Solar panel with circuit inside a PC box -Not working

In summary, the project involves a solar panel integrated within a PC box, but it is currently non-functional. The reasons for the malfunction are not specified, indicating potential issues with the solar panel, wiring, or internal components that require troubleshooting.
  • #1
Madhumkm12
2
0
TL;DR Summary
Solar panel and circuit not working as intended inside a Polycarbonate box.
Hi,
I am trying to build a product where i am placing a solar panel along with a driver board inside a Polycarbonate housing and closing it with a ABS cover at the back.
The driver board is soldered at the back of the solar panel and placed inside the PC box. Then a RTV(silicone sealant for leds ) layer is applied to hold still the setup inside the PC box. Then a 2 potting component is mixed and poured to make it waterproof IP68.

Here comes the problem. The panel is generating around 300mah when the panel board and the battery is outside in open air and the battery goes from 2.9v to 4v. But when the same setup is placed inside the PC box and kept for testing the battery is not getting charged. Still the solar panel generates the same 300mah current inside the box as well.

The doubt is whether the driver board is acting weird inside the PC case as the temperature inside the box is around 60'C and since the back is also covered there is a hot air inside thats not circulating. So some thermal reaction is happening.
How to over come this situation. There is no way i can make an air vent or Heat sink because in order to achieve IP68 i need to seal with potting.

Please help me out with a solution on this or the way it has to be approached
 
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  • #2
Welcome to PF.

Can you post some pictures? (Use the "Attach files" link below the Edit window.)

Also, can you consider a metal enclosure and thermally conductive epoxy to help get the heat out of the enclosure?
 
  • #3
There is no possibility to go for a metal enclosure as we are putting LED to light up at night. so need a transparent material so only chose PC. which allows 88% of light inside. Tested on that.
we use Potting which is thermally conductive only so that it doesn't allow external heat inside and absorb from the panel or driver board as well.

Before doing this we try to test in once before pouring potting. But now there is an anomaly caused because of this charging issue
 

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  • #4
Madhumkm12 said:
The doubt is whether the driver board is acting weird inside the PC case as the temperature inside the box is around 60'C and since the back is also covered there is a hot air inside thats not circulating. So some thermal reaction is happening.
The battery has three wires so it's likely with a thermistor, which is monitored by the controller board. It'll stop charging if the temperature is too high.
The controller will likely monitor its own temperature too and shut down if it is too high.
Though it should still charge periodically. Just not full time. You should be able to check that.

Since it's just the normal operation I guess the only thing you can do is to remove the heat and maintain stable temperature (for both the battery and the controller).
Maybe you can add some copper plates below the potting. But this will require some engineering...
 

FAQ: Solar panel with circuit inside a PC box -Not working

1. Why is my solar panel not generating any power?

There could be several reasons for this issue. First, ensure that the solar panel is receiving adequate sunlight; obstructions like trees or buildings can block sunlight. Additionally, check the connections and wiring for any damage or loose connections. If the panel is dirty or covered with debris, clean it to improve efficiency. Lastly, verify that the solar panel itself is functioning properly by testing it with a multimeter.

2. How can I troubleshoot the circuit inside the PC box?

Start by checking all the connections and ensuring that they are secure. Look for any visible signs of damage to the circuit, such as burnt components or broken traces. If you have a multimeter, you can test the continuity of the circuit and check for any shorts. If the circuit uses a microcontroller, ensure that it is programmed correctly and receiving power as intended.

3. Can the solar panel and circuit be damaged by overcharging?

Yes, if the solar panel is connected to a battery without a charge controller, overcharging can damage both the battery and the circuit. To prevent this, use a charge controller that regulates the voltage and current coming from the solar panel to the battery. This will protect your components and ensure safe operation.

4. What type of battery should I use with my solar panel circuit?

The type of battery you should use depends on the voltage and current output of your solar panel. Common choices include lead-acid batteries, lithium-ion batteries, or nickel-metal hydride batteries. Make sure to select a battery that matches the specifications of your solar panel and circuit to ensure compatibility and efficiency.

5. How can I improve the efficiency of my solar panel setup?

To enhance the efficiency of your solar panel setup, place the solar panel in a location with maximum sunlight exposure, ideally at an angle that optimizes solar gain. Regularly clean the panel to remove dust and debris. Additionally, consider using a solar tracker that adjusts the panel's position throughout the day to follow the sun. Finally, ensure that all components in the circuit are of high quality and properly matched to minimize energy losses.

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