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http://www.instructables.com/id/How-to-MAKE-PV-Solar-Panels/
Author:VIRON
I'm a figment of my own imagination. ---To Win the war on Terra Means to END the WORLD. How about a nice game of Chess? ---I'm chilling, but forgive me for sometimes believing I invented everything.
http://www.instructables.com/id/How-to-MAKE-PV-Solar-Panels/
Brass extrusions, bracket |_| shaped - Convenient for connecting to glass cells. Solder Soldering Iron - low wattage Small flat-head screwdriver Thin (around 20 AWG or less) stranded copper wire Lamp cord or Speaker Wire Alligator clips Deep Picture Frames or Shadow Boxes (Enclosure) -look for imported frames at the El Cheapo store and pray a machine made them Acrylic/Lexan/Plexiglas/Etc clear polymer sheets Router or Dremel to cut out the middle of one out of three sheets RTV (Silicone Glue) - or : High Temperature Hot Melt Glue (Caution-you don't want the sun to melt it!) Rectifier Diode such as 1N4001 or 1N4004 Voltage doubler or multiplier circuits (you can make) to increase voltage output. -examples: ICL7660, MAX1044, MAX232, etc. Wide Sticky Tape Double Sticky Foam Tape Rechargeable Nickel Batteries Gel Cells or Car Battery (you got one, might as well use it until it's useless) -Li Ion not recommended because they are harder to charge Analog volt meter (only because it doesn't need batteries like a digital one) AC Inverter - if you are charging a powerful battery and would occasionally run some mains-powered appliance. Some UPS's can be easily modified to be inverters, if they can be turned on after a power failure. Sources: Broken Solar Cells: Herbach and Rademan Silicon Solar Electronic Goldmine Glass (Amorphous) Solar Cells: Electronic Goldmine Note:Other links here may also supply Glass Solar Cells Indium Copper Selenide Cells: All Electronics Edmund Scientific Electronic Goldmine Other sources: Cheap weather damaged solar powered outdoor night lights -(common failures are circuit corrosion and defective batteries, not the solar cells) Defective solar calculators, solar charged flashlights, etc. Perhaps a little off topic: For a reasonably good deal on Complete and Useful Solar Panels I recommend "Solar Car Battery Chargers" that are about 1 or 2 watts and between $20 and $30, whenever an opportunity to get some arises. But those are what I am trying to show how to Make an approximate equivalent of.
http://www.instructables.com/id/How-to-MAKE-PV-Solar-Panels/
http://www.instructables.com/id/How-to-MAKE-PV-Solar-Panels/
either strands from stranded wire, or thin wire-wrap wire. What about thicker wire? It can pull the lines off the cell and then you can forget about soldering it. Put it in the "wire glue" bin. Now that there are two wires on the cell, test it with a meter. The Blue side of the cell will make up to 0.55 Negative volts, so connect the meter PLUS to the wire on the silver-gray bottom of the cell. My cell isn't getting much light but the meter needle is indicating that it is making electricity.
http://www.instructables.com/id/How-to-MAKE-PV-Solar-Panels/
http://www.instructables.com/id/How-to-MAKE-PV-Solar-Panels/
there is voltage in the light across the two extrusions, put stickytape or just a little plastic cement over the extrusion to help it stay there. The Glass cell is now ready to use. The long one shown is actually two 9-volt ones on one glass, and is the one that I put extruded contacts on because the copper mesh wouldn't stick..
http://www.instructables.com/id/How-to-MAKE-PV-Solar-Panels/
http://www.instructables.com/id/How-to-MAKE-PV-Solar-Panels/
DUTY CYCLES: In simple theory, if you get eight hours of sun and need one hour of power, you can get by with one eighth the solar power by saving it up in batteries. Also, if LED lights should run all night, it's easy to collect more than enough solar power during the day in batteries with the right sized panel.
http://www.instructables.com/id/How-to-MAKE-PV-Solar-Panels/
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Comments
50 comments Add Comment view all 69 comments
lizman says:
Thank you very much!!!!
lizman says:
Feb 7, 2011. 11:42 PM REPLY Hey guys im lisolomzi im doing my B-Tech and im doing a project on PV panel. I must design and manufacture it. so guys i need some information how to go about to design and manufacture it plz email me on imgushelo@yahoo.com.
frankjohnston25 says:
"MAKE SOLAR PANEL":http://makesolarpanelseasy.com
adnan.ad88 says:
hi my name is Adnan and i want to know that how can i creat our own solar panels and solar cells.
http://www.instructables.com/id/How-to-MAKE-PV-Solar-Panels/
solarJoan says:
May 24, 2010. 10:48 PM REPLY Hi Adnan, I'm Joan. I think you may be interested in manufacturing solar panels. If so, you can send me a mail. And then, I can give you more information for you. solar_solar@126.com . this is my mail box. I've deal with many people who are now manufacturing the solar panels. I'm looking forward to hearing you.
saluu20 says:
Dec 7, 2010. 1:33 AM REPLY hai this is salman from india and im intrested in making solar panal and solar power i need some steps so can u help me in it this is my mail salmannisar20@gmail.com
Aatif says:
May 29, 2010. 7:05 AM REPLY Hi. This is Aatif Khan, i m also intersted in solor pannel. please let me know, my e-mail address is anatomykhan@yahoo.com .
melvi says:
Oct 8, 2008. 8:35 AM REPLY Please help spread the word- what the world needs now is a Manhattan type project to manufacture solar cells cheaply to give to everyone free and in the process create public sector jobs. Socialism maybe, but the private sector will take too long. The world needs a silver bullet right now. And this bullet tackles both the economy and the climate change crisis. 1 Trillion not enough, why not get 2 or even 3 from whatever source Bush got his 5. Seems easy enough. If you agree - please tell your congressmen, senators and anybody who would listen.
evanpnz says:
Jun 11, 2010. 7:58 AM REPLY Actually cheap solar cells using printed nano-particle technology are already a reality, but right now the entire production of the first factory using this new tech (in California) is going to large scale commercial applications rather than private buyers.
poosthuizen says:
Nov 21, 2010. 11:10 PM REPLY Hi evanpnz, can you perhaps give me more information on this nano-techcology as there is no solar cells factories or any production in South Africa everything must be imported and is very expensive. My Email address is poosthuizen29@gmail.com
poosthuizen says:
Mar 1, 2010. 1:35 AM REPLY Hi there, I am from South Africa, with long sunny days all year around. With bad administration our country energy is in a crises end electricity prices went sky high, I am looking into solar or wind energy but this is a relatively new concept here and technology very expensive, is there somebody that can give advice on how to live of the grid, where to look for cells, what type of cells, wind energy the minimum wind speed needed and what type of generator etc. I am no slouch technically but the is new to our country.
vee-man.mol says:
you are such a lier thier is so much soler power you could eat it
Amathongo says:
Aug 24, 2010. 9:47 AM REPLY Have you tried solar water heating, low flow shower heads, geyser-timers etc etc. I have and its been quite good but I also want to get some PV panels and build up a battery bank, it seem expensive still in SA and there is conflicting information, I went to an Eskom conference last week and advised them that their video and info on turning down geysers was incorrect, the thermo. needs to be zero'd (click) before turning to the desired temp. They said they know.? Jun 19, 2010. 5:24 AM REPLY
Cleasonsook says:
would like to know about "ICL7660" When I check my local Electronics store they list 3 different versions ICL7660CPA ICL7660CSA ICL7660SCP dose it make a difference which one I pick ?
http://www.instructables.com/id/How-to-MAKE-PV-Solar-Panels/
ntn923 says:
Aug 16, 2010. 6:08 AM REPLY It shouldn't make too much difference. The different letters at the end are often just differences in max levels, whether of efficiency or of other small details. For a small project like this, any of the three should work fine. If you'd like more info on the chips, the datasheets can be found on alldatasheets.com, ti.com, or most other electronics providers sites.
ed_loy says:
what are the sources of those cells?
napjax3000 says:
Jul 11, 2010. 4:46 PM REPLY Very nice article and illustrations. You gave step by step instructions that were easy to understand. I've seen a few more of these on other sites, but got a little lost. Keep up the good work.
roseler says:
hello... I am Roseler and i want to know that how can i create our own solar panels and solar cells.
AlphaTwin says:
Jul 23, 2008. 7:43 AM REPLY Pretty Darn cool, I've got a little different angle on this. Let me explain. I live in the Midwest U.S. It's gets pretty darn cold/expensive in the winter. With the price of Corn sky rocketing it's no longer cost effective to heat my house with my corn burner. So I started playing with electrolysis to make Hydrogen to burn in my Natural gas Furnace. The problem is if I do this with the grid I'm burning coal not to mention it would be more efficient to forgo the electrolysis step. So here's what I want to do. I'd like to keep a battery charged from a solar panel. My output to the electrolyzer from the battery will be about 12 volts at 20 amps. Keep in mind it will only run for about 10 minutes every 20-30 minutes . That's it, if I can get it to work it will save me about $2000 a year in heating expenses.
evanpnz says:
Jun 11, 2010. 7:54 AM REPLY Be very careful - hydrogen is a dangerous gas. One little bit of air in there and you have a bomb. I will explain a little more. Hydrogen is the smallest gas molecule you can get. So it leaks through almost any sealing material. Also because of its low molecular weight it reacts with oxygen very quickly which means its "burn rate" is very fast. A lot of the reason you are not already driving a hydrogen powered vehicle has to do with these properties - many millions of dollars have been spent trying to make hydrogen safe to store and make it burn slowly enough not to destroy the engine.
curt41 says:
Feb 10, 2009. 10:56 PM REPLY Alpha twin hey i have been looking into hydrogen for a furnace also. Maybe we can share ideas. please get back to me iamhr12@yahoo.com thanks
digitalenigma says:
Mar 16, 2009. 2:34 AM REPLY i have pondered hydrogen heating myself, someone needs to make a instructable on hydrogen fuell cell heatingsystems powered by solar energy
rpvanpatt says:
Oct 1, 2007. 11:45 AM REPLY I am wondering how much power you can get from something like this. Also, what you could power or charge with it. And this may sound stupid, but can solar panels receive energy bouncing off a mirror? Thanks
VIRON says:
Oct 1, 2007. 3:29 PM REPLY Solar panels do receive energy reflected from a mirror and occasionally they are used with mirrors to collect more light or collect light from a different angle when the sun moves. In the picture above (IN STEP 1), , I put in series a 5 volt, 6 volt, and 7.5 volt panels I made from broken cells which were sorted by approximate size. The 5 volt panel made about an amp in full sun so it's 5 watts. The breaking of a solar cell in half generally makes two cells with half the power. The whole thing with the 3 panels stuck together in series is about 10 watts in full sun, that's over 12 volts and "almost" 1 amp. It can charge a car battery during times of full sun, and when the car battery is needed, it has stored up enough power to give a LOT of power for a short time (which is the normal use of car batteries anyway). I charge 12V batteries with solar panels to run radios (ham or CB) and lights if, when, and where utility power is not available. Usually, 15 to 18 volts panels are used to charge a car battery, so there is still extra charging voltage when it's not full sun. Most consumer car-battery charging panels put out about 200 mA at 15 or 18 volts, and are intended for cars not driven often. A car battery can power small plug-in things (few hundred watts) if they are plugged into an "inverter". This can be scaled up with more cells, panels, and batteries, but then it helps to know a smart electrician. Usually heat needs the most power and is done with water-heating panels, which are plumbing rather than electric. A solar powered hairdryer may be a particularly troublesome thing.
urthlvr says:
Aug 24, 2008. 1:06 PM REPLY My son is going to do a science experiment on solar power for a car. Can you please send me instructions on how you are doing it to: lenorebrunk@sbcglobal.net?
lodewijkadlp says:
You're yoking right? Sent you an email? I think he explains how it works in THIS instructable, and he won't need to email you.
http://www.instructables.com/id/How-to-MAKE-PV-Solar-Panels/
viraldalal says:
Apr 17, 2008. 8:05 AM REPLY hi there i jst want some info frm u that i m very much intrested in building my own solar panels and stuff so pls can u suggest me is ther any school or college to learn that or i can make solar cell or panel myself so pls kindly if u can give me some information regarding this thank you Oct 1, 2007. 6:34 PM REPLY if i were to make some panels like yours, and have a battery, it could run a tv or somethin maybe? or lights? im sory im just tryin to get a feel on how much power(havent taken physics in a while) i can get when i make my own
rpvanpatt says:
VIRON says:
Oct 1, 2007. 9:18 PM REPLY I have a 12 volt TV that I think works on the 10 watt panel in full sun even without a battery. Small LCD TV's may be even easier to power.
fyrspark says:
Apr 11, 2009. 9:07 AM REPLY i've been interested in wind energy as well as solar energy for a while, I want to build my own wnd generator but there are many versions and ideas, can someone point me in the right direction and just tell me how to do it. what type of motor especially, the design portion I have down but getting the motor to produce energy is the confusing part, i.e. what kind of motor is the most effective.
Rotten194 says:
http://www.instructables.com/id/Chispito-Wind-Generator/step2/MATERIALS/ This instructable mentions electric treadmill motors.
SoCell says:
Jan 28, 2010. 5:49 PM REPLY I have heard that a DC Motor made by Ametek is what you need. These motors will produce DC current when they turn backwards. You attach your blades per your design and it should turn the motor backwards. You will want a 30VDC Motor with a low RPM rating, under 400RPM @ 30V is the best bet. I hope this is helpful in some way.
digimancer says:
Large umbrella mounted solar panels. Just a thought, might be heavy...
Pamela69 says:
Hello guys,
Thanks for a great post, I found it very informative. It's not often that I've seen such good and detailed information. diamondwillow, you only use a small inverter for your laptop, right? Compared to buying a larger inverter - for your whole house - was it much less expensive? www.besthomeenergyguides.com/how-to-make-a-solar-panel.php
markwells says:
Oct 11, 2009. 6:57 AM REPLY hi there. I've read that the inverter you choose will be determined by how much kW you need to output. i connected up a 100W inverter to a car battery and was able to run a lamp and a fan at the same time, but when I tried to power a vacuum cleaner it stopped working. the guys at www.mysolarplans.com also said that you are able to buy special inverters just for solar power which is what i will be getting for my full set up.
Pamela69 says:
Hi Mark,
Thanks for your reply. Mmmm, that sure makes sense. It can easily get expensive can't it. I've heard about the special solar inverters, not sure what differences there are though, I'm really trying to save some money so not sure at this stage as to which components I can compromise on! Thanks again P.
danpet says:
Sep 10, 2009. 2:35 AM REPLY Interesting,but very bad pictures,unfortunately.Try to make them better (this is constructive). I couldn't solder on the back face (+) of my cells at all.I think is aluminium.I'll try with "silver resine" maybe. Sep 6, 2009. 9:43 PM REPLY Hiya folks. Just want to say thanks for the site. Loads of info here. I currently live off grid entirely. I have 2 solar panels, 1 X 32 watt and 1 X 80 watt. They are in series and charge 2 deep cycle 12 volt batteries, {deep cycle is VERY important...they can be drawn down and recharged many more times than a regular auto battery) no charge controller because I use the power and the batteries never "cook". My house runs mainly on 12 volt: tv, radio, lights, and I have a small inverter to run my laptop (low power draw) and to charge my pager for the fire department. Living in northern Ontario, our winters are long with short days... only 8 hours of limited solar charging time for the panels, so I am looking for ways to add to my panel bank to keep things better charged up in the winter.I sometimes need to run a generator in the winter to run a charger for my batteries, and I'd like to get away from that, so I am hoping this is the way! Thanks to this site I am now exploring more possibilities! Physics and chemistry and mechanics are NOT my strong suit, but since it is a way of life for me, I am highly motivated to learn how to build panels myself, instead of paying close to 10 bucks a watt for retail panels. Cheers!
diamondwillow says:
telebong says:
thanks to all concern, sites like this evolves ,very helpful and informative!!!!!
http://www.instructables.com/id/How-to-MAKE-PV-Solar-Panels/
du1200 says:
I'm glad to see someone who's truly interested in helping the planet instead of making a profit!!!!
norkaz says:
Many thanks for this highly instuctive article from a land of sunshine and very expensive solar panels! Thanks!
nowuknowjack says:
May 24, 2009. 10:47 AM REPLY My comment was deleted, don't know why, but I'll post it again as many want to get cheap parts and recycle broken parts. The solar powered traffic highway warning signs on trailers get damaged by just getting hauled around or encounters with drunk drivers etc. anyway they have to be fixed and the broken panels go into the dumpster many times. Look in the phone book for places that rent these signs and see if they have any broken panels you can experiment with. Many times they might just give them to you.
DualPhase says:
So are there any recommendations on some places to go to find these broken ones for the cheapest?
junits15 says:
Is that plexiglass? Where did you buy it? I can't find any place that isn't obnoxiously priced!
wibrle says:
I found plexiglass at lowes, when I was modding a computer case. Have you tried looking there?
junits15 says:
Mar 23, 2009. 6:51 PM REPLY I've always known lowes to have it I just though it would be pricy because it is an actual store. How moch did you pay? How much did you get?
wibrle says:
Mar 24, 2009. 3:29 PM REPLY For normal 1/8 inch thick plexiglass (in US currency) $43.99 for 36"x72", $6.77 for 18"x24", and $19.37 for 24"x48"; there where more sizes, but this gives you an idea. For the thick 1/4 inch plexiglass $13.49 for 16"x24" and $42.97 for 24"x48". Lows also carried high impact plexiglass, but it was high, so I didn't bother looking at the prices.
doobiesh says:
Mar 31, 2008. 3:18 PM REPLY hey guys I have a solar panel which is from radioshack but I'm not sure what is the top plastic layer is supposed to be. it looks like a bunch of tiny lenses but I'm not sure what they are.
DualPhase says:
Did you ever burn ants as a kid.... Same principle, just a bunch of magnifying lenses.
http://www.instructables.com/id/How-to-MAKE-PV-Solar-Panels/