CHAPTER 3

METHODOLOGY

3.1 Introduction

This chapter focuses on the project development process, covering the approaches, methodologies.
In order to ensure the end result is fully executed, the process of creating this portable solar-
powered water dispenser must be well-structured. The project's flowchart and block diagram are
also included in this chapter. The knowledge of the project's flow is ultimately improved by both
the flowchart and the block diagram.

3.2 Project Flowchart

Figure 3.1 shows the flowchart of this project. The project starts off with literature review
on portable solar-powered water dispenser. The proposed portable solar-powered water dispenser
comes with solar panel, charge controller, battery, inverter and water dispenser as the load. The
inverter is designed with full-bridge topology with low pass filter and controlled by unipolar
switching scheme which able to produce less harmonic of AC output. The inverter is included with
low pass filter to eliminate the high order of harmonics and smoothen the sinusoidal AC output.
The system's circuit and wiring diagram are then going to be developed. Before installing
hardware, the circuit will then be simulated and tested to ensure it meets the specifications. The
project will go into the prototype development stage after all the preliminary work is finished,
during which all the components must be constructed, put together and tested. The inverter's AC
output and ability to power the water dispenser will be the main focus of the testing. Data on the
characteristics of the output waveform and a THD analysis are acquired.
Figure 3.1: Flowchart of the project
3.3 Design Scenario

The main power supply for this project's 12 V rechargeable battery is solar. The solar
charge controller is utilized as a control device for the battery as the battery needs to be in its ideal
state to prevent malfunction and may influence on its efficiency. Next, the 12 V rechargeable
battery is employed as backup storage for the system during cloudy day or night. The inverter
block is supplied with power by the battery. The most important component is the inverter since it
converts the DC supply from the solar panels and batteries to AC supply, which is needed to power
the water dispenser. A single-phase sine waveform at a frequency of 50 Hz is generated by the
inverter. The step-up transformer then receives the inverter's AC output and steps up the voltage
to 220-240 VAC. The transformer then feeds the water dispenser the 220-240 VAC that it
generates as the power source to energize it. The block diagram of the system for the portable
solar-powered water dispenser is shown in Figure 3.2.

Figure 3.2: Block diagram of solar-powered water dispenser.

Figure 3.3 shows the block diagram of the inverter using SPWM method. The circuit
simulation will simulate by using the MATLAB Simulink software to obtain the waveform of
voltage, current and THD by using FFT Analysis function. After all actual parameters obtained,
the setting of parameter then being extracted to the Arduino controller by using Proteus for
hardware development purpose. The full-bridge inverter uses a unipolar switching method and the
SPWM method. However, the Arduino microcontroller is unable to supply the MOSFET with a
sufficient quantity of power for it to operate, so the MOSFET needs adequate input power. Gate
drivers are utilized to power on each of the MOSFETs in order to resolve this issue. The LC filter
is then applied to the inverter's output to remove any extraneous noise and harmonics from the
signal. After being filtered, the signal's waveform closely resembles a sinusoidal wave. The
transformer then increases the voltage and supplies it to the water dispenser.
 Figure 3.3: Block diagram of the inverter using SPWM method.

3.3.1 Software Design

The output of each circuit is simulated and examined using software design. To confirm
and evaluate the functionality of the circuit, simulation is performed prior to hardware design. The
software MATLAB Simulink is used to construct the circuit simulation since it includes the
necessary analysis feature. This enables the control method function to be implemented simply
and adaptably. The circuit simulation that was extracted to the Arduino microcontroller is likewise
programmed using Arduino Ide.

3.4 Software Simulation

For the software simulation, it includes the modelling of full-bridge inverter, generation of
unipolar SPWM and the LC filter design.

3.4.1 Simulation of Full-bridge Inverter Circuit

For this project, the Voltage Source Inverter (VSI) is modeled using the MATLAB
Simulink program. Four gate-controlled main switches make up the VSI. Figure 3.4 depicts the
layout of four MOSFETs which is S1, S2, S3 and S4 in a full-bridge inverter circuit. The inverter
circuit is designed using MOSFETs of the MOSFET type, which serve as switches. When
MOSFETs S1 and S2 are ON and another MOSFET, S3 and S4, is OFF, the inverter topology is
executed. The opposite half of this cycle is reversed throughout this cycle. The switches' ON and
OFF states must run continuously on the inverter circuit. To avoid a short circuit, the MOSFET in
the same leg cannot be turned ON simultaneously.
 Figure 3.4: Schematic of full-bridge inverter

3.4.2 Generation of Unipolar SPWM

The switching circuit also being done by using MATLAB Simulink software. It is to
generate SPWM unipolar switching scheme circuit. Figure 3.5 depicts the simulation of the SPWM
switching circuit performed using MATLAB Simulink. Two comparators have been utilized as a
generator for the unipolar switching method in order to compare the carrier signal and the reference
signal.
 Figure 3.5: SPWM unipolar switching circuit

This SPWM unipolar switching method uses a carrier signal with a 734 Hz switching
frequency and a reference signal with a 50 Hz switching frequency. The frequency modulation
ratio and amplitude modulation ratio are calculated using Equations 2.10 and 2.11. The switching
circuit's output is based on both parameters. The amplitude modulation ratio is 1, whereas the
frequency modulation ratio is 20.

3.4.3 SPWM Generation using Arduino Microcontroller

PWM signals are produced by an Arduino Nano microcontroller. Four PWM signals with
duty cycles and 180° out of phase can be produced using a microcontroller at a frequency of 734
Hz. The full-bridge inverter circuit is powered up using these four generated signals, which are
utilized to provide impulse to the MOSFET drivers.
The Arduino Nano microcontroller has been utilized because it is an open-source platform
designed to diminish the complexities of embedded systems, thus simplifying electronics
development. Additionally, it offers easy-to-use features to make programming easier, like
creating header files that are automatically included when an Arduino program is executed. Figure
3.6 shows the connection of Arduino-based PWM signal extraction between unipolar switching
circuit and Arduino digital output by using Proteus software.
 Figure 3.6: Arduino connection with unipolar switching scheme

3.4.4 Filter Design

The design and development of an LC filter that will produce a waveform that is almost
sinusoidal is the most crucial aspect of this project. Additionally, it has been used to reduce the
inverter system's PWM modulation frequency and associated harmonics.
The value of the cut-off frequency is crucial when designing an LC filter. Equation 2.8 is
used to get the maximum cut-off frequency using the previously determined modulating frequency
ratio value of 20. Thus, 2 kHz is the obtained maximum cut-off frequency. Therefore, the chosen
is 734 Hz, while it can be either between 50 Hz and 2 kHz.
By using Equation 2.9, a few designs for choosing the values of inductors (L) and
capacitors (C) have been constructed. Table 3.1 depicts the options of L and C that were made
throughout the filter's design. L and C's values are determined by assuming either one of these
components while the other is calculated. For this project, only the best design will be chosen. The
second design was chosen because it produced the finest THD results and a waveform that is
almost certainly a sine wave. Using the MATLAB Simulink software, Figure 3.7 represents a full-
bridge inverter with an LC filter.
 Table 3.1: LC parameter.
No. Capacitor, C Inductor, L
1 0.022 µF 1.15 H
2 470 µF 100 uH
3 220 µF 0.12 mH

Figure 3.7: Full-bridge inverter with the existence of LC filter

3.5 Hardware Development

For the hardware development, it consists of four main systems which is solar panel, charge
controller, battery and inverter. Each of these needs to go through some calculations in order to
determine the sizing of each system. It is crucial since a suitable sizing needs to meet the
requirement as it needs to supply a sufficient supply to the water dispenser.
3.5.1 PV Module Sizing

Sizing PV modules in watt peak (Wp) for water dispenser usage involves considering the
desired daily usage in hours and the sun's peak hour. By analyzing power requirements and peak
sunlight availability, appropriate module sizing can ensure efficient energy production and reliable
operation of the water dispenser using solar power.
PV module selection needs to through some calculation so it is suitable to be used for the
system. By referring to Equation 2.1, the total Watt-hours per day for each appliance is calculated.
The water dispenser specification obtained from the Midea official website. The water dispenser
system requirement is it can operate 2 hours in total per day.

𝐴𝑝𝑝𝑙𝑖𝑎𝑛𝑐𝑒 / = 1 × 420 × 1
= 420 Wh/day

Next, calculate the total Watt-hours per day needed from the PV modules by using
Equation 2.2. The total appliances Watt-hours per day needs to be multiply by 1.1 as the energy
lost in the system.

𝑃𝑎𝑛𝑒𝑙 / = 420 × 1.1

= 462 Wh/day

After that, calculate the total Watt-peak rating needed for PV modules by using Equation
2.3. The total PV panel Watt-hours per day needs to be divided by 6 as it is peak sun hour/day in
Malaysia [4].

𝑃𝑎𝑛𝑒𝑙 = 462 ÷ 6
= 77 Wp

Lastly, to determine the size of the PV panel, Equation 2.4 being used. The result will be
round off to the nearest bigger number as the system will perform better and battery life will be
improved.
 𝑃𝑉 𝑝𝑎𝑛𝑒𝑙 𝑠𝑖𝑧𝑖𝑛𝑔 = 77 ÷ 80
= 0.9625
≈ 1 solar panel of 80 W

3.5.2 Charge Controller Sizing

Sizing a charge controller involves considering the total short circuit current of the PV
array and applying a de-rating factor. The charge controller regulates battery charging in a solar
system. Accurate sizing ensures efficient operation, extends battery life and prevents overloading.
By evaluating the actual current delivered by the array under practical conditions, the charge
controller is sized to handle the expected current with a safety margin. Proper sizing protects the
charge controller and optimizes system performance.
By substitute parameter in Equation 2.5, charge controller sizing can be determined.

𝐶ℎ𝑎𝑟𝑔𝑒 𝐶𝑜𝑛𝑡𝑟𝑜𝑙𝑙𝑒𝑟 𝑠𝑖𝑧𝑖𝑛𝑔 = 9.35 × 1.3

= 12.16 A
≈ 13 A at 12 V or greater

3.5.3 Battery Sizing

Battery sizing involves considering the day of autonomy, battery efficiency and nominal
battery voltage. The day of autonomy determines the number of days a battery can power a system
without recharging. A longer day of autonomy provides extended backup power during periods of
low energy generation. Battery efficiency is the ratio of energy output to input, minimizing energy
losses and maximizing usable capacity. Matching the nominal battery voltage to system
requirements ensures seamless integration with other components. Accurate sizing ensures the
battery meets backup power needs, optimizes energy utilization and integrates efficiently. By
evaluating these factors, a reliable and efficient energy storage system can be designed to meet
specific requirements.
The capacity of the battery is calculated as shown in Equation 2.6.
 × .
𝐵𝑎𝑡𝑡𝑒𝑟𝑦 𝑠𝑖𝑧𝑖𝑛𝑔 =
. × . ×
= 75.49 Ah
≈ 80 Ah or greater

3.5.4 Development of SPWM Inverter

There are three main parts for the hardware implementation. There are PWM signal
generation, MOSFET driver circuit and the full-bridge inverter circuit. All the circuits need to
connected to produce SPWM inverter. The aim of the SPWM inverter is to obtain the sinusoidal
waveform AC output voltage of 12 VAC with the frequency of 50 Hz.
For the PWM signal generation, Arduino Nano microcontroller is used to gives impulse to
the MOSFET driver to power up the full-bridge inverter. Since the output from Arduino Nano
microcontroller is only 5 V, a gate driver is used because the input from the microcontroller is low
power input. The gate driver acts as an amplifier and buffer to produce signals which is suitable to
drive MOSFET into saturation. IRFZ44N MOSFET is chose as the switches to construct the full-
bridge inverter circuit. The datasheet of IRFZ44N can be referred in Appendix A. The IRFZ44N
is chose as it gives the voltage gate to source, 𝑉 of 10 V. Figure 3.8 shows the hardware
implementation of the full-bridge inverter.

Gate Driver
Full-bridge
Inverter
Arduino Nano

Figure 3.8: Full circuit of full-bridge inverter.

 The circuit is being supplied by the DC power supply with the input voltage of 12 VDC.
The circuit is tested and measured by using Digital Oscilloscope. The differential probe is
connected to the load in order to measure and display the output waveform.
The circuit is then transferred to the PCB board after completing all the testing on the
breadboard for soldering process. The purpose of the soldering process is to mount the component
on the PCB. For the soldering process, the full-bridge inverter with LC filter circuit is designed
first in the Proteus Software. Figure 3.9 shows the PCB layout for soldering process on its
component arrangement. The traces are placed in 2 layer for safety and neat purpose.

Figure 3.9: PCB layout of the inverter circuit.

The soldering process take place to mount the components on the PCB board based on the
circuit designed that has made in the Proteus Software. Figure 3.10 shows the designed circuit that
has been soldered on the PCB board. Circuit that has been soldered is tested once again to make
sure it produces the similar desired result.
 Figure 3.10: Component arrangement on the PCB.

3.5.5 Product Development

Based on the calculated ratings, all the main components in this solar-powered water
dispenser have been assembled. It involves 12 V 80 W solar panel, 12 V 13 A solar charge
controller, 12 V 80 Ah rechargeable battery, SPWM inverter, 12/230 VAC step-up transformer
and Midea YR1539-T water dispenser. A 2 gang 1 way switch for solar panel and battery also
included so that the power supply will not 24 hours connected as user can control the on-off state
of the product meanwhile a socket outlet for water dispenser also included for user convenience.
Figure 3.11 shows the entire product as final assemble.

Inverter

Figure 3.11: Entire product.

3.6 Summary

System’s sizing and parameters can be determined properly and suitable with the load
requirements. Inverter designation also provided in order to produce the desired requirements that
has been list out in this chapter. By construct the simulation and hardware followed the set value,
the project can be done and achieved the target outcome.