Solar Hacks

203 Articles

Solar Planes Are Hard

October 12, 2024 by 12 Comments

A regular comment we see on electric aircraft is to “just add solar panels to the wings.” [James] from Project Air has been working on just such a solar plane, and as he shows in the video after the break, it is not a trivial challenge.

A solar RC plane has several difficult engineering challenges masquerading as one. First, you need a solid, efficient airframe with enough surface area for solar panels. Then, you need a reliable, lightweight, and efficient solar charging system and, finally, a well-tuned autopilot to compensate for a human pilot’s limited endurance and attention span.

In part one of this project, a fault in the electrical system caused a catastrophe so James started by benching all the electricals. He discovered the MPPT controller had a battery cutoff feature that he was unaware of, which likely caused the crash. His solution was to connect the solar panels to the input of a 16.7 V voltage regulator—just under the fully charged voltage of a 4S LiPo battery— and wire the ESC, control electronics, and battery in parallel to the output. This should keep the battery charged as long as the motor doesn’t consume too much power.

After rebuilding the airframe and flight testing without the solar system, [James] found the foam wing spars were not up to the task, so he added aluminum L-sections for stiffness. The solar panels and charging system were next, followed by more bench tests. On the test flight, it turned out the aircraft was now underpowered and struggled to gain altitude thanks to the added weight of the solar system. With sluggish control responses,[James] eventually lost sight of it behind some trees, which led to a flat spin and unplanned landing.

Fortunately, the aircraft didn’t sustain any damage, but [James] plans to redesign it anyway to reduce the weight and make it work with the existing power system.

We’ve seen several solar planes from [rctestflight] and meticulously engineered versions from [Bearospace Industrues]. If long flight times is primarily what you are after, you can always ditch the panels and  use a big battery for 10+ hour flights.

Continue reading “Solar Planes Are Hard” →

Pi Zero Power Optimization Leaves No Stone Unturned

October 3, 2024 by 17 Comments

If you’ve ever designed a battery-powered device with a Pi Zero, you have no doubt looked into decreasing its power consumption. Generic advice, like disabling the HDMI interface and the onboard LED, is omnipresent, but [Manawyrm] from [Kittenlabs] goes beyond the surface-level, and gifts us an extensive write-up where every recommendation is backed with measurements. Armed with the Nordic Power Profiler kit and an SD card mux for quick experimentation, she aimed at two factors, boot time and power consumed while booting, and made sure to get all the debug information we could use.

Thanks to fast experimentation cycles and immediate feedback, we learn plenty of new things about what a Pi Zero does and when, and how we can tame various power-hungry aspects of its behavior. Disabling the GPU or its aspects like HDMI output, tweaking features like HAT and other peripheral probing, and even tactical overclocking during boot – it’s an extensive look at what makes a Pi Zero tick, and no chance for spreading baseless advice or myths.

All in all, this write-up helps you decrease the boot time from twelve seconds to just three seconds, and slash the power budget of the boot process by 80%. Some recommendations are as simple as config.txt entries, while others require you to recompile the kernel. No matter the amount of effort you can put into power optimization, you’ll certainly find things worth learning while following along, and [Manawyrm]’s effort in building her solar-powered Pi setup will help us all build better Pi-Zero-powered solar devices and handhelds.

Hard Lessons Learned While Building A Solar RC Plane

September 9, 2024 by 17 Comments

Although not the first to try and build a DIY solar-powered remote control airplane, [ProjectAir]’s recent attempt is the most significant one in recent memory. It follows [rctestflight]’s multi-year saga with its v4 revision in 2019, as well as 2022’s rather big one by [Bearospace]. With so many examples to look at, building a solar-powered RC airplane in 2024 should be a snap, surely?

The first handicap was that [ProjectAir] is based in the UK, which means dealing with the famously sunny weather in those regions. The next issue was that the expensive, 20% efficient solar panels are exceedingly fragile, so the hope was that hot-gluing them to the foam of the airplane would keep them safe, even in the case of a crash. During the first test flights they quickly found that although the airplane few fairly well, the moment the sun vanished behind another cloud, the airplane would quite literally fall out of the sky, damaging some cells in the process.

Continue reading “Hard Lessons Learned While Building A Solar RC Plane” →

Does Solar Energy Make Us Vulnerable?

August 20, 2024 by 86 Comments

Here’s a hypothetical situation. You decide to build your own steam generator plant and connect it to the electric grid. No matter where you live, you’d probably have to meet a ton of requirements from whoever controls your electric power, almost surely backed by your government. Yet, according to a recent post by [Bert], a version of this is going on in Europe and, probably, in many more places: unregulated solar power inverters driving the grid.

If you have just a few solar panels hanging around, that probably isn’t a problem. But there are a sizeable number of panels feeding power — and that number seems to grow daily — having control of the inverters could potentially allow you to limit the grid’s capacity or — if the inverters allowed it — possibly take the grid down by feeding power incorrectly back into the grid.

Continue reading “Does Solar Energy Make Us Vulnerable?” →

The Sunchronizer Keeps Your Solar Panel Aligned

August 15, 2024 by 34 Comments

In the past few years, the price-per-watt for solar panels has dropped dramatically. This has led to a number of downstream effects beyond simple cost savings. For example, many commercial solar farms have found that it’s now cheaper to install a larger number of panels in fixed positions, rather than accepting the extra cost, maintenance, and complexity of a smaller number panels that use solar tracking to make up the difference. But although this practice is fading for large-scale power production, there are still some niche uses for solar tracking. Like [Fabian], if you need to maximize power production with a certain area or a small number of panels you’ll wan to to build a solar tracker.

[Fabian]’s system is based on a linear actuator which can tilt one to four panels (depending on size) in one axis only. This system is an elevation tracker, which is the orientation generally with respect to latitude, with a larger elevation angle needed in the winter and a lower angle in the summer. [Fabian] also designs these to be used in places like balconies where this axis can be more easily adjusted. The actuator is controlled with an ESP32 which, when paired with a GPS receiver, can automatically determine the sun’s position for a given time of day and adjust the orientation of the panel to provide an ideal elevation angle on a second-by-second basis. The ESP32 also allows seamless integration with home automation systems like SmartHome as well.

Although this system only tracks the sun in one axis right now, [Fabian] is working on support for a second axis which mounts the entire array on a rotating table similar to an automatic Lazy Susan. This version also includes a solar tracking sensor which measures solar irradiance in the direction the panel faces to verify that the orientation of the panel is maximizing power output for a given amount of sunlight. Tracking the sun in two axes can be a complicated problem to solve, but some solutions we’ve seen don’t involve any GPS, programming, or even control electronics at all.

Continue reading “The Sunchronizer Keeps Your Solar Panel Aligned” →

New Solar Spheres Claim To Be Better Than Solar Panels

July 6, 2024 by 83 Comments

When you think of solar energy, you probably think of flat plates on rooftops. A company called WAVJA wants you to think of spheres. The little spheres, ranging from one to four inches across, can convert light into electricity, and the company claims they have 7.5 times the output of traditional solar panels and could later produce even more. Unfortunately, the video below doesn’t have a great deal of detail to back up the claims.

Some scenes in the video are clearly forward-looking. However, the so-called photon energy system appears to be powering a variety of real devices. It’s difficult to assess some of the claims. For example, the video claims 60 times the output of a similar-sized panel. But you’d hardly expect much from a tiny 4-inch solar panel.

Continue reading “New Solar Spheres Claim To Be Better Than Solar Panels” →

Solar Energy Plant Creates Fuel

June 29, 2024 by 24 Comments

Normally, when you think of solar power, you think about photovoltaic cells or using the sun to generate steam. But engineers at Synhelion — a spin off from ETH Zurich — had a crazy idea. Could you reverse combustion and change waste products back into fuel? The answer is yes if you can use the sun to turn things up to 1,500°C.

The input is water, carbon dioxide, and methane into syngas. The pilot plant in Germany is set to begin operations using a thermal storage device to allow the plant to operate around the clock. The new plant is slated to produce several thousand liters of fuel a year. Future plants will produce more, and they are targeting a cost of $1 per liter of fuel. The pilot plant has a 20-meter-tall tower and around 1,500 square meters of mirrors, producing 600 kW of output. The hexagonal mirrors are very thin, and the plant uses drones to aim the mirrors quickly compared to other methods.

Syngas shows up a lot lately. Getting to 1,500 degrees is a big ask, although we’ve seen ETH Zurich get to 1,000 using solar.