International Journal of Trend in Scientific Research and Development (IJTSRD)

International Open Access Journal | www.ijtsrd.com

ISSN No: 2456 - 6470 | Volume - 3 | Issue – 1 | Nov – Dec 2018

Optimization of Solar Energy Production using PLC & SCADA

Abhishek Kumar Chambel1, Er. Bharti Sood2
1
Electrical and Electronics Engineering, 2Electronics & Communication Engineering
Maharaja Agrasen University, Baddi
Baddi, Himachal Pradesh, India

ABSTRACT
This paper focuses on the maximizing the solar find alternative energy resources to meet the power
energy produced by Solar cells through the demands.
development of such a Sun-Tracking
Tracking system that can
be implemented using PLC & SCADA. In this paper a system for Optimization of Solar
Energy generation using PLC & SCADA is
The developed tracking system is innovative in developed. Nowadays,, Solar power generation has
relation to the usual sun tracking systems available in very low efficiency in terms of availability, utilization
the market. In fact, the developed solution has many and generation (ca. 12%).
advantages in relation to similar existing devices, as
this system can automatically work in order to Solar Energy is such an energy which is available to
optimize the energy production of photovoltaic cells us in abundance and without any limits. The Solar
as we know that in case of fixed Solar cells, the Energy incident on Earth atmosphere is 1017 Watts.
efficiency is very poor. This efficiency of power The Solar Energy that reaches the earth’s surface is
generation by Solar cells can be increased using this 1016Watts. The total power requirements
re of whole
13
system, so that as the position of sun changes, the world is 10 Watt. If, 5% of the total energy received
position of Solar cell is automatically adjusted by at the surface is fully utilized, it is still 50 times more
using stepper motors. An experimental prototype was than the actual requirement of the whole world.
built and field results have proven the good
performance of the developed tracking system. This paper focuses on the optimization of the electric
energy production by solar cells through the
KEY WORDS: Solar Cells, Photovoltaic cells, development of an intelligent sun-tracking
sun system.
Tracking Systems, Intelligent
igent sensors and Supervisory The developed tracking system is innovative in
Control. relation to the usual sun tracking systems available in
the market. The usual available solutions for tracking
1. INTRODUCTION systems rely on the knowledge of the geographical
According to market economy, the increasing position of the solar panel on the earth surface. With
worldwide demand for energy, forces a continuous this knowledge it is possible to know the relative
rise on the price of fossil combustibles. In fact, it is position of the sun, on a time basis, according to the
expected in the near future, that the demand for well-known solar tables.
energy will grow faster than the finding out of new
available fossil resources. Modern solutions incorporate a GPS system to
calculate the position of the solar panel on the Earth
This market behaviour brings a positive challenge to surface. The orientations to be followed by the
the scientific community as more funds are allocated photovoltaic panel, on a regular time-base,
time are then
for the research and development of new alternatives pre-programmed,
programmed, on an open loop approach. There
to the usual main energetic sources (fossil are significant
nificant efforts on the optimization of sun
combustibles). In this context, nowadays more effort tracking systems as it is documented by several
is being done to conserve the fossil fuels and also to registered international patents. These solutions are
based either on the above described principle either on

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 International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
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the quantification of the received solar energy, eithe
either photovoltaic park
ark in order to transfer the new optimal
on the maximization of the solar incident radiation orientation to all PV-production
production panels.
through the use of light concentration lens
lens.
Mechanical Structure
B. Electro-Mechanical
The solution developed in this paper is innovative The operational subset of the tracking system, named
related to the above referred approaches as this system Electro-Mechanical
Mechanical System, is presented in figs 2 and
is autonomous regarding the information needed to 3. This structure has two DOF, motorized
m by stepper
process the optimal orientation and it is intelligent in a motors with incorporated encoders; in order to track
way that it monitors, on a real-time time base, the exactly the prescribed path. The mechanical system
photovoltaic energy production and it avoids was designed using standard industrial Aluminium
systematic failures coming from changes on the profiles in order to obtain a simple and economic
assumed values (position, initial infrastructure structure.
orientation,
on, cleanness of the photovoltaic cells, etc.).
The mechanical structuree is mainly composed by
2. SYSTEM DESCRIPTION: Bosch Profiles and Aluminium plates. The two
A. Overall System Presentation motorized axis are composed by Step-motorsStep
The overall system is presented in fig. 1. The assembled to Aluminium shafts. Figure 2 illustrates
complete strategy is composed by 5 sub--systems: the several main components of the mechatronic
1. Electro-Mechanical Structure system:
2. Control Unit Part n. 6 = Step-Motor
Motor to control axis
axi 1;
3. Supervisory System Part n. 7 = Step-Motor
Motor to control axis 2;
4. Wind-meter Part n. 8 = Photovoltaic cell (150mmx150mm).
5. Photovoltaic Park.

Fig 2 Electromechanical System for Solar Tracking

Fig.1 overall system presentation

The developed tracking system searches the optimal

orientation of a surface, related to the sun incident
radiation. The global performance of the system is
described below. The planar surface is composed by a
photovoltaic cell which is motorized by 22-orthogonal
axis. These two controlled DOF (Degrees of
Freedom) are managed by a PLC (Programmable
Logic Controller) according to a search program that
compares the electric power produced by the
photovoltaic cell in each correspondent orientation.
The maximal power value is stored and the
correspondent orientations on both motorized axis are Fig.3 Design of Degree of freedom
stored. This new optimal orientation of the tracking Figure 3 details the two designed degrees of freedom
system is then communicated to the industrial (DOF).

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 International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
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C. Control Unit In the developed supervisory system, the SCADA
The control unit consist of PLC Siemens S7 S7-300 application
lication manages the overall system dynamics.
system (Programmable Logic Controller). This The Communication flux between the supervisory
control system has the complete operational system and the control unit is illustrated in fig. 5. The
management of the tracking system. The main tasks SCADA PC is simultaneously a SCADA server and
performed by the system are: an internet server, as the implemented SCADA

Controlling of the two stepper motors; application is web enabled.

Processing the data from both encoders;

Processing the voltage
oltage signal coming from the
Solar-Cell;

Processing the data from the external proximity
sensors that informs the system about the hard
hard-
home position reference.

LC controls directly the tracking system and

This PLC
commands all other Solar-Panels,
Panels, from the solar Park,
through a Profibus-DP network.

Figure 4 shows an example of a solar park with

several PV-Panels.
Panels. Figure 5 illustrates the Profibus
network implemented in this study.
Figure 5 This Figure from a first solar white paper.
“’Grid-Friendly’ Utility-scale
scale PV Plants,”
Plants, illustrates
the basic architecture and components of a Plant-level
Control system

3. EXPERIMENTAL PROTOTYPE
A. Physical Description
The prototype built followed the design presented in
figure 2. This system incorporates a PV- PV
cell150mmx150mm, Pmax=1,12W, (Polycrystalline
Silicon wafer) and the whole structure is made of
Aluminium alloy. In fig. 6 the global developed
prototype is shown.
Fig 4 Solar Panel Power Plant

D. Supervisory System
A SCADA system (Supervisory Control and Data
Acquisition) is implemented to monitor and supervise
the tracking system. A Supervisory Control and Data
Acquisition (SCADA) System is used as an
application development tool that enables system
integrators to create sophisticated supervisory and
control applications for a variety of technological
domains, mainly in the industry field. The main
feature of a SCADA system is its ability to
communicatee with control equipment in the field, Fig.6 Prototype assembly
through the PLC network. As the equipment is
monitored and data is recorded, a SCADA application The control unit was developed using an industrial
responds according to system logic requirements or Siemens S7-300 300 PLC (Programmable Logic
operator requests. Controller). The selected PLC system is a modular
device that is constituted by the following modules:

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 International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
2456
Slot1 = Power supply PS 307-2A B. Implemented Control Algorithm
Slot2 = Processor CPU 315-2DP The software used for the PLC programming was the
Slot4 = Communication module CP 342 -5 Siemens Simatic Step 7, with the Simatic 7
Slot5 = Digital card DI8/DO8xDC24V/0,5A ProdaveV5.5 needed for the communication between
Slot6 = Analog card AI8 x12bit the Scada system and the PLC network. The designed
Slot7 = Analog card AO4 x12bit control algorithm was implemented using the Ladder
Slot8 = FM card – Counter Module (FM350) Diagram language.
Slot9 = FM card – Counter Module (FM350)
Slot10 = FM card – Stepper Motor (FM353) The developed control algorithm
lgorithm is illustrated in fig.8.
fig.
Slot11 = FM card – Stepper Motor (FM353)

Additionally, the PLC-tracker

tracker has a modem for GSM
communication that provides the system capacity to
communicate through the mobile phone network.

The driving unit is composed by two motorized axis,

with the following characteristics:
1. Axis 1

Step motor: Nanotec ST4018L0804, 50Ncm;

Opt. Encoder: HP HEDL-5540 5540 A14, 500 Pulses

Coupling unit: Oldham D5

Proximity sensor: Omrom EA2 M8 PNP
2. Axis 2

Step motor: Nanotec ST5918L1008, 170Ncm;

Gear box: Nanotec PLE40-1S-4

Opt. Encoder: HP HEDL-5540 5540 A14, 500 Pulses

Coupling unit: Oldham D25

Proximity sensor: Omron EA2 M8 PNP

Figure 7 details the electro-mechanical

mechanical structure of
the developed sun-tracker system.

Fig.8 Control Algorithm for the Tracking System

A short description of the tasks performed by the

tracker controller, regarding the above referred
algorithm, is described below:

Box0: After reset is activated, the system stores the

PV-power
power generated in the actual position, Pactual, in
the variable Pin. The system searches its reference-
null position. It moves until it finds the hard-home
hard
position (both external proximity sensors on). In this
position the system assumes the absolute orientation
angles for both axis equal zero (α1
( = α2 = 0). The
maximal Power, Pmax is set to zero. Bothcounters,
Both
Fig 7 Prototype Assembly: Solar panel C1, C2, are loaded;

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 International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470
2456
Box1: After start is activated, the system initiates the
search for the maximal power generated in axis 1,
with an angle increment α10.10. The system stores the
power generated in variable P1.

Box2: If P1 < P max, the system goes to Box 4, and

follows for a new position;

Box3: If P1 > P max, this position is stored in the

variables: α1max, α2max. The max Power value, Fig 9 SCADA view of Solar Tracker
P max is actualized with the new Power value P1; As this SCADA platform is web enabled, all the GUI
displayed data is also on-line
line accessible through the
Box4: Counter for axis 1 is updated; internet.
Box5: After all orientations for axis 1 are evaluated, In fig. 9 it is shown the developed main menu for the
regarding a fixed orientation
ntation for axis 2, axis 2 is sun-tracker system. The on-line
line available information,
positioned in a new position, with an angle increment referring actual data from the tracker unit is: actual
20, and axis 1 returns to its initial position α1=0. The
α20, position for both axis, actual PV-power
PV generated,
system re-initiates
initiates the search for the optimal max. daily PV-powerpower generated, actual efficiency
orientation of axis 1, regarding the new position of ratio.
axis 2. The information
formation flux returns to box 1.
4. CONCLUSIONS
Box6: After all orientations for axis 1 are evaluated, The developed tracker for sun radiation worked very
regarding all different positions of axis 2, the system well. The increase in power generation, in relation to
compares the maximal power found (P max) with the other Solar Energy-systems,
systems, without tracking devices,
initial Power generated, before the search process had is of similar magnitude (ca. 25%) as for other usual
begun (Pin).
Pin). If the new Power value is greater than a tracking solutions. However, this system has
h a relative
pre-defined
defined gain, this new correspondent orientation advantage, as it measures exactly the controlled
co
(α1max, α2max)
2max) is sent to all park panels. If the variable: the actual Solar power generation.
power gain is not enough, the new found position is
not to follow by the other PV-panels. Note: If we can just utilize 5% of the total available
solar energy on earth surface, it will be 50 times the
Box7: After a pre-defined time interval (K) the tracker energy which is required by the whole world.
w And in
system initiates a new complete search process in both this way, there will never be any shortage of power
axis. The information flux returns to box 0. supply except in case of non-availability
non of direct
sunlight.
C. SCADA Supervisory System
The SCADA system used to implement this In such case, the other sources of power can be used
monitoring and control strategy permits the selective so that we use as much less fossil fuels as possible.
access to the application, depending on the user’s
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