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Design, Construction, and Testing of Maximum Power Point Tracking (MPPT)

Charge Controller for Photovoltaic (PV) Power Generation

Article · September 2020

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 Journal of Engineering Research and Reports

17(1): 36-47, 2020; Article no.JERR.61184

ISSN: 2582-2926

Design, Construction, and Testing of Maximum

Power Point Tracking (MPPT) Charge Controller for
Photovoltaic (PV) Power Generation
B. I. Madububa1*, JP. C. Mbagwu2 and D. O. Isiohia3
1
Department of Physics, Federal University of Technology Owerri, P.M.B. 1526,
Owerri, Imo State, Nigeria.
2
Department of Physics, Imo State University, Owerri, Nigeria.
3
Department of Mechanical Engineering, Imo State University, Owerri, Nigeria.

Authors’ contributions

This work was carried out in collaboration among all authors. Author BIM designed the work, draft the
manuscript, performed the calculations, statistical analysis and computation of result. Author JPCM
carried out the result analysis and discussion and author DOI proof read and managed the literature
searches. All authors read, reviewed and approved the final manuscript.

Article Information

DOI: 10.9734/JERR/2020/v17i117180
Editor(s):
(1) Dr. Guang Yih Sheu, Chang-Jung Christian University, Taiwan.
Reviewers:
(1) J. Barsana Banu, Mahath Amma Institute of Engineering and Technology, India.
(2) Navdeep Singh, Madan Mohan Malaviya University of Technology, India.
(3) Tarana Afrin Chandel, Integral University, India.
Complete Peer review History: http://www.sdiarticle4.com/review-history/61184

Received 10 July 2020

Original Research Article Accepted 17 September 2020
Published 25 September 2020

ABSTRACT

Maximum Power Point Tracking (MPPT) charge controller is designed for using an easy and
effective way to charge a 12v battery and a laptop charger of 19v simultaneously through the
principle of the bulk-boost converter. This research work is suitable for 150W solar panels, as the
Maximum Power Point (MPP) of Photovoltaic (PV) power generation systems changes with
variation in atmospheric conduction, an important consideration in the research work is the
efficience of PV systems to track the Maximum Power Point (MPP) correctly. It enhances battery
life by providing higher efficiency to it. The efficiency of the research work was calculated from the
power dissipated, and also calculated the point at which the battery extracts maximum power from
the PV module. As the work was tested, the voltage and current were obtained which was used to
_____________________________________________________________________________________________________

*Corresponding author: Email: [email protected];

 Madububa et al.; JERR, 17(1): 36-47, 2020; Article no.JERR.61184

plot the voltage-current and voltage-power characteristics curve. Though a lot of works have been
published on this topic, but none has researched on MPPT that can charge both 12v battery and
19v laptop charger simultaneously. Hence, this work is aimed at researching on Maximum Power
Point Tracker (MPPT) that will be able to perform the above mentioned features. Also, it is the
objective of this work to compare the theoretical and experimental relationship between MPPT and
PWM charge controller which the efficiency of the MPPT was calculated theoretically to be 97%
while, experimentally we obtained it as 91.1% while for PWM the efficiency was calculated
theoretically as 75% and experimentally as 70.4% which shows that MPPT charge controller is
approximately 30% efficient more than the PWM charge controller.

Keywords: Maximum power point; battery; photovoltaic; pulse width modulation; solar panel.
1. INTRODUCTION systems and the distribution sector is growing
significantly. Research shows that the
Maximum Power Point Tracking (MPPT) of a contribution of PV systems to energy generation
photovoltaic array is a very important stage of a was approximately 14,000MW in 2010 and is
PV system. Hence, a lot of MPPT methods have expected to be 70,000MW in 2020 [5].
been introduced and numerous variants of each Generating power from photovoltaic cell has
method have been proposed to overcome been one of the leading sources of power due to
specific disadvantages. Avalanche of methods the combination of these following factors such
proposed can make it tedious to determine the as low maintenance, minimal wear and tear of
best technique to adopt when implementing a PV components, absence of moving parts, lack of
system [1-2]. However, all the methods vary in audible noise, absence of fuel cost, and
complexity, a number of sensors required; digital pollution-free operation after installation [6].
or analog implementation, convergence speed, Small-scale PV installations are very popular as
tracking ability, and cost-effectiveness. lighting and water pumping solutions in
Furthermore, the type of application can have a developing countries, remote villages, and small
significant impact on the selection of the MPPT rural and urban communities. These systems are
algorithm [3]. Maximum Power Point Tracking also commonly used in developed countries that
(MPPT) and Pulse Width Modulation (PWM) have a considerable amount of solar irradiation,
charge controllers are both mostly used to modern photovoltaic technology transforms
charge batteries with solar power. The MPPT buildings from energy users to energy producers
controller is more refined and more expensive; it [7]. Hence, this work is aimed at researching on
will adjust its input voltage to harvest the Maximum Power Point Tracker (MPPT) that will
maximum power from the solar array and be able to work on principle of buck-boost
transform this power to supply the varying converter, where the MPPT charge controller will
voltage requirement of the battery plus load. be able to charge a 12v battery by buck
Thus, it essentially unlinked the array and battery converter method and 19v laptop battery by
voltages so that there can be, for example, a method of boost converter. Also, it is the
12volt battery on one side of the MPPT charge objective of this work to compare the theoretical
controller and panels wired in series to produce and experimental relationship between MPPT
36volts on the other. It is generally accepted that and PWM charge controller which the output
MPPT will outperform PWM in a cold temperate power and efficiency of the MPPT and PWM will
climate. The PWM controller is a switch that be calculated and analyzed both theoretically
connects a solar array to the battery. The result and experimentally. However, in this work the
is that the voltage of the array will be pulled down best approach will be adopted in order to design
to near that of the battery. Global warming and and construct an MPPT charge controller that will
energy policies have become a hot topic on the be able to charge both 12v battery and 19v
international agenda in the last years. Developed laptop charger simultaneously with high
countries are trying to reduce their greenhouse efficiency.
gas emissions. For example, the European
Union (EU) has committed to reduce the 2. MATERIALS AND METHODS
emissions of greenhouse gas to at least 20%
2.1 Materials
below 1990 levels and to produce no less than
20% of its energy consumption from renewable In the design and construction of the maximum
sources by 2020 [4]. The demand for power point tracking system, the major materials
photovoltaic (PV) power generation in power used are as follows:

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 Madububa et al.; JERR, 17(1): 36-47, 2020; Article no.JERR.61184

Led: 1 red LED display 150W solar panel for source, 12V lead-acid type
Jumper Wire (s): Twenty pieces of jumper wires rechargeable battery as load, and a charge
Vero Board (s): Two Vero boards controller for control both portion. The voltage
Socket: One Eight pin dip socket sensor senses the voltage and output are given
Fuse (s): Two 5amps Fuses to the microcontroller in MPPT. It demonstrates
USB Port: One USB port maximum power point tracking capability, using
Solar Panel: One 150W/ 21V Solar panel the calculation below;
Battery: One 12v battery
Switch: Two push switch The solar panel power (Ps) = 150W
Screws/Nu and Bolts, Soldering Iron, Hobby The maximum voltage (V ) of the panel =18.5V
knife, wire cutter, ruler and pencil, multi-meter, Therefore; the maximum Current ( I ) of the
12 Volt Cooling Fan. panel is given by;

The following Specifications of components were

I = = (1)
used in the construction of the project .
I = 8.11A
2.2 Experimental Design and Method
The power output from the buck converter is
The approach used in experimental design and given by the formula
method is to design an effective MPPT controller
from few components. P = Vout × Im (2)

2.3 Experimental Setup Where V= 13.8V (Output voltage that will change
the battery
Fig 1. shows the block diagram of the charge
controller. This block diagram is divided into I = 8.11A
three portions namely source, control, and load. P = 13.8 × 8.11 = 111.9W

Table 1. Specifications and Quantities of the Proposed Components

Components Specifications/ Rating Quantities

Capacitors 1 x 2200µF16v, 2 x 2200µF/ 32v 3
Resistor 1 x 22kΩ, 3 x 10kΩ, 1 x 1000kΩ, 1 x 100kΩ 6
Variable Resistor 1 x 10kΩ, 1 x 100kΩ 2
Integrated Circuit 1 x LM358, 2 x NE555, 3
Diode 2 x IN4148 2
Zener diode 1 x IN5817, 1 x IN5359B 2
Transistor 1 x MOSFET IRF1407 1
Inductor 1 x 1351µH 1
Voltage Regulator 1 x 78L05 1

Fig. 1. Block diagram of the MPPT Controller

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 Madububa et al.; JERR, 17(1): 36-47, 2020; Article no.JERR.61184

Thus the bulk converter (PWM) utilizes only 111.9W of the power from a 150W solar panel. And the
remaining 38W power was dissipated as heat or wasted.

.
Hence; the theoretical Efficiency of PWM = × 100 (3)

.
Efficiency of PWM = × 100 = 75% (4)

For the MPPT, solar charge controller boosts the current output from the panel to 30%

Therefore; I = ×I +I (5)
I = 0.3 × 8.11 + 8.11
I = 10.54A

From the formula; P =V ×I (6)

P = 13.8V × 10.54A
P = 145.45W

Theoretical Efficiency of the MPPT Controller = × 100

.
The Efficiency of MPPT= = 97% (7)

When the MOSFET is ON, the current would flow Output current, I = (8)
through the inductor, delivered to the output ,

capacitor. Since the diode is forward biased thus .

current flows, and magnetic energy is stored in I =
.
the inductor and electrical energy in the
capacitor. When this MOSFET is off the stored I = 7.15A
energy in the inductor is released and the current
completes its path through the diode and at the Switching frequency, F = 2KHz
same time the charge stored energy in the
capacitor supplies current to the load. IRF1407 DUTY CYCLE, D = (9)
MOSFET is used for better and quick switching.
Since it has a very low amount of voltage drop it .
increases the total efficiency of the system. D=
Liquid crystal display (LCD) is used to display
panel and battery voltages and load conditions of D = 0.657 = 66%
the maximum power point tracker. Now, Inductor, L =
( )
(10)
∆
2.4 Converter
Where ∆ = Inductor ripples current.
For this research, we used a product that
converts and regulates a certain DC (V of 21V A good estimation for the inductor ripple current
for our case) voltage level to different DC (V of is 20%to 40% of the output current. Let,
13.8V for our case) voltage level. ∆ = 40% of the rated current
∆ = 40% of 7.15A
2.5 Design Consideration and Calculation ∆ = 2.86A

2.5.1 Inductor selection Now, from equation (1)

The inductor used in this project was arrived by ( )
doing the following calculations; L= (11)
∆

The output voltage, V = 13.8V (21 − 13.8) 0.66

The input voltage, V = 21V L= = 831 H
2000 × 2.86

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 Madububa et al.; JERR, 17(1): 36-47, 2020;; Article no.JERR.61184

∆
Inductor peak current I = I + (12) 2.6 Simulated Circuit Diagram of a Buck
. Converter of Mppt
I = 7.15 +
I = 8.58A The buck converter circult used in this work in
order to step down the voltage that will charge a
2.5.2 Capacitor selection 12v battery was designed and simulated with
Proteus 8.7 professional software.
The output of the buck converter and the charge
controller has a certain amount of ripple. A 2.7 Simulated Circuit Diagram of the
capacitor is used to minimize the voltage Boost Converter
overshoot and ripple and also store charges.
∆ The boost converter circult used in this work in
Output Capacitance, C = (13) other to step up the voltage that will charge a 19v
× ×∆
laptop charger was designed and simulated with
Where, Inductor ripple current, ∆ = 2.86A Proteus 8.7 professional software.
Switching frequency, F = 2 KHz
Output voltage ripple, ∆V = 125mV mV (assumed) 2.8 Experimental Procedures
Now, from equation (13) we have,
∆
C = The circuit was designed according to the
× ×∆
diagram shown in Fig. 4.
where ∆= 2.86
. The step by step process taken in the
C =
× × . construction of the bulk converter maximum
C = 1430 F power point tracking solar charge controller.

2.5.3 Mosfet selection Simulation of the circuit using Proteus software

was made to verify if the circuit diagram is
The IRF1407 MOSFET is used, in this project correct before mounting it in the Vero board, after
has a voltage rating of 20% more than the that the components stated in the circuit diagram
required voltage, with minimum heat conduction were mounted in the prototype circuit board
loss. (Vero board) as illustrated in the circuit diagram

Fig. 2. Simulated circuit diagram of the Buck converter maximum power point tracking solar
charge control designed with Proteus 8.7 professional software

40
 Madububa et al.; JERR, 17(1): 36-47, 2020;; Article no.JERR.61184

Fig. 3. Simulated circuit diagram of the Boost converter to charge a laptop using a 12V battery
designed with Proteus 8.7 professional software

Fig.
ig. 4. The complete simulated circuit of the research

in Fig. 4 and the components were connected solar panel. Fig. 5. Shows the picture of the
with jumper wires were necessary. Then the device. The output of the simulat
simulated, and the
components and the jumper wires were soldered tested circuit is discussed, and also the
using soldering iron and soldering lead after comparison is done between the output powers
which the designed circuit was tested with a 12V extracted with the MPPT circuit and without the
battery and 150W solar panel. MPPT circuit when the same insolation is
provided. The output waveforms are also shown
3. RESULTS AND DISCUSSION to verify the results. A table of comparison is
formed to show directly the usefulness of the
The outcome of this research work gave rise to a MPPT circuit. The efficiency is also
constructed maximum power point tracker calculated with and without the presence of an
system equipment with a robust search and MPPT circuit and a table of comparison is
discovery capabilities in terms of a photovoltaic formed to show the direct compariso
comparison. Also, the
was tested with a 150 W maximum output power results are compared with the results of

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 Madububa et al.; JERR, 17(1): 36-47, 2020;; Article no.JERR.61184

Fig. 5. The designed image of a buck converter of MPPT controller

Fig.
ig. 6. The designed image of a boost converter for charging of laptops

Fig. 7. The complete image of the Designed and Constructed Maximum Power Point Tracker
(MPPT) couple with plastic material in under to serve as an insulator to avoid overheating of
the components

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 Madububa et al.; JERR, 17(1): 36-47, 2020; Article no.JERR.61184

similar work done with different types of of the testing, at 1.00 PM, PWM and MPPT
Converters. In Table 1 the output power at load power was 106.4W and 131.9W respectively. It
and the maximum power that can be was also observed that at the same time PWM
delivered by the solar panel is shown. A and MPPT voltage are 13.3V and 13.6V and the
comparison is done between the output power current was 8.0A and 9.7A respectively, at that
with the MPPT circuit and without the MPPT time experimented efficiency was 70.9% and
circuit. 91.1%. The highest efficiency for PWM which is
74.0% was obtained at 2.30 PM while at 1.30
3.1 Analysis of the Experimental Results PM, the highest efficiency for MPPT was
recorded as 96.6%, while the lowest efficiency
Experimental data of the solar charge controller was 67.9% at 3.30 PM. For PWM and 88.0% at
in Tables 1 and 2 represents the experimented 3.30 PM as well.
data of voltage, current, and powers for both the
PWM and MPPT, from this tested value, the Fig. 6, and Fig. 7 Show the relationship between
overall efficiency of these charge controllers was the PWM and MPPT power as they vary with
determined. The average Efficiency of the PWM time due to the sun intensity, it was
is 70.4% while the average Efficiency of the observed that the MPPT Controller has
MPPT is 91.1%. The graph shows the efficiency more power at every time interval than the load
of the controllers as time varies. At the beginning power.

Table 2. Showing the result of Current, Voltage, and Efficiency when Maximum Power Point
Tracker (MPPT) is not connected i.e. (PWM)

Time (PM) Voltage (V) Current(A) Power(W) EFF(%)

1:00 13.3 8.0 106.4 70.9
1:30 13.6 7.9 107.4 71.6
2:00 13.8 7.8 107.6 71.7
2:30 13.7 8.1 111.0 74.0
3:00 13.6 7.5 102.0 68.0
3:30 13.4 7.6 101.8 67.9
4:00 13.5 7.9 106.7 71.1
4:30 13.2 8.0 105.6 70.4
5:00 13.8 7.4 102.1 68.1
5:30 13.6 7.7 104.7 69.8
Solar Panel Power = 150W

The efficiency of the PWM = × 100 (14)

The Experimental Average Efficiency of the PWM = 70.4%

Table 3. Result showing the Current, Voltage and Efficiency when MPPT is connected

Time (PM) Voltage (V) Current (A) Power (W) EFF (%)
1:00 13.6 9.7 131.9 87.9
1:30 13.8 10.5 144.9 96.6
2:00 13.7 9.8 134.3 89.5
2:30 13.4 10.4 139.4 92.9
3:00 13.8 10.0 138.0 92.0
3:30 13.6 9.8 133.3 88.9
4:00 13.8 10.1 139.4 88.0
4:30 13.5 10.3 139.1 92.9
5:00 13.7 9.9 135.6 90.4
5:30 13.5 10.2 137.7 91.8
Solar Panel Power = 150W

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 Madububa et al.; JERR, 17(1): 36-47, 2020;; Article no.JERR.61184

Efficiency of the MPPT = × 100 (15)

The Experimental Average Efficiency of the MPPT = 91.1%

EFF(%)
100
EFFICIENCY (%) 95
90
85
80
1:00 1:30 2:00 2:30 3:00 3:30 4:00 4:30 5:00 5:30

EFF(%)

TIME (1:00PM - 5:30PM)

Fig. 8. The Graph Showing the Efficiency of the Controller PWM

EFF(%)
98
96
EFFICIENCY (%)

94
92
90
88
86
84
82
1:00 1:30 2:00 2:30 3:00 3:30 4:00 4:30 5:00 5:30
EFF(%)

TIME (1:00PM - 5:30PM)

Fig. 9. The Graph Showing the Efficiency of the MPPT Controller

160.00
140.00
120.00
POWER (W)

PANEL POWER (W)

100.00
80.00
60.00 LOAD POWER (W)
40.00
20.00
0.00
0.00 1.00 2.00 3.00 4.00 5.00 6.00
TIME (MIN)

Fig. 10. The Graph Showing the Power of the Panel and Power of the Load of MPPT Controller

44
 Madububa et al.; JERR, 17(1): 36-47, 2020;; Article no.JERR.61184

Table 4. Shows the Voltage and Current Reading obtain from the MPPT Controller

Voltage (V) Current

C ( A) Power ( W)
3.74 10.52 39.34
5.62 10.48 58.89
7.49 10.44 78.20
9.36 10.26 96.03
11.24 10.08 113.30
13.11 9.90 129.79
14.10 9.27 130.71
14.80 9.00 133.20
15.50 8.19 126.95
16.01 7.65 122.48
16.70 7.02 117.23
17.78 5.13 91.21
18.21 4.05 73.75
18.26 3.33 60.81
18.29 3.06 55.96
18.32 2.25 41.22
18.35 1.80 33.03
18.38 0.36 6.62
18.41 0.18 3.31
18.44 0.10 1.84

Fig. 11. I-V

V Characteristic Curve of the MPPT Controller

140
120
100
80
60
40
20
0
0 5 10 15 20 25

Fig. 12. P-V

V Characteristic Curve of the MPPT Controller

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 Madububa et al.; JERR, 17(1): 36-47, 2020; Article no.JERR.61184

3.2 Analysis of the Curves in Fig. 10, and lead-acid type rechargeable battery at the
Fig. 11 voltage of 13.8V by using buck converter and at
the same time charge a laptop battery with a
The graphs which we obtained are the expected different voltage 19V, by using a boost converter.
ones though, it has a little variation due to some The theoretical result from our calculation shows
factors that affect the operation of the MPPT. that MPPT efficiency was 97%, as compared to
From the I-V curve, we can find that the 75% of the PWM charge controller. In The
maximum voltage the panel can attain is 18.44V, experimental result on the other hand, due to
and the maximum current of the panel is 10.52A. some losses, we obtained the efficiency of the
It shows that depending on the level of isolation a constructed MPPT as 91.1% as compared to
PV array has a point where power derived from PWM, which is 70.4%. Converter and overall
the array is maximum, this point is the maximum system are calculated at different irradiances.
power point (MPP). Using the MPPT charge controller with solar
panel installations has a clear advantage
Also in Fig. 12. we can see from the P-V curve because the PWM charge controller gives low
that the maximum energy of our solar panel is power output.
almost 133W attainable at a load of
approximately 2-ohms load. Generally, the application of PV array normally
faces the shading problem of solar light which
From this formula: lead to inconsistent power generation and low
efficiency of the MPPT charge controller. Hence,
= (16) future research can investigate to solve the
133 = 15 x I partial shaded problems in photovoltaic power
I= = 8.87A generation employing Z-source inverter. More
improved MPPT methods or other intelligent
Using = (17) MPPT methods can be applied so that it can run
15 = R × 8.87 both in standalone and in grid connected
15 mode.
R=
8.87
COMPETING INTERESTS
R = 2 ohms (approx.)
Authors have declared that no competing
So for this specific panel, we need to use a load
interests exist.
closer to two (2) ohms to get the maximum
power output from the panel. But as the sun
condition changes, the "maximum power REFERENCES
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© 2020 Madububa et al.; This is an Open Access article distributed under the terms of the Creative Commons Attribution
License (http://creativecommons.org/licenses/by/4.0), which permits unrestricted use, distribution, and reproduction in any
medium, provided the original work is properly cited.

Peer-review history:
The peer review history for this paper can be accessed here:
http://www.sdiarticle4.com/review-history/61184

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