Do you want to get clean and renewable energy for free? Cut your electricity bill? Try to build your own solar panels! These cost much less than those on the market and work great! Read the instructions below to make them yourself.
Steps
Part 1 of 6: Assemble the Parts
Step 1. Buy the cells
There are a few different types of solar cells that you can buy, but the best choice in terms of cost / efficiency is polycrystalline cells. However, buy enough for the electrical power you intend to produce. Specifications should be available when you buy the cells.
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Make sure you buy more. These cells are very fragile.
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Cells are generally easier to buy online, but you might find something in local specialty stores.
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It may be necessary to remove the wax that is usually used to protect cells during shipping. To do this, put them in hot, but not boiling water.
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Step 2. Measure and cut a board
You will need a thin board made of non-conductive material to secure the cells. Lay the cells in the configuration you will use, then take your measurements and cut a board of that size.
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Leave a 2.5 - 5 cm border on both sides of the board. This space will be used for the cables that connect the rows to each other.
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Step 3. Measure and cut the entire tabbing wire
Looking at the polycrystalline cells, you will see a large number of small lines going in one direction (the long distance) and two larger lines going in the opposite direction (the short distance). You need to connect the cable along the larger lines to the back of the next cell in the series. Measure the length of the largest line, double the length, then cut two pieces for each cell.
Step 4. Weld the backs of the cells
Use the soldering flux pen on each of the three squares on the back of the cell and then use the silver alloy to solder the first half of the tab lead to the three squares.
Part 2 of 6: Connecting the Cells
Step 1. Glue the cells to the board
Put a small amount of glue in the center-back of the cells and then press them to the board. The tab cord should run in a single straight line through each row. Make sure the ends of the tab wire pass between the cells and are free to move, with only the two pieces attached between each cell. Keep in mind that a row will have to run in the opposite direction to the one next to it, so that the tab stops at the end of one row and on the opposite side of the next.
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You should plan to arrange the cells in long lines, reducing their number. For example, three rows each with 12 cells arranged along the long side.
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Remember to leave a space of at least 2.5 centimeters at both ends of the board.
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Step 2. Weld the cells together
Apply the welding liquid to the length of the two thick lines (contact platforms) on each cell, then take the free sections of the tabulation cable and weld them along the entire length of the platforms. Note: The tabulation cable connected to the back of one of the cells must be connected in any case to the front of the next cell.
Step 3. Connect the first row using a bus cable
At the beginning of the first row, weld the tabulation cable on the front of the first cell. The tabulation cable should be about 2.5 cm longer than necessary to cover the lines, and extend towards the additional interval in the table. Now solder these two cables together with a piece of bus wire, the same size as the distance between the thick lines of the cell.
Step 4. Connect the second row
Connect the end of the first row with the beginning of the second with a long piece of bus cable that extends between the two large distant cables (one at the edge of the panel and the second positioned further away in the next row). Now you need to prepare the first cell of the second row with the tabulation cord, as you did with the first row.
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Connect all four cables to the bus cable.
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Step 5. Continue connecting the rows
Continue connecting the rows with bus cables until you reach the end, where you will connect to a short bus cable again.
Part 3 of 6: Building the Panel Box
Step 1. Measure the panel
Measure the space occupied by the panel where you placed the cells. The box will have at least these dimensions. Add about 2.5cm to each side to allow room for the sides of the box. If there is no free space of about 2.5 square cm in each corner after inserting the panel, try to get it.
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Also make sure that there is enough space for the bus cables at the end.
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Step 2. Cut the back flat
Cut a piece of plywood the size from the previous step, plus space for the sides of the box. You can use a stationary or mobile saw, depending on what you have available.
Step 3. Shape the sides
Cut out two pieces of the length measurement of the base of the box. Then measure two more pieces to complete the box. Join these pieces together using screws and joints.
Step 4. Join the sides
With screws, join the sides and bases of the box. The number of screws to use depends on the length of the sides, but three screws per side are the minimum.
Step 5. Paint the box
Paint the box in the color of your choice. Use paint suitable for outdoors. This varnish will help protect the wood from the elements and make the panel last a long time.
Step 6. Secure the solar panel
Glue the panel with the cells you built into the box. Make sure it is fixed well and that the cells are exposed at the top and can take in sunlight.
Part 4 of 6: Wire the Panel
Step 1. Connect the end of the bus cable to a diode
Take a diode a little more powerful than the panel amperage and connect it to the bus cable, fixing it with silicone. The light side of the diode should be facing where you will be placing the batteries.
Step 2. Connect the cables
Connect a black wire to the diode and bring it up to a terminal block that you need to mount on the side of the box. Then, connect a white wire to the terminal block starting with the short wire to bus on the opposite side.
Step 3. Connect the panel to a charge controller
Purchase a charge controller and connect the panel to the controller, making sure to connect the positive and negative correctly. Lead the wires from the terminal block to the charge controller, using color coded wires to track loads.
If you are using more than one panel, you can connect all the positive and negative cables together using connection plates, ending up with just two cables
Step 4. Connect the charge controller to the batteries
Buy batteries that will work with the size of the panels you built. Connect the charge controller to the batteries according to the manufacturer's instructions.
Step 5. Use the batteries
Once you have the batteries connected and charged by the panels, you can connect your appliances to the battery taking into account their electrical absorption capacity. Enjoy your energy for free!
Part 5 of 6: Seal the Box
Step 1. Take a piece of Plexiglas
Buy a piece of Plexiglas that fits the inside of the box you made for the panel. Buy it at a specialty or hobby store. Make sure you buy Plexiglas and not glass, as this is easily broken or chipped (hail will be the torment of your existence).
Step 2. Attach glass holders
Cut pieces of wood to attach to the corners. Glue these glass clips using wood glue or something similar.
Step 3. Insert the plexiglass
Mount the plexiglass on the box so that the glass rests on the glass holders. Using special screws and a drill, carefully screw the plexiglass to the glass holders.
Step 4. Seal the box
Use a silicone sealant to seal the edges of the box. It also seals any cracks that may be found. The box must be water-proof as much as possible. Use the manufacturer's instructions to properly apply the sealant.
Part 6 of 6: Mount the Panels
Step 1. Mount on a cart
One option is to build and mount the panels on a cart. This allows you to arrange the panel at a corner and change its orientation in order to increase the amount of sun it can receive in a day. To achieve this, however, the panel will need to be moved 2-3 times a day.
Step 2. Mount on the roof
This is a usual way of mounting the panels, but the angle will need to be consistent with the sun's path, and will only give you full exposure during limited times of the day. This option is preferable, however, if you have a large number of panels and little floor space to arrange them.
Step 3. Mount on satellite support
The structures usually used to mount satellite dishes can also be used to mount solar panels. They can also be programmed to move with the sun. However, this solution is only good if you have a very small number of solar panels.
