How to create a solar panel | Solar panel wholesaler

How to create a solar panel

Making your own solar panel takes time and requires some electrical knowledge. It may also be quite satisfying — building your own PV panel is a terrific way to learn about solar energy generation.

Step-1 Making a template and a frame

First, construct a solar cell template. To make a template, use scrap plywood, a solar cell-sized piece of cardboard, tile spacers, and a staple gun. It’s easier to cut the plywood with a jigsaw, but a basic hand saw would do perfectly.

After finishing the template, the frame was assembled. 1x2x8 plywood trimmed to suit the outer frame of the plywood. Ensured the outer frame was not too high to avoid wasting any available sunlight.

Step-2 Building solar cells

While the first coat dried, started assembling the solar cells. Watching the video is the best approach to learning how to manufacture solar cells. The bottom of the solar cell is the positive side, and the top is the negative side. You want to connect 36 solar cells in sequence to get 63 watts.

Step-3 Making holes for connections

After two coats of deck and siding paint on the pegboard and plywood, screw the pegboard within the frame (plywood). The solar cells were first placed inside the frame to help locate the screws, then they were removed and the pegboard was screwed down. Next, drilled 2 holes at the frame’s end for negative and positive connections.

Step-4 Gluing solar cells

Then we used silicon to attach the solar cell strings to the pegboard. Having two strings completed, I could next solder bus wire to one end to connect the two solar cell strings. It’s recommended practice to check the voltage/current after soldering any string together or adding new connections.

Step-5 Wire soldering

After connecting all three solar cell strings in series, we’re ready to attach 22 gauge red and black wires. Connectors were attached to the gauge wire leads to allow connecting them to the bus wire easier.

To make the inside of the solar panel seem prettier, run the cables inside two wiremold strips. To test the panel’s voltage/current, I took it outside in the sun for a few minutes.

Step-6 Pressure on the plexiglass

Next, learned that to secure a 2×4 sheet of plexiglass, even pressure around all edges was required. To achieve this, put another set of the same outer frame pieces of plywood on top of the plexiglass to give even pressure. Drill slowly into the plexiglass to avoid cracking it, and use screws meant for pressure-treated lumber.

Step-7 The junction box installed

Installed a junction box on the back of the solar panel. It has a blocking diode that stops the current from flowing backward when connected to a battery. If your charge controller does not prevent current backflow, you will need to place a blocking diode on the solar panel. It is advisable to install the blocking diode on the exterior of the panel so it may be readily replaced.

Finally, wrap silicon around the solar panel and the junction box on the back. After a final voltage/current check, the panel was ready to be mounted.

Overall Project Thoughts

The project was enjoyable, and the whole cost was $400-500, which includes the battery, charge controller, and deep cycle battery. You saved a lot of money by creating your own solar system, as a commercial solar panel would have cost $400 or more.

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