a classroom and for 24-hour data collection outdoors.
The goal is to teach students about efficient solar power production. Students are able to
interact with the device by moving a light source. As the device tracks the light source, solar
power is produced. The voltage through the photoresistive load can be measured to calculate
the current and solar power production, which can be used in laboratory exercises.
Design challenges include the orientation of photoresistors in order to sense the
brightest source of light, compatibility with data acquisition software LabView, learning to
program the Arduino microcontroller, and designing an aluminum frame that is light enough to
be oriented by the stepper motors. These design challenges will be addressed through careful
design, program debugging and lab testing. When completed, the project will look like Figure 1.
Figure 1: Sun Tracking Solar Panel
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In this document, the high-level architecture of the design and an in-depth explanation
of each individual component will be discussed. These components include: the software,
hardware, user interface, integrated circuits, control system and mechanical components. This
document also includes the system test plan, revised developmental process and the final
budget. Readers are expected to have a technical background and a basic understanding of
analog electronics and solar power production.
High-Level Architecture
This project involves a combination of mechanical and electrical components that work
together to maximize the power production of the solar panel. The main components of the
Sun Tracking Solar Panel can be found in the block diagram below:
Figure 2: Block Diagram of Device
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The components that make up the device are as follows:
Light Source: The light source is the analog input signal into the system. It will be in
the form of a halogen light bulb or the sun.
Photoresistors: When light of a certain frequency falls on a photoresistor, electrons
are excited and a current is produced. This current can be drawn from the
photoresistive load and measurements can be made. Methods for data acquisition will
be discussed in the user interface section of this document. Four photoresistors will be
placed in strategic locations around a base, allowing the Arduino to identify which
photoresistor is sensing the highest intensity of light. Photoresistor placement will be
discussed further in the mechanical component of this document.
Arduino: Arduino microcontrollers are an “open-source electronics prototyping
platform based on flexible, easy-to-use hardware and software”. This will function as
the “brain” of the device by performing logic on the information from the photoresistors
to determine which stepper motor to move, and sending voltage and current
measurements from the solar panels to the display. As mentioned above, the Arduino
will be able to distinguish which direction the light source is coming from by comparing
the intensities of light from the photoresistors. The Arduino will then signal the
appropriate stepper motor to move the solar panel toward the direction of the light
source. Based on the project specification, the Arduino UNO microcontroller will be
used.
Stepper Motors: These motors will change the position and angle of the frame,
which is attached to the solar panel, in order to orient the panel towards the brightest
source of light. Stepper motors respond to pulse inputs, which allow for quick, rapid
adjustments to a stimulus. The clock speed of the Arduino UNO is 16 MHz; however, we
will be having the Arduino make adjustments to the frame position at a much slower
speed, to be determined in testing. This design includes two motors: Motor 1 is
attached to a horizontal beam and Motor 2 is attached to a circular base (see Figure 1).
Motor 1 will rotate the horizontal beam, which will tilt the solar panel and frame to the
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desired angle, within 180° with respect to the plane in parallel to the base of the device.
Motor 2 will rotate the solar panel and frame within 360° clockwise and counterclockwise with respect to the base.
External Power Source: The Arduino requires a power source to function. This will
be a portable 5V battery source.
Display: The LCD module display will show the real-time current and voltage
measurements from the photoresistors. This module connects directly to the Arduino
microcontroller. The device is also designed to allow the positive and negative leads of
the solar panel to connect to LabView for data acquisition. This feature allows students
to monitor real-time voltage, which is used to calculate current and solar power
production.
Solar panel: The solar panel uses photovoltaic cells to harness light energy (photons)
to generate electricity. Photovoltaic (PV) cells are made from semiconductors such as
silicon, which absorb photons and cause electrons to flow freely. The potential
difference in free flowing electrons produce an electric field, which is intrinsic to the PV
cell. In this device, one solar panel, which is attached to an aluminum frame, is used.
The solar panel is rated for 12V direct current, has the dimensions of 8.74 in by 10.63 in,
and weighs 1.65lbs.
Component Structure
Software Component
The main software component of the device is an Arduino microcontroller, which will be
programmed to distinguish and compare light intensities from the photoresistors. The
determined lowest resistance indicates the direction of the light source with the greatest
intensity. The Arduino will signal the stepper motors to move to the corresponding direction
based on the photoresistor with the lowest resistance. This comparison will continue
recursively until all photoresistors measure the same resistance.
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The Arduino UNO uses Arduino programming language, which is implemented in C/C++.
This is beneficial as each member of the team has had training in a C coding environment.
Control structures include familiar loops such as: for, while, do-while, etc. Data types include:
void, boolean, char, int, etc.
Three wires are typically attached to the stepper motors, which connect to power,
ground, and a signal. The power wire will connect to a 5V source while the signal and ground
wires will connect to the programmed Arduino microcontroller. The I/O pins of the Arduino
have a current limitation of 40.0mA, and the stepper motor will have a maximum output
voltage of 5V. Functions such as stepper(), setSpeed(), and step(), will be used to program the
Arduino microcontroller. In the Arduino environment, the function stepper() can be used to
define an instance of the Stepper class, indicating a stepper motor. The setSpeed() function will
not cause the motors to move. It will set the speed of the motors at a given rotational velocity
in revolutions per minute (rpm) and will only be used when the step() function is called. The
step() function takes a numerical input argument which indicates the number of steps. This
function will signal the motor to increase by number of steps, indicated by the input argument,
at the speed set by the function setSpeed(). Figure 3 shows an example of code, which will test
the motor functionality using a potentiometer input.
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/*
* MotorKnob
*
* A stepper motor follows the turns of a potentiometer
* (or other sensor) on analog input 0.
*
* http://www.arduino.cc/en/Reference/Stepper
* This example code is in the public domain.
*/
#include <Stepper.h>
// change this to the number of steps on your motor
#define STEPS 100
// create an instance of the stepper class, specifying
// the number of steps of the motor and the pins it's
// attached to
Stepper stepper(STEPS, 8, 9, 10, 11);
// the previous reading from the analog input
int previous = 0;
void setup()
{
// set the speed of the motor to 30 RPMs
stepper.setSpeed(30);
}
void loop()
{
// get the sensor value
int val = analogRead(0);
// move a number of steps equal to the change in the
// sensor reading
stepper.step(val - previous);
// remember the previous value of the sensor
previous = val;
Figure 3: Sample Arduino coding
After testing the motors, this code will be modified to take the input from the
photoresistors instead of the potentiometer. Logic will be performed to determine which
photoresistor is pointing towards the brightest source of light. After determining the number of
steps, a signal will be sent to the motors to orient the solar panel into the specified direction.
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User Interface Component
There are two main ways the user may interact with the device. They are through the LCD
screen and data acquisition through LabView. The LCD screen will display voltage, current and
angle values of the device as shown on Figure 4.
Figure 4: LCD Display
The current and voltage values displayed are measured across the photoresistive load.
The angle is determined by the Arduino based on an algorithm determining the direction of the
brightest source of light. Students are also able to acquire data from the solar panels using the
DAQmx extension on LabView as shown on Figure 5.
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Figure 5: LabView User Interface
Using LabView, the students will write a simple program to measure voltage and calculate
current and power. The lab is equipped with an NI-cDAQ-9172 device that has an analog input
module, NI 9215, which is capable of measuring up to 10V. In order to reduce the output
voltage of the solar panel, a circuit is constructed on the breadboard to reduce the output
voltage by one-tenth (see breadboard for more information). Students will measure voltage
across R1 (see Figure 7), and calculate the output current using Ohm’s law. The output voltage
will be measured across a R3 (see Figure 7), and multiplied by ten. Using the output current and
voltage measurements, students are able to calculate the power produced by the solar panel by
Ohm’s Law.
Digital Systems Component: Breadboard
The Arduino microcontroller, photoresistors, stepper motors and LCD display will all be
connected to the breadboard as shown on Figure 6.
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Figure 6: Breadboard Layout
Power will be calculated by measuring current and voltage across the photoresistors.
The resistance of a photoresistor decreases with light intensity. This enables the device to
determine where to move based on which photoresistor detects the most light. Data from the
photoresistors will be processed on the Arduino microcontroller, which uses an algorithm to
determine the direction of the brightest light source. The microcontroller will then signal the
stepper motors to move and display the angle values on the LCD screen.
A secondary circuit will also be constructed on the breadboard to scale down the output
voltage by a factor of one-tenth as shown in Figure 7. This method will be used to avoid
measuring voltages greater than 10V using LabView.
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Figure 7: Step-down circuit and LabView Measurement
This circuit uses high precision resistors in order to avoid extra losses, which reduce the
reliability of current and voltage measurements. By measuring across R3, the output voltage
measured will be one-tenth of the actual voltage. Measuring the voltage across R1 can be used
to calculate current. The small value of R1 functions similar to the internal resistance of a digital
multimeter (DMM).
Control Systems Component
Figure 8 outlines the negative feedback block diagram of the system.
Figure 8: Negative Feedback Diagram
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The input of this negative feedback system is the sun orientation. The sun orientation is
detected by four photoresistors, which produce different resistive intensities based on the
intensity of the photos received. The resistive intensity is converted to voltage in the Arduino
microcontroller, which sends analog signals to the two stepper motors. These motors control
the orientation of the solar panel. Unity feedback occurs at the analog output of the
microcontroller. The Arduino will continue to monitor the four photoresistors and signal the
motors to move the solar panel until all the photoresistors receive the same light intensity. By
this point, the solar panel will be in the optimal orientation for maximum power production.
Mechanical Component
The sun tracking solar project contains many mechanical components. These components
include the frame and the motors.
Frame
The frame, which is shown on Figure 9, can be divided into two components. The first
component consists of the frame that holds the solar panel and contains the first motor, which
moves horizontal beam connected to panel. The panel is held on an aluminum beam attached
to the Motor, which rotates the panel in the y-axial direction. Motor 1 will rotate the horizontal
beam within 180° with respect to the plane in parallel to the base of the device.
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Figure 9: Frame Design with Dimensions
The base of the sun tracker will be a 16 by 16 inch stationary square with a well in the
center to hold the second motor. Above the motor is a secondary base, which holds the
Arduino microcontroller, breadboard, and solar panel. Motor 2 rotates the secondary base r,
which rotates the solar panel in the x-axial direction by 360° clockwise or counter-clockwise
with respect to the base.
The second frame component is the base for the photoresistors. They key is to place the
photoresistors on the base so each is oriented in a different direction. Photoresistor placement
is crucial because the photoresistors will determine which direction the solar panel should
move in order to receive the greatest light intensity for maximum power production. Figures 10
and 11 display the two possible configurations that will be tested.
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Figure 10: Cone Configuration for Photoresistor Frame
Figure 11: Cross Configuration for Photoresistor Frame
The cone design allows each of the four photo resistors to be angled in opposite
directions. The angle allows for accurate detection of the position of the light source. The cross
design allows for a sun-dial effect for the four photoresistors. The photoresistor within the
direction of the light source receives the most amount of light while the others are shadowed
out. In both designs, the panel will move toward the direction of the photoresistor with the
lowest resistance (facing the greatest light intensity) and will continue to move until resistance
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in each photoresistor is approximately the same. Equal resistance levels indicate that the solar
panel is directly oriented in the position of the light source.
Motor
Two stepper motors will be used for x and y axial rotation of the solar panel. The motors will be
compatible with the Arduino microcontroller.
System Test Plan
To test functionality of solar panel:
1. Attach digital multimeter (DMM) to solar panels output leads.
2. Shine halogen light source on cells of the solar panel.
3. Read voltage measured across the leads of the solar panel.
4. Expect measurement to be greater than zero volts.
To test functionality of photoresistors:
1. Attach DMM to photoresistor output wires.
2. Shine halogen light source on photoresistor frame.
3. Read that a voltage is measured and that configuration provides enough difference
between individual photoresistors.
4. Expect measurement to be greater than zero volts.
5. Cover three of the photoresistors and shine light source on only one photoresistor.
6. Expect all covered photoresistors measure zero volts and the uncovered measures a
values greater than zero volts.
To test functionality of Arduino/photoresistor interconnect:
(Note: At this point, the Arduino code will be in test phase, containing a section included which
will print out the values of the voltage measured from each photoresistor and which
photoresistor the light source is most likely directed to.)
1. Attach photoresistor output wires to appropriate input pins on Arduino.
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2. Shine light on photoresistor configuration, pointing closer to one photoresistor
specifically. Mark down which photoresistor is chosen.
3. Expect the Arduino to measure voltage from each photoresistor and logic determines
the light source comes from the direction of the previously chosen photoresistor.
To test functionality of entire device (photoresistors/Arduino/Stepper Motors)
(Assuming all wires are appropriately attached)
1. Shine light on photoresistor cone, pointing closer to one photoresistor specifically. Mark
down which photoresistor is chosen.
2. Expect the Arduino to measure voltage from every photoresistor, the direction from
which the light is coming from based on photoresistor placement is determined by logic,
and the stepper motors orients the solar panel to point in the direction of the light
source.
Modifications of Functional Specifications Document
A few major changes have been made since Functional Specifications v1.0. In order to
satisfy the LabView maximum voltage measurement constraint of 10V, Team Peacock Lane
decided to buy a solar panel rated at 12V instead of using the panel donated from the City of
Portland, which was rated at 20V. Size was also a factor in deciding to purchase an additional
solar panel. For optimum light detection, the photoresistors will be mounted on the left end of
the rod, opposite to the servomotor. Team Peacock Lane has decided to use a stepper motor to
rotate the panel within a range of 180° and a stepper motor to rotate the base of the frame
within a range of 360°. Finally, a basic 20x4 character LCD display will be used to display
voltage, current and angle values.
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Final Budget
The following table, Table 2, lays out the final budget for this device.
Table 2: Final Budget
Part
SainSmart
UNO R3
Starter Kit
SunFouder
ULN2003
Stepper
Motor
Control
Board with
5V Stepper
Motor
Description
Qty
Rate
Package includes:
- 1 x Arduino UNO R3
- 1 x 1602 LCD
- Module
- 1 x USB Cable
- 1 x Buzzer
- 1 x Nixie Tube
- 1 x Temperature Sensor
- 1 x 74HC595
- 1 x Infrared Remote
Control
- 1 x Infrared Receiver
- 1 x Photoresistor
- 1 x Potentiometer
- 2 x Tilt sensor
- 4 x Pushbuttons
- 1 x RGB
- 1 x Flame Sensor
- 1 x Cell Box
- 1 x 2-Channel 5V Relay
- 1 x Prototype Shield
- 1 x Mini Breadboard
- Resistors
- Jumper wires
- LEDs
- Voltage: 5V
- Diameter: 28mm
- Step angle: 5.625 x 1 / 64
- Reduction ratio: 1 / 64
- 5 Line four-phase can be
driven by ULN2003 chip
can be connected in-phase
to development board
- Motor driver board with
ULN2003
A, B, C, D four-phase LED
indicates the status of
motor
- Motor with standard
interface, when used
directly pluggable
1
$ 39.50
$ 39.50
http://www.amazon.co
m/SainSmart-TutorialBeginners-Prototype-2Channel/dp/B00BWIPD
QA/ref=sr_1_21?ie=UTF
8&qid=1383629051&sr=
821&keywords=arduino+
uno+kits
2
$7.99
$15.98
http://www.amazon.co
m/SunFouder-ULN2003Stepper-Mega2560Duemilanove/dp/B00E0
O50Q6/ref=sr_1_15?ie=
UTF8&qid=1383611516
&sr=815&keywords=stepper+
motor+for+arduino#pro
ductDetails
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Subtotal
Link
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Photoresistors
Solar Panel
VER. 1.0
- Maximum Voltage: 150
Volt DC
- Maximum Wattage:
50mW
- Operating Temperature: 30 ~ +70 deg C
- Spectral Peak: 540nm
- 20 x Photo Light Sensitive
Resistor Photoresistor
Optoresistor 4mm
GL4537-1 4537-1
- Package contains 20pcs.
11/15/2013
1
$12.99
$12.99
http://www.amazon.co
m/gp/product/B00AR7Z
B78/ref=ox_sc_act_title
_3?ie=UTF8&psc=1&smi
d=A28PCZ3GGXGBES
1
- 12V 5W PV module
- Peak Power: 5W
- Peak Power Voltage: 17 V
- Peak Power Current: 0.29A
- Open Circuit Voltage: 21.6V
- Short Circuit Current: 0.34A 5 W
- Weight: 1.65 lbs
- Length: 8.74 in.
- Width: 10.63 in.
- Nominal Voltage: 12V
$29.00
$29.00
http://www.solarpanelst
ore.com/solarpower.small-solarpanels.smallspssolarcoll
ectors.solarland5.info.1.
Multihtml
crystalline
Cell Type:
TOTAL $106.47
All parts and components listed in table above will be purchased through the Electronics
Technician. Before purchase, the Electronic Technician will review the list and inform Team
Peacock Lane of any items that the school already has in stock. Allen Hansen and his team in
the tool room located in engineering building will construct the devices frame. Since this project
will be used as a teaching device, the materials will be retrieve from the current inventory in
the School of Engineering and will not affect the projects budget. At this point, the proposed
final budget is $110.
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Conclusion
In conclusion, this document addresses the major design decisions associated with
constructing the sun tracking solar panel. The high-level architecture of the design and an indepth explanation of each individual component of the design, such as the software, hardware,
user interface, integrated circuits, control system and mechanical components, were discussed.
This document also included the system test plan, revised developmental process and the final
budget. By reading this document, a better understanding of how team Peacock Lane intends
to build the sun tracking solar panel should be achieved.
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http://www.arduino.cc/
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<http://arduino.cc/en/Tutorial/MotorKnob>.
"Arduino - Stepper." Arduino - Stepper. N.p., n.d. Web. 05 Nov. 2013.
<http://arduino.cc/en/Reference/Stepper?from=Tutorial.Stepper>.
Gotanda, B. H., & Reiter, D. (2011). Fueled by the sun: 10 sizzling Legal issues in solar energy
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How do solar cells work?| Explore | physics.org. (n.d.). physics.org | Home. Retrieved
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Physics - Home. Retrieved September 15, 2013, from
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Rogers, H. (n.d.). THE WAY WE LIVE NOW - 6-03-07 - RECONSIDERATION - Current Thinking NYTimes.com. The New York Times - Breaking News, World News & Multimedia.
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Solar ABCs: Codes & Standards. (n.d.). Solar America Board for Codes and Standards. Retrieved
September 12, 2013, from http://www.solarabcs.org/codes-standards/index.html
http://www.oregon.gov/ODOT/HWY/OIPP/docs/life-cyclehealthandsafetyconcerns.pdf.
(n.d.). Oregon.gov. Retrieved September 15, 2013, from
www.oregon.gov/ODOT/HWY/OIPP/docs/life-cyclehealthandsafetyconcerns.pdf
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