Upgrade Your Backup Power with Solar Generator Version 2

Table of Contents

1. Introduction
2. Concerns with the Original Design
   • Heating Issue
   • Daily Charging
3. Upgrading the Solar Generator
   • Cooling Fan Installation
   • Using a Bi-Metal Switch
4. Adding a Fuse for Protection
5. Incorporating an Inverter
6. Testing the Upgraded Solar Generator
7. Conclusion

Introduction

In this article, we will discuss the DIY solar generator and its recent upgrades. The original design served as a backup power generator, but some DIYers wanted to utilize it as a solar generator. However, this led to concerns about heating and frequent charging. To address these issues, we will explore the process of upgrading the solar generator by installing a cooling fan, using a bi-metal switch, adding a fuse for protection, and incorporating an inverter. We will also test the functionality of the upgraded solar generator. So, let's dive in and see how these upgrades improve the performance and usability of the DIY solar generator.

Concerns with the Original Design

Heating Issue

One of the major concerns with using the DIY solar generator as a solar generator is that it tends to get hot when charging. While this heating issue was not a problem when it was used as a backup power generator, charging it every day as a solar generator caused the heat to build up. This heat can be detrimental to the components and reduce the efficiency and lifespan of the generator.

Daily Charging

Another concern arises from the fact that as a solar generator, the DIYers need to charge it daily. This constant charging not only adds to the heating issue but also consumes more power since it is designed as a backup power generator that only needs to be charged occasionally. Hence, using it as a solar generator poses challenges in terms of energy consumption and heat management.

Upgrading the Solar Generator

Cooling Fan Installation

To address the heating issue, the first upgrade involves the installation of a cooling fan or exhaust fan. This fan will help dissipate the heat generated during the charging process. By creating a negative pressure, the fan will exhaust the heat outside, thus reducing the temperature inside the generator. The cooling fan will be strategically placed near the buck converter and the MBR blocking diode, which are the components that tend to get hot during charging.

To ensure the efficient operation of the cooling fan, a bi-metal switch will be used. This switch will activate the fan when the temperature reaches a certain threshold. The switch is designed to close and complete the circuit when the temperature exceeds a specific degree Celsius. This ensures that the fan remains on only when necessary, preventing the battery from being constantly drained.

Using a Bi-Metal Switch

The bi-metal switch is a vital component in the cooling system of the upgraded solar generator. It acts as the switch mechanism, allowing the fan to turn on and off automatically based on the temperature. When the temperature reaches the specified threshold (such as 45 degrees Celsius), the bi-metal switch will close the circuit, activating the fan. This ensures that the generator remains cool during the charging process.

The bi-metal switch is chosen based on its capability to handle high voltage (250V) and current (5A). It is a normally open switch that closes when the temperature exceeds the threshold. To demonstrate how the bi-metal switch works, a lighter and a heat sink are used. When heat is applied to the switch, it closes the circuit, resulting in a beeping sound indicating continuity. When the switch cools down, it reopens the circuit, breaking the continuity.

Adding a Fuse for Protection

To provide additional protection, a fuse is added to the solar generator's input. The fuse acts as a safety device that protects the components from short circuits. In case of a short circuit in the charger, the fuse will blow, preventing any damage to the buck converter. It acts as a safeguard for the generator and enhances the overall safety of the system.

A blade fuse is used for this purpose, with a 15A rating. The fuse is placed in its holder and connected to the input, which goes to the buck converter. By adding this fuse, the solar generator is protected against potential short circuits and electrical hazards.

Incorporating an Inverter

For those who desire an all-in-one package, an inverter can be added to the solar generator. This modified sine wave mini inverter allows the generator to produce AC output. By removing the heat sink and placing the inverter in the available space, the generator becomes capable of powering AC devices.

To compensate for the removed heat sink, a larger cooling fan is installed. This fan provides sufficient cooling for the inverter, ensuring its proper functionality. With the addition of the inverter, the solar generator becomes a versatile power bank, suitable for charging laptops and other AC-powered devices.

Testing the Upgraded Solar Generator

After completing the upgrades, it is essential to test the functionality of the solar generator. The charging process is carried out, and the performance of the cooling fan is observed. By monitoring the temperature and the activation of the fan, it can be determined whether the upgrades have been successful in resolving the heating issue. Additionally, the AC output of the inverter is tested to ensure its proper operation.

The results of the testing phase will provide valuable insights into the effectiveness of the upgrades and their impact on the overall performance and usability of the solar generator.

Conclusion

In conclusion, the upgrades made to the DIY solar generator have addressed the concerns related to heating and daily charging. By installing a cooling fan and utilizing a bi-metal switch, the solar generator can now efficiently manage heat and maintain optimal temperature levels. Furthermore, the addition of a fuse for protection and an inverter for AC output enhances the functionality and versatility of the generator.

These upgrades cater to the needs of DIYers who wish to use the solar generator as an all-in-one power bank. The successful implementation of these upgrades ensures a reliable and efficient power source for various electronic devices. With the upgraded solar generator, DIYers can enjoy the benefits of renewable energy while maintaining the safety and performance of their DIY projects.