ENGINEERING FACULTY

DEPARTMENT OF MECHANICAL ENGINEERING

Integrated Project

Subject: MED360S

Date: 22 June 2023

216157250 Z MNTUMNI Signed:

220355606 Y.I CANCA Signed:

220537526 S MJUZA Signed:

219203792 S.COPISO Signed:

219476799 B.L MOYO Signed:

218132158 Z NCAPHAYI Signed: Z.Ncaphayi

214309444 M QEKELE Signed: M. Qekele

214097285 A JELE Signed:

I (We) swear that this is the original work of the author(s). All information obtained directly or indirectly from
other sources has been fully acknowledged.
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TITLE PAGE

DESIGN OF A PV CHARGING SYSTEM 2023

Prepared for: Mr F.Ismail

Mechanical Engineering Design 3 (MED360S) Lecture
Mechanical engineering department

And

Mr W.Kholofer
Applied Strength of Materials Lecture
Mechanical engineering department

Prepared by : Ms Z.Mntumni
Ms S.Copiso
Ms B.Moyo
Mr M.Qekele
Mr S.Mjuza
Mr Y.A.Canca
Ms A.Jele
Mr Z.Ncaphayi
Mechanical Engineering third Year Students

Date submitted: 08/06/2023

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ABSTRACT
This design report presents a solar charging station that aims to enhance
accessibility and convenience for disabled students and other individuals in need of
charging their study devices and golf carts. The project focuses on retrofitting a
disabled parking bay outside the mechanical engineering building, where a solar
charging station and a bench will be installed. The design ensures compliance with
safety standards and specifications while considering strength of materials and
structures.

According to Rokde et al (2017) the solar charging station provides a sustainable

and environmentally friendly solution by utilizing solar energy as the primary power
source. It consists of a photovoltaic panel array mounted on a study frame, designed
to withstand various weather conditions. The panels convert solar energy into
electrical power, which is then stored in a battery bank for continuous availability.

To accommodate multiple users, the charging station includes several charging ports
strategically located near the bench. This allows at least six students to charge their
study devices simultaneously, promoting a collaborative and inclusive study
environment. Additionally, the charging station incorporates a specialized port
capable of providing power to a golf cart, catering to the transportation needs of
individuals on campus.

Throughout the design process, emphasis is placed on validating the strength of

materials and structures to ensure long-term durability and safety. Throughout
research is conducted to identify and adhere to relevant safety precautions,
standards, and specifications to guarantee a secure and reliable charging
experience for users.

The design report encompasses comprehensive manufacturing drawings, including

rendered views, to provide clear visual representations of the proposed solar
charging station. These drawings outline the dimensions, assembly details, and
necessary components, aiding in the successful implementation of the project.

By implementing this solar charging station, the disabled parking bay outside the
mechanical engineering building becomes an inclusive and sustainable space,
supporting the energy requirements of disabled students and other individuals while
promoting eco-conscious practices (Ismail, 2023)
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ACKNOWLEDGEMENTS
We would like to thank our lecture Mr F.Ismail for giving us the opportunity to work
on this great project, it was innovative and opened our eyes on the new technology
around the world that might be our solution to the load shedding crisis in South
Africa.

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LIST OF ILLUSTRATIONS

Figure 1: Structural architecture and components of the Pv charging system...........................4

Figure 2: Solar Carport at University of York...................................................................................7
Figure 3:Vermont CESA Solar Carport Cost Study(CESA 2016).................................................8
Figure 4:Schematic representation of carport charging infrastructure (Khan et al., 2017).......9
Figure 5:Cruess Hall Solar Charging Station design proposal (Ferguson, 2020)....................10
Figure 6: Cantilever beam (Solar charging station)......................................................................14
Figure 7: Overhanging beam (charging station)...........................................................................15
Figure 8: Solar charging station......................................................................................................16
Figure 9: System connection demonstration.................................................................................18
Figure 10: Battery Rack...................................................................................................................28
Figure 11: Aluminium flat support...................................................................................................29
Figure 12: Battery Housing..............................................................................................................30
Figure 13: Hybrid Inverter 5500VA 48V MPPT 5500W/5.5KW..................................................32
Figure 14: 12.7mm x 12.7mm x 1.6mm Aluminium Square Tube..............................................32
Figure 15: Aluminium Oralium Strong Roofing Sheet, Thickness: 0.56mm..............................33
Figure 16: Plugs sockets for laptop charger..................................................................................33
Figure 17: Demonstration of the golf cart charger connected to the inverter...........................34
Figure 18: Table-bench set for 6 students.....................................................................................34

Table 1: Project comparison............................................................................................................10

Table 2: Methodology.......................................................................................................................12
Table 3: System components..........................................................................................................13
Table 4: Tasks planning...................................................................................................................21
Table 5: Table below summarizes the contribution of team members in the project...............21
Table 6: Bill of material.....................................................................................................................23

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LIST OF SYMBOLS

PV - Photovoltaic
DC - Direct Current
AC - Alternating Circuit
EV - Electric Vehicle
MCU - Microcontroller Unit
MMT - Multi-Mode transmitter
SPWM - Sinusoidal Pulse Width Modulatio

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Table of Contents
TITLE PAGE........................................................................................................................................ii
ACKNOWLEDGEMENTS................................................................................................................iv
LIST OF SYMBOLS..........................................................................................................................vi
1. INTRODUCTION.............................................................................................................................3
1.1 Project Definition...................................................................................................................3
1.2 Project Objectives..................................................................................................................3
1.3 Project specifications.............................................................................................................3
1.4 Structural architecture and components...............................................................................4
...........................................................................................................................................................4
1.5 Applications...........................................................................................................................5
2. LITERATURE REVIEW......................................................................................................................6
2.1 PROJECT BACKGROUND.........................................................................................................6
2.2 PREVIOUS WORK...................................................................................................................6
2.2.1 Smart grid solar-powered charging station (2015, University of York)..........................6
2.2.2 Vermont CESA Solar Carport Cost Study (CESA 2016)....................................................7
2.2.3 Design and Analysis of a Solar-Powered Electric Vehicle Charging Station for Indian
Cities 8
2.2.4 Cruess Hall Solar Charging Station design proposal.......................................................9
2.2.5 Comparative study.......................................................................................................10
3. SYSTEM DESIGN...........................................................................................................................11
3.1 Design Constraints...............................................................................................................11
3.1.1 Sustainability................................................................................................................11
3.1.2 Environmental..............................................................................................................11
3.1.3 Design Constraints: Economic......................................................................................11
3.2 Design Methodology............................................................................................................12
3.3 Product Subsystems and Components................................................................................13
3.4 Concept formation...............................................................................................................14
3.4.1 First concept:...............................................................................................................14
3.4.2 Second concept:...........................................................................................................14
3.4.3 Final concept:...............................................................................................................16
4. SYSTEM ANALYSIS AND RESULTS.................................................................................................17
4.1 CALCULATIONS....................................................................................................................17
5. PROJECT MANAGEMENT.............................................................................................................21
5.1 PROJECT PLANNING.............................................................................................................21

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5.2 CONTRIBUTION OF TEAM MEMBERS...................................................................................21

5.3 PROJECT EXECUTION MONITORING....................................................................................22
5.4 CHALLENGES AND DECISION MAKING.................................................................................22
5.5 MATERIAL AND BUDGET......................................................................................................23
5.5.1 Cost of material............................................................................................................23
6. ENGINEERING DESIGN PARAMETER ANALYSIS............................................................................24
6.1 LIFE-LONG LEARNING...........................................................................................................24
6.2 IMPACT OF ENGINEERING SOLUTIONS................................................................................24
7. CONCLUSION...............................................................................................................................25
8. RECOMMENDATIONS..................................................................................................................26
9. REFERENCES................................................................................................................................27
APPENDIX A: design drawings.............................................................................................................28
APPENDIX B: GANNT CHART................................................................................................................31
APPENDIX C: MATERIAL PICTURES.......................................................................................................32

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1. INTRODUCTION

1.1 Project Definition

The aim of this project is to design a solar charging station in one of the disabled
parking bays in front of the mechanical engineering building. The parking bay will
require reconstruction and modified and have a bench located next to the charging
station to assist at least 6 students with energy required to charge their normal study
devices such as laptops. The charging station must be able to provide charge to a
four-sitter golf cart as well. The project adopts the concept of renewable and green
energy by generating power and electricity via photovoltaic array such as solar
panels mounted all over the roof only structure. The need for renewable and green
projects is in high demand in the entire country due to power cuts, this project is part
of permanent solution to the energy crisis.

1.2 Project Objectives

The objective of this project is to design a charging station for with a solar energy
input for on-campus use. This project includes a theoretical analysis of the total load
required while considering all year-round weather conditions and thorough
investigation of how solar radiation is affected by panel orientation. The of strength
and structure should be validated.

A 3D drawing design which consists of rendered views and sketches that will meet
the project’s specifications. In addition, it includes a mechanical design for the final
product. Lastly, the final results implementation phase, a final prototype.

1.3 Project specifications

• Generates renewable energy using solar PV panels mounted on roof only structure
with maximum output of 466.7 W for a duration of 6 hours

• Contains DC/AC Inverter with output of 1068 W.

• Contains energy storage (battery) for 150 Ah, 36 V which acts as a backup source
capable to provide continuous power for 6 hours for maximum load of 466.7 W.

• Charges golf cart with charger output of 48V.

• Energizes 6 student studying devices 6 laptops up to 178W

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1.4 Structural architecture and components

SOLAR PV

CHARGER
CONTROL MCU
MCU
UNIT

STUDENT DC/AC BATTERY EV GOLF

TABLE DC CHARGER CART

Figure 1: Structural architecture and components of the Pv charging system.

The figure above displays the system's overall block diagram. It has a battery
storage system, a DC converter, and a DC inverter to convert the solar panel’s DC
output to AC so that student study appliances can be powered. To convert DC to AC,
the sinusoidal pulse width modulation (SPWM) technique will be employed. This
method samples a sinusoidal waveform, with each sample denoting the PWM duty
cycle percentage. In order to create a look-up table, these duty cycles are saved in
the microcontroller's memory as an array. To produce gate control signals that are
supplied to an H-bridge inverter to produce the correct output voltage and frequency
signal, the microcontroller uses stored load intervals. In addition to powering up the
student devices, a golf cart charging station will be provisioned in parking bay.
Voltage and current sensors will be used by the golf cart charger to measure the
charging current and voltage and determine the actual charging rate. It will be
equipped with variable charging rates for electric vehicles (Larminie, 2012).

Since the placement of solar panels and their angle have a significant impact on the
quantity of energy produced, having a solar charging station offers flexibility in the
way solar projects can be customized and designed. Consequently, a solar charging
station can be designed to maximize the arrangement of solar panels, whereas a
rooftop solar panel system may find it more difficult to do so (Chellaswamy et

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al,2018). To further encourage the university toward smart and green

transformations and use of renewable sources on a daily basis, which saves
electricity and helps to correct load shedding, the solar charging station has been
integrated with a student device charging table and an electric vehicle charger.
Anandakumar et al stated that, since the power being produced by solar panels will
be affected due to sunlight exposure, a battery has been used to overcome the
variation of power being produced by solar systems. It intends to feed into the golf
cart battery and power the student devices load after being processed by DC/AC
inverter and DC/DC converter and it is an important element to off grid independent
power system. Overall, a solar charging station gives a significant amount of
flexibility over how to use the solar energy and it is a greet option for residential and
commercial purposes.

1.5 Applications

The main applications of solar charging system are:

• Provide solar power to charge studying devices golf cart.

• To aid by providing power during load shedding/national power cuts.

• Provide renewable energy to, and to save energy by generating solar power.

• Provide battery bank system to have grid independent renewable system.

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2. LITERATURE REVIEW

2.1 PROJECT BACKGROUND

The information in this part was compiled with the intention of emphasizing the value
of renewable energy sources, solar panels, solar carports, and EV charging stations.
Investigating the overall load necessary and developing the solar charging station
based on the weather conditions throughout the year. Additionally, the study findings
are meant to be used as sources of information, so only projects whose scopes are
comparable to ours will be examined and discussed in this chapter. Both unexpected
breakthroughs and clear and useful applications have sprung from the expanding
demand for renewable energy, particularly solar technology. Solar carports are one
of these solar technology's applications. Solar carports, which are solar panels
positioned above automobile parking spaces, are a versatile and economical solution
to deploy solar power because they take up no additional space. Additionally, solar
carports are a variation on conventional carports that offer shade and protection for
the vehicle. This is because the panels serve as a dual-purpose solution for both
covering the vehicle and creating clean, renewable energy.

2.2 PREVIOUS WORK

2.2.1 Smart grid solar-powered charging station (2015, University of York)

To lessen the carbon footprint of its facilities in York, York St. John University has
collaborated with green energy suppliers on a significant project. The project is
anticipated to result in an annual save of 640,000 kilowatt hours (kWh) and an
annual reduction of 82 tonnes of CO2 emissions. The University is now definitely on
track to reach its 2030 goal of an 80% decrease in emissions over a 25-year period.
The work was completed because of a successful financing application to Salix
Finance, a program supported by the government to fund sustainability initiatives in
the public sector (Sandramc, 2017)
Since December 10, 2015, York University has offered solar energy to those who
commute in electric vehicles. Dr. Jose Etcheverry of the Faculty of Environmental
Studies created and constructed a smart grid solar-powered charging station that
can weather the freezing Canadian winters and store solar energy.

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Figure 2: Solar Carport at University of York

According to Chandra (2016) the solar carport and charging station are a step in the
right direction toward cutting emissions. It is a local, effective reaction to climate
change, as well as an inventive smart grid strategy for expanding campus electric
mobility options. The solar carport system with a solar electric vehicle charging port
was created with the intention of spurring fresh, doable local ideas as well as new
technological advancements in the fields of renewable energy, smart grids, and off-
grid systems.

2.2.2 Vermont CESA Solar Carport Cost Study (CESA 2016)

According to CESA (2016) 100 kW DC system mounted on parking lot canopy
support by steel foundation posts. Array tilt is 15 degrees, facing 15 degrees west of
true south. DC array to AC inverter ratio is 1.2. There are several obstacles that have
deterred investment in this kind of system in Vermont, even though covering parking
lots with PV canopy structures seems to be an effective siting strategy, giving a dual
use of land area and protection for parked automobiles from the elements. The
greatest drawback is cost, but there are also performance, maintenance, and liability
concerns. Parking lot PV canopies are widespread in the southwest of the United
States, but in colder and cloudier northern regions, their viability and cost-
effectiveness suffer. Vermont ranks quite poorly for the economic viability of placing
PV on parking lot canopies because it is the second-most cloudy state in the country
and has significant snowfall. Consequently, less than five PV parking canopies have
been constructed over the past ten years. Many of the top solar installers and
manufacturers in the country, including SunPower, SunEdison, and RBI, now provide
standardized solar carport structures. These have typically been put in place at
colleges and business campuses where solar panels cannot be placed on buildings

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and land is scarce or extremely expensive. The University of Vermont is now

analyzing the outcomes of an RFP that took solar canopies for parking lots into
account in collaboration with Burlington Electric. The first significant development of
parking canopies in the state could arise from this (CESA, 2016).

Figure 3:Vermont CESA Solar Carport Cost Study(CESA 2016)

2.2.3 Design and Analysis of a Solar-Powered Electric Vehicle Charging

Station for Indian Cities
Sharma (2021) stated that the PV array produces energy during the hours of the
sun, from morning to dusk. The residual energy is sent to the battery after
completing the load. The charge controller makes sure that the amount of immediate
energy generated does not exceed the amount of battery capacity that is available
and the consumer's energy needs. The battery bank provides the EVs with energy
from the end of the day until the early hours of the morning.

Another significant factor that is dependent on the solar PV application is the choice
of station construction. The parking area and the installation area for the array are
integrated by a carport structure, which is preferred for the design in question. The
parking area and the battery room's roof are likewise made of the array
(Brenna,2020).

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Figure 4: Schematic representation of carport charging infrastructure (Khan et al., 2017)

2.2.4 Cruess Hall Solar Charging Station design proposal.

The final suggestion for an off-grid system has a footprint of 16 x 12 feet and was
developed through the design process of a solar charging station said Austin (2017).
The customized solar charging station design for the courtyard of Cruess Hall at UC
Davis is shown in Figure The charging station will function as a solar classroom for
research and offer charge for wheelchairs, e-bikes, and e-scooters. According
Dunlop (2007) it will have chairs, an air quality sensor with a visible LED display,
outlets, and an electrical enclosure for the battery bank, and a solar roof canopy. In
addition to Charge Points level charging, which allows users to charge their devices
quickly—in minutes as opposed to hours—this future innovation hub offers DC fast
charging so that users can explore the Eco District. The solar-powered kiosk offers
mobile devices and charging stations for electric wheelchairs, scooters, and bicycles.
The building offers emergency electricity during blackouts and covered seats. Based
on the popularity and success of the Electric Drive pilot program, which earned the
Austin Green Award in 2017, Austin Energy recently awarded $1.6 million from the
Texas Commission on Environmental Quality to extend their EV charging
infrastructure. Electric pedicabs charged at the Electric Drive Solar Kiosk during the
SXSW 2018 Technology and Music Festival, demonstrating the rising popularity and
effectiveness of solar mobility.

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Figure 5:Cruess Hall Solar Charging Station design proposal (Ferguson, 2020)

2.2.5 Comparative study

Table 1: Project comparison

Projects 1 2 3 4 Our Project

Solar carport     
EV charging     
system
Local storage     
system
(Battery Bank)
Residential  
load( student
electric
devices)
Residential 
load (Green
home)

Our project differs from other projects by incorporating some of the characteristics
and subsystems described in section 2.2 of the information explanation. The CPUT
solar charging station will be constructed utilizing solar panels set on a carport with
the goal of supplying renewable energy to power golf carts and electronic devices for
students on campus. To counteract the variability of electricity generated by solar
panels and give enough power to electric gadgets for students and golf carts at any
time of day, the system will be connected to a local storage system.

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3. SYSTEM DESIGN

3.1 Design Constraints

3.1.1 Sustainability
Design solar energy to power a parking facility that will help students to charge
their studying equipment’s and help to charge chart. As a renewable source of
power, solar energy has an important role in reducing greenhouse gas emissions
and mitigating climate change. Which is critical to protecting students &
workers, wildlife, and ecosystems. Solar energy can also improve air quality
that will also help student to be focused (Harris 1987).

3.1.2 Environmental
Solar energy plays crucial role in promoting a more sustainable future by
reducing carbon emissions. The energy generated by the panels is clean and
does not produce any harmful emissions, making it more environmentally
friendly option than tradition energy source or any kind of energy sources
(Bauer, 2006). Solar energy is a highly innovate solution that provides a unique
approach in produce clean energy while also providing improved parking
facilities.

3.1.3 Design Constraints: Economic

When it comes to solar solution for home or business, the key is designing a
self-sufficient energy system that can meet all students power needs. This can
involve a variety of components including solar panels that can optimize your
energy usage and reduce your reliance on the grid. By taking a comprehensive
approach to solar energy, you can not only reduce your carbon footprint and
save money on your bills but enjoy greater energy independence and resilience
in the face of power outages or other disruption (Rossouw 2010).

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3.2 Design Methodology

Table 2: Methodology

During Design Methodology & Project Management:

PHASE 1: Initiating
Doing research based on solar panels, how much light rays we get from long
and short days in Cape Town. How much power is needed by learning tools
for six students and how much power is needed by golf cart for it to charge?
Every member of the group was tasked to bring up a concept on how we are
going to do it and it must be in reasonable dimensions.
.

PHASE 2: Planning

Having a different concept, Concept 3 was chosen based on looking at how

much it will cost, how long it will take to design, how long it will last and is it
easy to maintain there because it has all these characteristics.
Project management and planning, design a path for the project with list of
tasks. Tasking everyone and giving deadlines.

During Assessment III:

PHASE 3: Project commissioning
Having meetings for discussion on the reasonable dimensions and do some research based
on Cape Town weather to know how much energy can be produced during the day and
how much during the night.
Combining of the findings.

Finalizing Phase:
Do final touches on the design.
Do conclusion and write technical report.
Having it ready for submission.

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3.3 Product Subsystems and Components

Table 3: System components

Components Specifications Reason for selection

Solar Panels 300W (mecer) It has desired output in terms of
Energy production and it fit range of
power needed.

Square 8 × 8 cm High durability and very strong

Aluminum bar 20 m long

Inverter Hybrid Inverter To control the charging current to EV.

5500VA 48V MPPT
5500W/5.5KW

DC current SCK3 _5dc Good quality and accurate DC

sensor current sensor used on the golf cart
charger Controller

Table 6 to 8 seater table- Able to last on outside temperature,

bench set and is big enough to accommodate
6-8 students of any size.

batteries 3x 12 volts batteries For power backup when there is bad

weather.

Adapter 6 to 8 adapter socket For charging enough study devices

socket on top of the table.

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3.4 Concept formation

3.4.1 First concept:
This project at Cape Peninsula University of Technology (CPUT) involves mounting
solar panels on the parking lot's roof to create a solar charging station. The major
objective of solar charging is to provide students with power so they can recharge
their electronics on campus. A socket for charging electric vehicles (EVs) will also be
included in the solar charging station so that they can be parked there while being
charged.

Figure 6: Cantilever beam (Solar charging station)

3.4.2 Second concept:

For many people, attending college is a rite of passage. This is an important time for
young people to develop and grow. Universities and colleges serve as an incubator
for this potential. Solar charging stations are a fantastic method to teach young
people to the advantages of solar energy and give universities a means to launch
eco-friendly projects, forge a sustainable future, and earn Leadership in Energy and
Environmental Design (LEED) accreditation. For both students and colleges,
installing solar-powered charging stations on college campuses is a brilliant concept.
It promotes solar awareness while giving staff and students a simple, cost-free way

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to charge their mobile devices. Mobile phones, laptops, tablets, and even electric
bikes common things used by students can all be charged at the charging stations.
Additionally, it would encourage students to utilize the outdoor campus. For their
campuses, many institutions are implementing this new technology. A path to
sustainability will be made possible by colleges investing in this technology, in
addition to the fact that they like to keep up with their competitors. If solar charging
stations are successful, institutions may decide to invest in more extensive
renewable energy projects like rooftop photovoltaics and EV charging stations. This
concept is not chosen due to insufficient power that will be produced by the solar
panels.

Figure 7: Overhanging beam (charging station)

Overhanging solar carports was installed on a concrete slab on the ground using a
ballast solution. The dimensions of the crate are 122mX48mX52m, weights
approximately 1270kg. Overhanging feature a table with benches and provide and
charging stations to the institution for students and Golf Cart. The solar panels have
two functions, they provide shade while also soaking up the sun’s rays to energize a
battery that powers the charging stations and night-time lights.

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3.4.3 Final concept:

Due to the two panels on the overhanging beam being insufficient to power the golf
cart's high voltage and battery, it will not work. And it might be expensive to build a
cantilever beam with bending panels. A cantilever can be a cost-efficient yet effective
solution if all you're looking for is a means to keep your vehicle cool and shielded
from the elements. We create the cantilever solar panel with a standardized 5,4m x
5,4m dimension, allowing the customer to cover two typical parking lots. The inner,
which is formed of steel, acts as a conduit for electrical conducts. The best grade of
PVC is used to create the cover. The cover is replaceable and is fade, light and
water resistance. It is designed to withstand all weather conditions .The frame is
powder coated. Solar carports are increasingly popular for charging electric vehicles
in public and private parking areas. Solar carports aren’t just for charging electric
cars. They can also provide energy to be pumped into nearby businesses, homes or
institution. Solar carports produce just as energy as standard roof mounted solar
power systems.

Figure 8: Solar charging station

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4. SYSTEM ANALYSIS AND RESULTS

4.1 CALCULATIONS

The PV Charging System is to be built in these coordinates 33.93337°S,18.64365°E.

This is a location front of the Mechanical building a disable parking spot. The location
selected was because it is at an advantageous point as it can receive both sunrise
and sunset by that it improves the number of hours the solar panels will get

Weather
The Cape town region is in the Mediterranean climate conditions. Most of the rainfall
happens in winter. The conditions down in the region of where the country is located
makes a strong belief backed by scientific examinations, that the country
experiences at least four months each of the Winter and Summer seasons. The
average rainfall in Cape town I about 505 mm per year. In summer the temperature
reaches 33 degrees, and the sunlight will be available for 11 hours of the day. The
winter season brings tougher climate, the temperature can be as low as 3 degrees
and highest being 26 degrees. On average the maximum wind speed is experienced
in October where the wind reaches 19 kph.

Peak Sun hour

It is the hour where the Sunlight intensity (solar irradiance) averages 1000 Watt per
square meter (m 2). This can also be solved to the fact that it will equal 1kwh.
1 peak sun hour = 1 hour of sunlight at 1 kW/m 2 = 1 kWh/m2
For the Cape town Region, the following are the Record Average peak hours
January: 7.66
February: 7.37
March: 6.44
April: 5.12
May: 4.18
June: 3.36
July: 3.39
August: 4.53
September: 5.41
October: 6.48
November: 7.37
December: 7.44

Calculation Appendix
Length → L
Width → w
SA → Surface area
Current → I (A)
Voltage → V
Current Solar →Ip

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Disable parking
L = 5m
w = 3.7m
Poly- Crystalline Solar Panel
L = 2m
w = 1m
Roof dimension (One Side)
L = 5.25m
w = 2.2m
6 Students Laptops
I = 2A (each laptop )
Total I = 12 A
Voltage = 12V (each laptop

Figure 9: System connection demonstration

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Aroof =L∗w

A=5.25∗2.2 A=11.55 m2 ( One side of roof )8 Solar Panels to be used(Poly

crystalline with 72 cells )

Total Iph=8∗Rated IphTIph=8∗10.98Iph=87.84 A V T =V Students +V bulb +V Cart

36∗36
V T= +120+240V T =378 ( ∑ of individual circuit voltage )Voltage to be used is
36+36
parallel 240 (National standard) in the each wire at 50Hz
Psupplied =8∗Max rated power of each solar panel Ps =8∗350Ps =2.8 kWh Assuming all
laptops are on the charger plus the Golf chart is to be charged from 0% battery
power

Pl=P students + Pcart + P bulb Pl=6∗12∗2+18∗48+60Pl=1.068 kWh

The Cart will be charging for 6 hours. The system was developed to be strong
enough to keep up with an output of 48V. This system is a direct current (DC). Once
the charger is inserted the cables bring in 240V then the output from the charger to
the Golf Cart is 48V.

Voltage will be in series as to consider the laws of physics and work using the
formular P= V*I. At this rate this will make the system not fail when at maximum
usage. Three 12V batteries will be used to power the system. This is only done
because we need the highest voltage possible than we need current.
V= 3* batteries Voltage
V= 3*12
V T =36 V

Poly-Crystalline solar Panels

Rectangular Bars

Lipped Channel Galvanized sheet metal

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Solar Panels
72 cells weighs = 28kg
F=m∗gF=28∗9.81∗8 F T =2.2 kN Rectangular bars
MS Hot rolled tubbing
Dimensions: 80 x 100 (see table)
Sy = 355Mpa
Finish: Galvanized
Sheet Metal
Hot Rolled sheets – Commercial Quality
EN 10111 DD 14 = KHR1 (P&O) Previously BS 1449 KHR1 - Drawing & Forming
Quality
Dimension: 2450x1225(see table)
Finish: Galvanized
Lipped channel
Cold formed Sections
Dimension: 125x75x20(see table)
Finish: Galvanized

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5. PROJECT MANAGEMENT
5.1 PROJECT PLANNING
Table 4: Tasks planning

TASK DATES
PROJECT MEETINGS re-occurring - weekly

Concept Formation 20/03/2023 - 28/03/2023

Work Allocation
29/03/2023 - 30/03/2023
Research of Project 31/03/2023 – 08/04/2023

Concept Design 09/04/2023 – 16/04/2023

Theoretical Working 17/04/2023 – 20/04/2023

Material Research 21/04/2023 – 24/04/2023

Practical Research 25/04/2023 – 27/04/2023

Project Compiling 28/04/2023 -10/05/2023

Final Draft 11/05/2023 – 13/05/2023

5.2 CONTRIBUTION OF TEAM MEMBERS

Table 5: Table below summarizes the contribution of team members in the project

TASK Z. S. Y.I. Z. A. B. S. M.
MNTUMNI MJUZA CANCA NCAPHAYI JELE MOYO COPISO QEKELE

Search & 30% 50% 50% 40% 40% 40% 30% 25%
acquire
compone
nts
Design 20% 30% 20% 5% 15% 10% 30% 50%
Subsyste
ms
Write 50% 20% 20% 5% 20% 50% 40% 25%
Reports &
Presentati
ons
TOTAL 100% 100% 100% 50% 100% 100% 100% 100%
OUT OF
100%

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5.3 PROJECT EXECUTION MONITORING

Weekly progress meetings with team members are carried out with the purpose of
providing updates regarding what has been accomplished, what is due to be
completed, and what challenges have been anticipated within the week. In addition,
biweekly meetings were conducted with the project advisor to have feedback and
provide him with updates regarding the project. Lastly, the WhatsApp group has
been created and all parties (students and advisors) have been added for easy
access and quick response.

5.4 CHALLENGES AND DECISION MAKING

When conducting this project there were challenges that we faced and took
decisions regarding those challenges, which includes the following:
 System Size and Capacity: Determining the appropriate size and capacity of
the solar charging station required careful analysis. Considering the
anticipated demand for charging, the number, and types of devices to be
charged, and the available space for solar panels and storage batteries.
 Charging Infrastructure:
Decisions regarding the type and number of charging ports, compatibility with
various devices (smartphones, laptops, electric vehicles), and charging
speeds are essential. Balancing user demand and infrastructure costs is
crucial.
 Energy Storage:
Integrating energy storage systems such as batteries is vital to ensure a
continuous power supply, especially during periods of low sunlight or high
demand. Deciding on the selection of an appropriate battery technology,
capacity, and managing the associated costs.
 Safety and Security:
Ensuring the safety of users and the equipment is paramount. Consider
implementing safety measures such as surge protection, monitoring systems,
secure charging infrastructure, and user authentication mechanisms.

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5.5 MATERIAL AND BUDGET

5.5.1 Cost of material

The budget is set at R100000, the selection of the best material is an important
factor for this project. Material selection is very important in any project, to ensure its
success thorough research and proper price comparison should be done. Most of
the material used for this project is obtained from trusted vendors, the vendors are
well known and at a convenient distance from the university.

Table 6: Bill of material

MATERIAL OBTAINED QUANTITY UNIT PRICE (ZAR) TOTAL

DESCRIPTION FROM (ZAR)

Poles Macsteel 8 R240 R1,920

IBR Macsteel 8 R650 R5200
Rail Macsteel 6 R700 R4,200
Solar panel Takealot 8 R3,300 R26,400
Table Makro 1 R4,300 R4,300
Battery housing Macsteel 8 R3,500 R3,500
Inverter Computer mania 1 R15,000 R15,000
Flat support Macsteel 1 1000 R1000
Charging controller Computer mania 1 R6,000 R6,000
Breaker switch box Computer mania 1 R700 R700
TOTAL R68,220

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6. ENGINEERING DESIGN PARAMETER ANALYSIS

6.1 LIFE-LONG LEARNING

This project enabled us to implement the knowledge we have gained and
acquired and developed our conceptual by brainstorming towards new solutions
and experiencing various aspects of our discipline. We have given the
opportunities to learn, implement, and examine power electronics topics such as
DC/DC converters and DC/AC inverters and integrate them to come up with new
solutions that lead to the specification and the project scope. Therefore, we had
the chance to design, leading us to face new challenges and gain more
experience and knowledge. In addition, the project has a significant influence and
developed our research skills. Different types of project management, self-
learning, time management, and cost management techniques have been used.
6.2 IMPACT OF ENGINEERING SOLUTIONS

 Sustainability and Renewable energy: While coal still dominates the South
African energy mix, by incorporating photovoltaic technology into the charging
station design, the university promotes renewable energy usage and reduces
its carbon footprint. Solar energy is a clean and sustainable power source,
contributing to a greener campus and overall environmental stewardship.
 Cost Savings: The PV charging station can help reduce electricity costs for
the university. Solar energy is free and abundant, providing a long-term and
stable source of electricity for the charging infrastructure. By generating
electricity on-site, the university can offset the need for grid power and lower
energy expenses.
 Improved Campus Resilience: Incorporating battery storage system in the
PV charging station design enhances campus resilience during power
outages (load shedding) or emergencies. The stored solar energy can be
utilized to power critical infrastructure, emergency services, or provide
charging capabilities during grid disruptions, making the campus more self-
sufficient and prepared for unforeseen events.

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7. CONCLUSION

The objective of this project was to design a charging station for with a solar energy
input for on-campus use. In this project, a solar-based charging station for student
studying devices and golf cart has been designed and thoroughly investigated for
better performance. The main goal is to make it a compact, versatile, weather-
resistant charging station that can easily be transported and used in many locations.
The results have led to the following conclusions:

1) All the design requirements have been met. The station can charge six laptops
which require 144Wh in total. The system overall efficiency is measured to be
76.8%, which is good for solar-inverter systems.

2) On a very cloudy day, when all outlets are used to charge six laptops, the golf cart
and the bulb with the total demand of 40% of the total power output of 1068 Wh, the
system could be sustainable for 2.6 hours. The system could provide sufficient
energy to power the average worst-case load of 213Wh for 4.1 hours. For better sun
days, the system is likely able to supply power for 6 hours. From the month of May to
August the peak sun hours range from 5 to 3 hours in Cape Town, which will cause
the charging time to be shorter new to bad weather.

3) The system is expandable. The number of outlets can be easily increased. The
energy storage capability can also be extended by simple addition of batteries. This
will increase the energy storage capability to supply power during higher demand,
help decrease the charging time for the connected devices, and lower power losses.
The entere system can be built under the set budget of R100000.

4) The system is proven to be compact, versatile, and due to the shelter of the
design it is weather resistant. It could stand the unusually hot summer months of
November to February of Cape while operating properly. The charging station
provides as an option to use the emission-free solar energy as a versatile and
convenience power source for consumers. It benefits the university while keeping the
clean environment.

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8. RECOMMENDATIONS

 This design should be used as a starting point, in the future years emphasis
should be on using at least two to three parking sports to increase the number of
solar panels from 8 to 24 and thus increase the charging time as well as the load
capacity of the design. This improvement would require more batteries for
storage.
 A voice warning prompt should be programmed on the device to inform the users
of the charging time remaining.
 Two bench tables could be added to the shelter to allow the students to have
more space for their devices and not be packed closely on one table.
 The structure could have retractable plastic covers on the sides to protect the
charging outlet from rain damage.

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9. REFERENCES

[1] Rokde, K., Patle, M., Kalamdar, T., Gulhane, R., & Hiware, R. (2017). Peltier
based ecofriendly smart refrigerator for rural areas. International Journal, 7(5).
[2] Sonkhede, P. G., & Pathrikar, A. (2016). Portable thermoelectric refrigeration
system for medical application. International Journal of Innovative Research in
Computer and Communication Engineering, 4(3), 3190-3195.
[3] Anandakumar, H., & Umamaheswari, K. (2017). Supervised machine learning
techniques incognitive radio networks during cooperative spectrum handovers.
Cluster Computing, 20(2),1505-1515.
[4] S, D., & H, A. (2019). AODV Route Discovery and Route Maintenance in
MANETs. 2019 5th International Conference on Advanced Computing &
Communication Systems (ICACCS).doi:10.1109/icaccs.2019.8728456
[5] H. Anandakumar and K. Umamaheswari, An Efficient Optimized Handover in
Cognitive Radio Networks using Cooperative Spectrum Sensing, Intelligent
Automation & Soft Computing, pp.1–8, Sep. 2017.
doi:10.1080/10798587.2017.1364931
[6] Anandakumar, H., & Umamaheswari, K. (2017). An efficient optimized handover
in cognitive radio networksusing cooperative spectrum sensing. Intelligent
Automation & Soft Computing, 1-8.
[7] Suganya, M., & Anandakumar, H. (2013, December). Handover based spectrum
allocation incognitive radio networks. In 2013 International Conference on Green
Computing,Communication and Conservation of Energy(ICGCE) (pp. 215-219).
IEEE.
[8] Umamaheswari, K. (2014). Energy efficient network selection using 802.16 g-
based GSM technology.
[9] Anandakumar, H., & Umamaheswari, K. (2018). A bio- inspired swarm intelligence
technique for social aware cognitive radio handovers. Computers & Electrical
Engineering, 71, 925-937.
[10] Chellaswamy, C., Nagaraju, V., & Muthammal, R. (2018). Solar and wind
energy-based charging station for electric vehicles. International Journal of
AdvancedResearch in Electrical, Electronics and Instrumentation Engineering, 7(1),
313-324.
[11] Larminie, J. (2012). Electric vehicletechnology explained. John Wiley & Sons
CORE. 2022. “Solar Canopies and Commercial Solar Carport Systems.” Solar
Canopies and Commercial Solar Carport Systems. Accessed April 29, 2023.
https://www.coredevusa.com/projects/car-ports/

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APPENDIX A: DESIGN DRAWINGS

Figure 10: Battery Rack

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Figure 11: Aluminium flat support

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Figure 12: Battery Housing

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APPENDIX B: GANNT CHART

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APPENDIX C: MATERIAL PICTURES

Figure 13: Hybrid Inverter 5500VA 48V MPPT 5500W/5.5KW

Figure 14: 12.7mm x 12.7mm x 1.6mm Aluminium Square Tube

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Figure 15: Aluminium Oralium Strong Roofing Sheet, Thickness: 0.56mm

Figure 16: Plugs sockets for laptop charger

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Figure 17: Demonstration of the golf cart charger connected to the inverter

Figure 18: Table-bench set for 6 students.

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