Maximum Power Point Tracking Solar Charge Controller

ESP32-based intelligent solar charge controller achieving up to 98% efficiency with remote monitoring capabilities and advanced protection systems.

ESP32 Based
98% Efficiency
Blynk App Control
Completed

Project Overview

An intelligent solar charge controller that maximizes energy harvesting through advanced MPPT algorithms and IoT connectivity.

Abstract

This project focuses on designing and implementing a Maximum Power Point Tracking (MPPT) solar charge controller using the ESP32 microcontroller. The system integrates advanced sensing capabilities through ASC712-30A current sensor and ADS1015 ADC for precise measurements.

A Blynk app provides wireless telemetry for remote monitoring and control. The controller includes automated protection systems and achieves up to 98% efficiency in optimal conditions, making it ideal for sustainable energy applications.

MPPT Solar Charge Controller
ESP32-based MPPT Solar Charge Controller with LCD Display

Key Features & Objectives

Advanced capabilities designed for maximum efficiency and user convenience

MPPT Algorithm

Robust algorithm implementation ensuring maximum energy harvesting with up to 98% efficiency in optimal conditions.

Precise Current Sensing

ASC712-30A sensor integration for accurate solar panel input current measurement and monitoring.

Voltage Monitoring

High-precision voltage measurement using voltage dividers and ADS1015 12-bit ADC for accurate readings.

Protection System

Automated 12V relay protection system to safeguard solar panels during non-operational hours.

Wireless Telemetry

Real-time monitoring and control through Blynk app integration with ESP32 wireless connectivity.

Performance Testing

Comprehensive testing under various environmental conditions for optimal performance tuning.

Hardware Design & Components

Carefully selected components for optimal performance and reliability

ESP32 Microcontroller
Main control unit with WiFi capabilities for MPPT algorithm execution and wireless communication
ASC712-30A Current Sensor
High-precision current measurement sensor for monitoring solar panel input current
ADS1015 12-bit ADC
High-resolution analog-to-digital converter for accurate voltage and current measurements
IRFP3206 MOSFETs
High-power switching transistors for efficient power control and regulation
12V Relay (30A)
Automated protection system for solar panel isolation during non-operational periods
1602 LCD Display
Real-time display of system parameters with I²C interface for easy monitoring
See Circuit Diagram
Sl No. Component Qty Specifications Purpose
1 ESP32 Module 1 Dual-core, WiFi/Bluetooth Main Controller & Wireless Communication
2 ADS1015 12-bit ADC 1 12-bit Resolution, I²C Interface Precision Voltage/Current Measurement
3 Buck Converter LM2596 2 Adjustable Output, 3A Current Voltage Regulation
4 IRFP3206 N-MOSFET 2 60V, 57A, Low RDS(on) Main Power Switching
5 STPS3045C Schottky Diode 1 45V, 30A, Low Forward Drop Reverse Current Protection
6 12V Relay 30A 1 30A Contact Rating, SPDT Solar Panel Protection
7 ACS712-20A Current Sensor 1 Hall Effect, ±20A Range Current Measurement & Monitoring
8 PC817 Optocoupler 2 CTR 50-600%, 5kV Isolation Signal Isolation
9 IR2104 MOSFET Driver 1 Half Bridge, 200mA Output MOSFET Gate Drive
10 Push Button 4 Momentary, SPST User Interface Control
11 7805 5V Regulator 1 Fixed 5V Output, 1A 5V Power Supply
12 7815 15V Regulator 1 Fixed 15V Output, 1A Gate Drive Power Supply
13 10000µF 25V Capacitor 1 Electrolytic, Low ESR Main Power Filtering
14 470µF 50V Capacitor 2 Electrolytic, High Ripple Power Supply Smoothing
15 2200µF 50V Capacitor 1 Electrolytic, Low ESR Energy Storage
16 104 100nF Capacitor 8 Ceramic, X7R Dielectric Decoupling & Filtering
17 474 470nF Capacitor 1 Ceramic, Non-Polar Signal Filtering
18 100µF 16V Capacitor 1 Electrolytic, Low Profile Local Power Filtering
19 10µF 50V Capacitor 1 Electrolytic, General Purpose Voltage Smoothing
20 AO4446 N-MOSFET 1 30V, 15A, SOT-8 Package Auxiliary Switching
21 Heat Sink 1 TO-220 Package Compatible Thermal Management
22 Thermal Pad 1 Silicone Based, High K Heat Transfer Interface
23 Vero Board 2 FR4 Material, Copper Clad Circuit Construction
24 25µH Inductor 1 Ferrite Core, High Current Energy Storage & Filtering
25 1N5419 Schottky Diode 3 40V, 1A, Fast Recovery Flyback Protection
26 1N4007 Diode 2 1000V, 1A, Silicon Rectification & Protection
27 103 10K NTC 1 Negative Temp Coefficient Temperature Sensing
28 1K Resistor 2 1/4W, 5% Tolerance Current Limiting
29 10K Resistor 12 1/4W, 5% Tolerance Pull-up & Voltage Divider
30 100Ω Resistor 3 1/4W, 5% Tolerance Gate Resistance
31 100K Resistor 4 1/4W, 5% Tolerance High Impedance Biasing
32 5.1K Resistor 2 1/4W, 5% Tolerance Voltage Reference
Total Project Cost: ৳2,181.17 BDT

Results & Achievements

Outstanding performance metrics demonstrating project success

98%

Maximum Efficiency Achieved

Our MPPT algorithm successfully achieved close to 98% charging efficiency under favorable environmental conditions, significantly outperforming traditional charge controllers.

Real-time Monitoring

Successfully implemented wireless connectivity with Blynk app for remote system monitoring and control capabilities.

Automatic Protection

Reliable solar panel protection system using 12V relay, preventing damage during non-operational hours and adverse conditions.

Stable Performance

Consistent performance across varying environmental conditions with minimal noise interference and reliable operation.

Project Team

Dedicated team members who contributed to this project's success

Kawsar Mahmud Tanveer
Md. Mahmudul Hasan
Md. Habibullah Belali
Rafat Anam Ibne Hossain Tuhin
Md. Ibrahim Ali Mahfuj

Supervised by: Md. Sohel Rana
Senior Lecturer, Department of Electrical & Electronic Engineering
Daffodil International University

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