Design and Fabrication of Solar Operated Drilling Machine

Design and Fabrication of Solar Operated Drilling Machine

Dinesh Choudhury , Devara M S Mohana Madhumitha , Devanaboyina Avinash Kumar , Davala Mohan Sai Kumar, Kandrala Sai Venkat

Vignan's Institute of Information Technology, Andhra Pradesh

Abstract – Solar energy is one of the most abundant renewable energy sources available for sustainable power generation. This paper presents an experimental investigation of the conversion of solar energy into electrical energy and subsequently into mechanical energy using a photovoltaic panel and DC geared motor. A 12 V, 3 W polycrystalline solar panel was used to generate electrical energy under varying climatic conditions. The electrical output was measured and used to drive a 12 V DC motor with rated torque of 3 kg·cm and speed of 100 RPM. The mechanical power, mechanical energy, shaft work, and spindle speed were calculated using standard engineering relations. Experimental results show that maximum electrical power of 3.51 W and corresponding mechanical energy of 11.08 kJ were obtained under clear sky conditions. The study demonstrates that solar photovoltaic systems can effectively power mechanical devices and convert renewable solar energy into useful mechanical work.

Keywords: Solar energy, photovoltaic system, DC motor, mechanical energy, shaft work, renewable energy

1. INTRODUCTION

   The increasing demand for energy and depletion of fossil fuels have led to the exploration of renewable energy sources. Solar energy is one of the most promising renewable energy sources due to its abundance, sustainability, and environmental friendliness. Photovoltaic (PV) systems convert solar radiation directly into electrical energy using semiconductor materials.

   The electrical energy generated from solar panels can be used to power mechanical systems such as pumps, fans, drilling machines, and automation systems. Conversion of solar energy into mechanical energy is an important process in solar-powered engineering applications.

   DC motors are commonly used for converting electrical energy into mechanical energy due to their simplicity, reliability, and ease of control. When powered by solar panels, DC motors enable solar-driven mechanical work without dependence on conventional electricity sources.

   The objective of this study is to experimentally investigate the conversion of solar energy into electrical energy and subsequently into mechanical energy and shaft work using a photovoltaic panel and DC motor under different climatic conditions.

2. LITERATURE REVIEW

   Duffie and Beckman (2013) explained the fundamental principles of solar radiation and photovoltaic energy conversion. Solanki (2015) discussed photovoltaic system performance and electrical power generation using solar panels.

   Several researchers have investigated solar-powered motor systems. Nema and Nema analysed photovoltaic system performance under varying radiation conditions and demonstrated direct proportionality between solar radiation and electrical output.

   Rattan (2019) described the relationship between torque, angular velocity, and mechanical power in rotating systems. These principles are used to calculate mechanical power and shaft work in DC motor systems.

   Previous studies confirm that photovoltaic systems can effectively power mechanical systems such as water pumps and automation systems.

3. METHODOLOGY

   The energy conversion process in this study follows the sequence:

   Solar radiation Electrical energy Mechanical energy Shaft work The following equations were used:

   Solar electrical power:

   P= V×I

   Mechanical power: P=T×

   Angular velocity:

   = 2N/60 Mechanical energy: E=P×t

   Torque conversion:

   T (N.m) =T(kg.cm) ×9.81×0.01

   Where:

   P = Power (W) V = Voltage (V) I = Current (A)

   T = Torque (N·m)

   = Angular velocity (rad/s) N = Speed (RPM)

   t = Time (s)

4. EXPERIMENTAL SETUP

   The experimental setup consists of: Polycrystalline solar panel (12 V, 3 W)

   DC geared motor (12 V, 100 RPM, 3 kg·cm torque) Digital multimeter

   Solar radiation measurement data Load-free motor shaft

   The solar panel was exposed to sunlight under different climatic conditions. The output voltage and current were measured, and the motor was operated using the generated electrical power.

5. CALCULATIONS

   Motor torque conversion:

   T=3×9.81×0.01=0.294 N.m

   Angular velocity:

   = 2×100/60

   =10.47 rad/s Mechanical power:

   P= 0.294×10.47 P= 3.08W

   Mechanical energy per hour:

   E= 3.08×3600 E=11088 J

   Table: Solar Radiation vs Electrical and Mechanical Output

   Climatic Condition	Solar radiation(W/m2)	Electrical Power (W)	Mechanical Energy (J)	Spindle Speed (RPM)
   Clear winter noon	1000	3.51	11088	100
   Warm sunny day	900	2.92	10512	95
   Mild sunny day	800	2.61	9396	85
   Partly cloudy	600	1.96	7056	64
   Cloudy sky	400	1.33	4788	43
   Rainy weather	200	0.70	2520	23

6. RESULTS AND DISCUSSION

   Results show that electrical power output depends directly on solar radiation intensity. Maximum electrical power of 3.51 W was obtained under clear sky conditions. Mechanical energy output depends on available electrical energy and motor characteristics.

   Spindle speed decreases under low radiation conditions due to reduced mechanical power availability. This confirms that solar radiation significantly affects mechanical performance.

   The results demonstrate effective conversion of solar energy into mechanical work using photovoltaic systems.

   1. Electrical Power generation at various solar radiation Graph Title:

      Solar Radiation vs Electrical Power Axes:

      X-axis: Solar Radiation (W/m²) Y-axis: Electrical Power (W)

      4

      3.5

      3

      2.5

      2

      1.5

      1

      0.5

      0

      Electrical Power

      0 200 400 600 800 1000 1200

      • The graph shows how electrical power output of the solar panel changes with solar radiation.

      • As solar radiation increases from 200 1000 W/m², electrical power increases from 0.70 3.51 W.

      • The relationship is almost linear (directly proportional).

      • The graph is increasing because of the photooltaic effect. Reason 1: More Sunlight = More Energy

      • Solar radiation represents the amount of sunlight falling on the panel.

      • Higher radiation means more energy available per unit area. Reason 2: Increase in Photons

      • Sunlight consists of photons.

      • When radiation increases: More photons strike the solar cells More electrons are excited

        This increases electric current (I) Reason 3: Power Equation P=V×I

      • Voltage (V) changes slightly

      • Current (I) increases significantly Therefore, power increases

        Reason 4: Direct Proportionality PG

        Where:

      • P= Power

      • G= Solar radiation

        It is Not Perfectly Straight

        Reason 1: Temperature Effect

      • At higher radiation, panel temperature increases

      • High temperature reduces efficiency slightly Reason 2: Material Losses

      • Internal resistance of solar cells

      • Electrical losses in connections Reason 3: Environmental Factors

      • Dust

      • Angle of sunlight

      • Minor shading

   2. Electrical power at various spindle speed Graph Title:

      Electrical Power vs Spindle Speed Axes:

      X-axis: Electrical Power (W) Y-axis: Spindle Speed (RPM)

      Spindle Speed

      120

      100

      80

      60

      40

      20

      0

      0 0.5 1 1.5 2 2.5 3 3.5 4

      • The graph shows how spindle speed of the DC motor varies with electrical power input.

      • As electrical power increases from 0.70 W to 3.51 W, spindle speed increases from 23 RPM to 100 RPM.

      • The relationship is direct (increasing trend) but not perfectly linear. Reason 1: More Electrical Power More Motor Output

        Electrical power supplied to the motor:

        P=V×I

      • As power increases, the motor receives more energy per second

      • This allows the motor to rotate faster Hence, spindle speed increases

        Reason 2: Relation Between Power and Speed P=T×

        Where:

        T= Torque

        = Angular speed For a geared motor:

        Torque is approximately constant So: P

        Speed increases with power

        Reason 3: Overcoming Losses at Low Power At low power (0.7 W):

      • Motor struggles to overcome: Friction

        Internal resistance

      • So, speed is very low (23 RPM) As power increases:

      • These losses are overcome

      • Speed rises quickly

        The graph is not perfectly linear

        Reason 1: Motor Saturation (Speed Limit)

      • The motor is rated at 100 RPM

      • After ~2.9 W, speed increases very slowly Graph starts flattening near the top

        Reason 2: Mechanical Losses

      • Gear friction

      • Bearing losses

      • Air resistance

        These reduce efficiency at higher speeds Reason 3: Voltage Limitation

      • The motor is designed for 12 V

      • Even if power increases slightly, speed cannot increase beyond design limit

7. CONCLUSION

• The study investigated the conversion of solar energy into electrical and mechanical energy using a photovoltaic panel and DC motor.

• Maximum mechanical energy of 11.08 kJ was obtained under clear sky conditions.

• System proves feasibility of solar-powered mechanical applications.

• Future work can focus on energy storage integration and improved solar panel efficiency.

REFERENCES

1. Duffie, J.A., Beckman, W.A., Solar Engineering of Thermal Processes, Wiley, 2013.

2. Solanki, C.S., Solar Photovoltaics: Fundamentals, Technologies and Applications, PHI Learning, 2015.

3. Mehta, V.K., Basic Electrical Engineering, S. Chand, 2018.

4. Rattan, S.S., Theory of Machines, McGraw Hill, 2019.

5. Nema, A., Nema, R.K., Renewable Energy Journal, Elsevier.

6. IEEE Transactions on Energy Conversion.