The Problem
The Need for Efficient Solar Energy
Harnessing solar energy efficiently is crucial in the world's shift towards renewable resources. Solar panels, composed of photovoltaic cells protected by glass, convert sunlight into electricity. The efficiency of these panels largely depends on how much sunlight reaches the cells. However, dirt accumulation on panels can decrease their efficiency by up to 30%, demanding regular maintenance.
The Cost Conundrum
Currently, maintaining solar panels is a significant cost driver for solar farms. The prevalent use of water and soap for cleaning is labor-intensive and requires frequent repetition. This maintenance issue underlines the need for a more efficient solution.
Enter the Nanoparticles
UofT's Lash Miller Chemical Laboratories has been developing a nanoparticle solution that can break down dirt when activated by sunlight, vastly reducing maintenance needs. However, the challenge lies in applying these nanoparticles uniformly. Any inconsistency, like streaks or gaps, could hinder panel efficiency.
Unmet Need for Uniformity
This project addresses the critical gap in current technology: developing a method to uniformly apply this nanoparticle solution. The goal is to create a device that can distribute these nanoparticles evenly across solar panels, ensuring no gaps or streaks and maintaining the required film thickness.
My Role in it All
As Design Lead, my role in this project was to guide the team through the conceptual design phase, ensuring adhesion to the objectives through the metrics developed. Once the prototype was fabricated, I worked to refine the final design based on the outcomes of the testing phase.
The Objectives
Achieving Uniform Coverage
Objective: The paramount goal is to ensure uniform coverage of the nanoparticle solution on the solar panels. This uniformity is critical as it directly impacts the efficiency of the solar panels.
Metric & Goal: The device must apply the solution in a way that leaves no streaks or gaps, ensuring a flawless film over the entire panel surface. Achieving this level of precision is imperative for the project's success.
Minimizing Material Waste
Objective: Efficient use of the nanoparticle solution is another critical factor. Minimizing waste not only makes the process more sustainable but also more cost-effective.
Metric & Goal: The design aims to ensure that no more than 20% of the solution is wasted during the application process. This is a large decrease from Lash Miller's current method of using a hose to disperse the solution.
Cost-Effectiveness
Objective: The project also focuses on the economic aspect, aiming to make the device more cost-effective than existing solar panel cleaning methods.
Metric & Goal: By reducing maintenance costs, the device should offer a financially viable alternative to traditional methods, factoring in both manufacturing and maintenance expenses.
Intuitive Design
Objective: Ensuring that the device is user-friendly and easy to understand is key to its practicality and widespread adoption.
Metric and Goal: The design should be intuitive enough that learning to operate the device takes no longer than an hour. This ease of use is crucial for efficient deployment in solar farms.
Portability and Usability
Objective: The physical design of the device is as important as its functionality. Portability and ease of use are essential for practical application.
Metric and Goal: The device should weigh no more than 20lbs, making it easily manageable by a single person
The Concepts
Sponge Saturation
One of the first concepts proposed during our conceptual design phase used a sponge to apply the layer by first saturating it with the solution, then spreading it over the solar panel. This was a good start but, still struggled to reduce material waste as the sponge would require a lot of solution to saturate evenly.
Rolling on to the Next Idea
The roadblocks we hit with the sponge design led us to consider a design with a mounted sponge roller. This design was ideal due to the reduced solution amount needed for saturation, as well as its resemblance to a common paint roller, making use much more accessible.
Final Design
After iterating on the design to improve cost effectiveness and modularity, we settled on a final design to begin prototyping with. This design used a pump system to disperse the solution onto a 3/8'' roller to be spread across a panel.
The Design
Updates from Testing
Nozzle Improvement
Nozzle Improvement
Nozzle Improvement
Improving solution application involves replacing drilled holes with precise nozzles for more accurate spraying on the roller. While this promises better efficiency, challenges like nozzle clogging and wear must be carefully managed to maintain the system's effectiveness.
Wiper Mechanism
Nozzle Improvement
Nozzle Improvement
To enhance uniformity, a wiper mechanism, akin to a windshield wiper, is proposed. This addition aims to more easily distribute the solution across solar panels evenly. The wiper's modular design allows for easy replacement to counter wear and ensure consistent application quality.
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