School of Engineering

Mechanical Engineering Department

DESIGN AND FABRICATION OF A SEMI-AUTOMATED

SOLAR PANEL CLEANING SYSTEM-MECHANICAL
APPROACH

Felix Daka 18124244

A Thesis Presented to The Copperbelt University, Mechanical department in the school of

engineering in partial fulfillment of the requirements for the award of the
bachelor’s degree in Electromechanical Engineering (Hons).

The Copperbelt University

2023
 Declaration
I hereby declare that I carried out the work reported in the Department of Mechanical
Engineering, Copperbelt University under the supervision of Mr. Bwembya. I solemnly declare
that to the best of my knowledge no part of this report has been submitted here or elsewhere in
a previous application for award of a diploma. All the sources of knowledge used have been
duly acknowledged.

Felix Daka
Signed…
Date…

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 Approval
This is to certify that the project titled Design and Fabrication of a Semi Automated Solar Panel
Cleaning System_Mechanical Approach carried out by Felix Daka has been read and approved
for meeting part of the requirements and regulations governing the EM 500 Projects course in
BEng. Electromechanical Engineering at the Copperbelt University, Kitwe, Zambia.

Mr. Emmanuel Bwembya.

(Project Supervisor)
Signed: …………………
Date: ……………………

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 Dedication
This project is dedicated to the unwavering support and guidance of those who have been
instrumental in its completion. To my family, whose boundless love and encouragement have
been my pillar of strength, your belief in me has fueled my determination to pursue knowledge
and excellence. To my friends and peers, who have been a source of inspiration and positive
encouragement throughout this journey, your discussions, debates, and shared experiences
have enriched my understanding and perspective. Thank you all for being a part of this
meaningful chapter in my academic and personal growth.

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 Acknowledgements
I would like to express my deepest gratitude to my supervisor, Mr. E. Bwembya, for the
guidance, support, and invaluable expertise throughout the entire duration of this thesis. His
insightful feedback, encouragement, and commitment to my academic development have been
instrumental in shaping this research project.
I would also like to extend my sincere appreciation to the faculty members of the Mechanical
and Electrical department for their valuable inputs and constructive discussions. Their expertise
and dedication have greatly enriched my understanding of the subject matter and have
contributed to the overall quality of this thesis.
I would like to acknowledge the contributions of my colleagues and fellow researchers who
provided valuable insights, shared resources, and engaged in thought-provoking discussions.
Their collaboration and camaraderie have made this research journey both stimulating and
enjoyable.
I would like to express my heartfelt appreciation to my family for their unwavering love,
encouragement, and understanding throughout my academic journey. Their constant support
and belief in my abilities have been a source of inspiration and motivation. To all those
mentioned above and to anyone else who has contributed in any way to the completion of this
thesis, I offer my deepest gratitude. Your support and encouragement have been vital, and I am
truly thankful for your presence in my academic and personal life.

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 Abstract
In the search for sustainable energy sources and the reduction of carbon emissions, solar energy
has emerged as a promising renewable energy source. However, compared to traditional energy
sources, solar technology faces a number of difficulties. In addition to variations in the intensity
of the sun, panel orientation, overheating, and natural shade, soiling, or the buildup of dirt,
dust, and other organic or inorganic particles on panel surfaces, can significantly reduce the
efficiency and performance of solar panels. In order to maintain optimal power generating
efficiency, solar panels need to be cleaned frequently. Contrarily, manual cleaning procedures
are time-consuming, expensive, and labor-intensive, necessitating the creation of an automated
system that can. Solar panels must be cleaned on a regular basis if maximum efficiency in
power generation is to be maintained. Manual cleaning methods on the other hand are labor-
intensive, time-consuming, and costly, making it necessary to develop an automated system
that can efficiently clean solar panels without human intervention. This thesis focuses on the
development and evaluation of an automated solar panel cleaning system to improve the
efficiency of solar power plants by implementing a low-cost environmentally friendly method
of addressing the problem of soiling thus, lowering the consumption of water, energy and the
hiring of labor. The cleaning mechanism will include a microcontroller, roller brush, water tank
and a sprayer to remove all dirt and grime from the panel’s surfaces.

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 List of Figures
FIGURE 2-1: NATURAL SOLAR PANEL CLEANING METHOD ..................................................................................... 8
FIGURE 2-2: MANUAL SOLAR PANEL CLEANING METHOD .................................................................................... 10
FIGURE 2-3: ECOPPIA E4 AUTOMATED SOLAR PANEL CLEANING MACHINE ........................................................... 11
FIGURE 3-1: MARKET ANALYSIS QUESTIONNAIRE RESULTS .................................................................................. 14
FIGURE 3-2: SOLID EDGE DRIVESHAFT DISPLACEMENT ANALYSIS......................................................................... 23
FIGURE 4-1: SPECIFICATION PREFERENCES RESULTS ............................................................................................. 25
FIGURE 4-2: TECHNICAL CONSIDERATION RESULT ................................................................................................ 26
FIGURE 4-3: DETAILED DESIGN ............................................................................................................................. 27
FIGURE 4-4: TYPICAL IV CURVE OF A SOLAR PANEL SHOWING MPP .................................................................. 28
FIGURE 4-5: IV CURVE COLLECTED BY SOLMETRIC ANALYZER ........................................................................... 29

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 List of tables
TABLE 1: PRODUCT DESIGN SPECIFICATIONS ........................................................................................................ 15
TABLE 2: FUNCTIONAL DESCRIPTION OF MACHINE UNITS ...................................................................................... 15
TABLE 3: MORPHOLOGICAL CHART ...................................................................................................................... 16
TABLE 4: PUGH'S MATRIX FOR CONCEPT SELECTION ............................................................................................. 17
TABLE 5: PUGH’S MATRIX FOR MATERIAL SELECTION FOR THE MOUNTING STAND ............................................... 19
TABLE 6: PUGH’S MATRIX FOR MATERIAL SELECTION FOR THE ROLLING BRUSH ................................................... 19

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 Table of Contents
Declaration .............................................................................................................................................. ii
Approval ................................................................................................................................................ iii
Dedication .............................................................................................................................................. iv
Acknowledgements ................................................................................................................................. v
Abstract .................................................................................................................................................. vi
Chapter 1: Introduction ........................................................................................................................... 1
Background ......................................................................................................................................... 1
1.2 Problem Statement .................................................................................................................. 2
1.3 Relevance of the Project ......................................................................................................... 3
1.4 Aim ......................................................................................................................................... 4
1.5 Objectives ............................................................................................................................... 4
1.6 Scope ....................................................................................................................................... 4
1.7 Limitations .............................................................................................................................. 5
1.8 Report Organization ................................................................................................................ 5
Chapter 2: Literature Review .................................................................................................................. 6
2.1 Importance of solar panel cleaning include ............................................................................ 7
2.2 Natural solar panel cleaning methods ..................................................................................... 7
2.2.1 Advantages ...................................................................................................................... 7
2.2.2 Limitations and Challenges ............................................................................................. 8
2.3 Manual solar panel cleaning methods ..................................................................................... 9
2.3.1 Advantages ...................................................................................................................... 9
2.3.2 Limitations and Challenges ............................................................................................. 9
2.4 Automatic solar panel cleaning methods .............................................................................. 10
2.4.1 Advantages .................................................................................................................... 10
2.4.2 Limitations and Challenges ........................................................................................... 11
Chapter 3: Methodology ....................................................................................................................... 12
3.1 Literature Review.................................................................................................................. 12
3.2 Market Analysis .................................................................................................................... 13
3.3 Product Design Specification (PDS) ..................................................................................... 14
3.4 Model Detailed Design ......................................................................................................... 15
3.4.1 Morphological chart ...................................................................................................... 16
3.4.2 Concept Selection Evaluation ....................................................................................... 16
3.5 Material Selection and Specification .................................................................................... 18
3.6 Prototype Fabrication and Assembly .................................................................................... 20
3.7 Testing and Performance Evaluation of the Prototype ......................................................... 20
3.7.1 Pump Selection ............................................................................................................. 20
3.7.2 Drive Shaft determination ............................................................................................. 22

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Chapter 4: Findings and Results ........................................................................................................... 24
4.1 Literature review and Survey ................................................................................................ 24
4.2 Market Analysis .................................................................................................................... 25
4.3 Quality Functional Deployment (FQD) ................................................................................ 25
4.4 Detailed design...................................................................................................................... 27
4.5 Implementation ..................................................................................................................... 27
4.6 Testing................................................................................................................................... 28
4.7 Testing Results ...................................................................................................................... 29
4.8 Observations and Proposed Mitigations ............................................................................... 29
Chapter 5: Conclusion and Recommendations ..................................................................................... 30
5.1 Conclusion ............................................................................................................................ 30
5.2 Recommendations ................................................................................................................. 30
5.3 Proposed Future Works......................................................................................................... 31
References ............................................................................................................................................. 32
Appendices............................................................................................................................................ 33

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 Chapter 1: Introduction
4.1 Background
Solar energy is a clean and renewable source of power that plays a vital role in mitigating
environmental challenges and meeting the increasing global energy demand. Solar panels, also
known as photovoltaic (PV) modules, are the primary components used to convert sunlight into
electricity. Solar panels play a crucial role in renewable energy generation. However, the
performance of solar panels can be significantly hampered by various factors, including dust,
debris, and other contaminants that accumulate on their surfaces over time. Dust and debris on
solar panels create a barrier that reduces the amount of sunlight reaching the photovoltaic cells.
This obstruction leads to a decrease in energy generation efficiency, resulting in lower power
output and financial losses for solar power plant operators. Additionally, the accumulation of
dirt on solar panels can cause hotspots and potential damage to the panels, further impacting
their performance and lifespan. Manual cleaning methods are time-consuming, costly, and
often impractical, especially for large-scale solar installations.
This thesis presents the design and development of a semi- automated solar panel cleaning
system to address the challenge of dust and debris accumulation on solar panels, which
significantly reduces their energy generation efficiency. The research focuses on optimizing
the cleaning process, maximizing energy output, and ensuring the system's efficiency and
reliability. The proposed system employs an intelligent robotic mechanism equipped with
cleaning modules to autonomously remove contaminants from solar panels, ensuring optimal
performance.
The research begins with a comprehensive literature review on solar panel performance
degradation and existing cleaning technologies. The review highlights the limitations and
challenges associated with manual and automated cleaning methods. Based on the findings, a
detailed system design and architecture are proposed, considering factors such as cleaning
mechanism selection, robotic navigation, control and automation systems, sensor integration,
and communication protocols. To optimize the cleaning process, the thesis explores various
techniques for dust detection and analysis, as well as efficient cleaning methods. Factors such
as cleaning frequency, scheduling, and water usage are also addressed to strike a balance
between cleaning effectiveness and resource conservation. The energy efficiency and
performance evaluation of the automated cleaning system are conducted, comparing its results
with those of manual cleaning methods. System reliability, maintenance requirements, and
environmental impact assessments are also performed to ensure sustainable operation.
A working prototype of the automated solar panel cleaning system is developed and tested.
The hardware implementation includes the integration of cleaning modules, sensors, and
control mechanisms. The prototype undergoes rigorous testing and validation to assess its
cleaning efficiency, energy generation enhancement, reliability, and maintenance needs. The
results and discussion chapter presents findings related to the cleaning efficiency, energy
output enhancement, and comparative analysis with manual cleaning methods. The thesis
concludes with a summary of the contributions to the field, implications, and recommendations
for future research. Overall, this research provides valuable insights into the design,
development, and performance evaluation of an automated solar panel cleaning system, paving
the way for increased efficiency and sustainability in solar energy generation.

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 1.2 Problem Statement
The accumulation of dust, dirt, and debris on the surfaces of solar panels poses a significant
problem for solar power generation. These contaminants act as barriers, reducing the amount
of sunlight reaching the photovoltaic cells and hindering the panels' performance. As a result,
the energy generation efficiency of solar panels decreases, leading to lower power output and
financial losses for solar power plant operators.
The existing manual cleaning methods used to maintain solar panel cleanliness have several
limitations. Firstly, manual cleaning is labor-intensive and time-consuming, requiring
significant manpower and resources, especially for large-scale solar installations. This
translates into higher operational costs and increased maintenance efforts. Additionally,
manual cleaning operations may not be feasible in remote or inaccessible locations, limiting
the effectiveness of cleaning efforts in such areas. Furthermore, manual cleaning methods are
not always efficient in removing stubborn stains, grime, or contaminants that may require
specialized cleaning techniques or equipment. This can result in suboptimal cleaning outcomes,
leading to persistent dust residues and reduced energy generation efficiency. Another challenge
associated with manual cleaning is the safety risk it poses to maintenance personnel. Working
at heights to clean solar panels can be dangerous and increases the potential for accidents or
injuries.
To address these challenges, an automated solar panel cleaning system needs to be developed
that overcomes the limitations of manual cleaning methods. This system should be capable of
autonomously removing dust, dirt, and debris from solar panels, ensuring their optimal
cleanliness, maximizing energy generation efficiency, and reducing maintenance efforts and
costs. By developing an automated solution, the goal is to enhance the performance and
viability of solar power generation while promoting the adoption of clean and sustainable
energy technologies.

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 1.3 Relevance of the Project
Traditionally, manual cleaning methods involving the use of water, brushes, or cleaning
equipment have been employed to maintain the cleanliness of solar panels. However, manual
cleaning is labor-intensive, time-consuming, and expensive, especially for large-scale solar
installations. Furthermore, manual cleaning operations may not be practical in remote or
inaccessible locations, and they can pose safety risks for maintenance personnel working at
heights. The limitations of manual cleaning methods have driven the need for automated solar
panel cleaning systems. These systems utilize robotics and intelligent technology to
autonomously clean the surfaces of solar panels, improving their efficiency and reducing
maintenance costs. By implementing an automated cleaning solution, solar power plant
operators can optimize energy generation, minimize downtime for cleaning operations, and
enhance the overall performance of their installations.
The motivation behind this research is to address the challenges posed by dust and debris
accumulation on solar panels and develop an effective and efficient automated solar panel
cleaning system. By designing and developing a reliable and intelligent robotic mechanism,
this thesis aims to provide a solution that significantly improves the cleanliness and
performance of solar panels while minimizing the associated costs and safety risks. The
development of an automated solar panel cleaning system holds great potential for the
renewable energy sector. It can enhance the viability and competitiveness of solar power as a
sustainable energy source, promote the adoption of solar technologies on a larger scale, and
contribute to achieving global energy sustainability goals. Furthermore, an automated cleaning
system reduces the dependency on manual labor, allowing solar power plant operators to
optimize their resources and focus on other critical aspects of their operations. By addressing
these challenges, the research contributes to the advancement of solar energy technology and
facilitates the widespread adoption of clean and sustainable power generation.

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 1.4 Aim
To design and develop a semi-automated solar panel cleaning system that efficiently and
effectively removes dust, dirt, and debris from solar panels, thereby improving their energy
generation efficiency and performance. To design and manufacture a solar panel cleaning
system that minimizes human intervention by operating automatically in order to maintain a
high level of efficiency of the solar panel.
1.5 Objectives
The main objectives of this research are as follows:
 To conduct a comprehensive review of existing automated solar panel cleaning
technologies, considering their advantages, limitations, and technological
advancements.
 To determine a suitable cleaning material in order to optimize the cleaning process by
evaluating different cleaning techniques and methods, considering factors such as
cleaning frequency, scheduling, and water usage.
 To design a suitable mounting system and carry out stress analysis using Solid Edge
in order to enhance the reliability, maintenance requirements, and environmental
impact of the automated solar panel cleaning system.
 To develop a working prototype of the automated cleaning system and evaluate the
performance to ensure its functionality, efficiency, and safety.
By accomplishing these objectives, this research aims to contribute to the development and
advancement of automated solar panel cleaning systems, providing a reliable, efficient, and
cost-effective solution to maintain the cleanliness and performance of solar panels. The
research outcomes will aid in optimizing energy generation efficiency, reducing maintenance
efforts and costs, and promoting the widespread adoption of solar power as a clean and
sustainable energy source.

1.6 Scope
The scope of this research encompasses the design and development of an automated solar
panel cleaning system with the aim of enhancing the performance and energy generation
efficiency of solar panels. The research focuses on the following aspects:
 Design and Architecture: The research includes the design and development of an
intelligent robotic mechanism capable of navigating, positioning, and cleaning solar
panels autonomously. This involves selecting appropriate cleaning modules,
integrating control and automation systems, and incorporating sensors for dust
detection and analysis.
 Cleaning Process Optimization: The research explores various cleaning techniques and
methods to optimize the cleaning process. Factors such as cleaning frequency,
scheduling, and water usage are considered to achieve effective and resource-efficient
cleaning.
 Energy Efficiency and Performance Evaluation: The research evaluates the energy
output and performance enhancement achieved by the automated cleaning system.
Comparative analysis with manual cleaning methods is performed to assess the system's
efficiency in improving energy generation.

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  Reliability and Maintenance: The research addresses the reliability and maintenance
requirements of the automated solar panel cleaning system. System durability,
maintenance intervals, and the need for periodic inspections are considered to ensure
long-term performance.
 Environmental Impact Assessment: The research assesses the environmental impact of
the automated cleaning system, particularly regarding water usage and conservation.
Environmental sustainability considerations are taken into account during the system's
development and operation.

1.7 Limitations
Despite the comprehensive scope of this research, certain limitations should be
acknowledged:
 Climatic Variations: The research focuses on the development of an automated solar
panel cleaning system that primarily addresses dust and debris accumulation. Other
climatic factors, such as snow or extreme weather conditions, which may affect solar
panel performance, are not specifically considered in this study.
 Commercial Viability: While the research aims to design and develop a functional
prototype, the commercial viability and scalability of the automated cleaning system
may require further evaluation and market analysis beyond the scope of this research.
 Site-Specific Considerations: The research considers general site conditions and solar
panel configurations. However, specific site characteristics, such as topography,
shading, and installation layout, may influence the performance and feasibility of the
automated cleaning system and are not extensively examined.
 Cost Analysis: While the research acknowledges the goal of reducing maintenance
costs, a detailed cost analysis, including system implementation, operation, and
maintenance, is beyond the immediate scope of this study. Further cost assessment and
economic analysis may be necessary to provide a comprehensive understanding of the
system's financial implications.
Despite these limitations, this research endeavors to contribute valuable insights and
advancements in the development of automated solar panel cleaning systems, addressing the
need for improved performance, efficiency, and maintenance in solar power generation.
1.8 Report Organization
The project will highlight the most prominent factor that affect solar power output and the solar
panel cleaning device that was developed as a solution to reducing dust soiling on solar panels.
This thesis is made up of six chapters. The outline is as follows;
Chapter 1: Introduction
This chapter provides an overview of the research topic, presenting the background and
motivation for developing an automated solar panel cleaning system. The problem statement
and research objectives are defined, outlining the scope and limitations of the study.
Chapter 2: Literature Review
In this chapter, a comprehensive literature review is conducted to explore the factors
contributing to solar panel performance degradation, the limitations of manual cleaning

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methods, and the existing automated solar panel cleaning technologies. The review highlights
the gaps in current research and sets the foundation for the proposed system design.
Chapter 3: Methodology
The chapter details the development and testing of a working prototype of the automated solar
panel cleaning system. It covers the hardware implementation, software development, and
integration of the cleaning modules, sensors, and control mechanisms. Rigorous testing and
validation are performed to ensure the functionality, efficiency, and safety of the prototype.
Chapter 4: Results and Discussion
In this chapter, the results of the prototype testing and performance evaluation are presented
and discussed. The findings related to cleaning efficiency, energy output enhancement,
comparative analysis with manual cleaning, system reliability, maintenance requirements, and
environmental impact are discussed in detail.
Chapter 5: Conclusion and Recommendations
The final chapter summarizes the research findings and contributions to the field of automated
solar panel cleaning systems. It reiterates the significance of the research objectives and
discusses the implications of the findings. Recommendations for future research directions and
system improvements are provided, concluding the thesis.

Chapter 2: Literature Review

Zambia as part of its renewable energy targets has been progressively adopting renewable
technologies such as solar panels and has set ambitious targets for renewable energy
deployment as part of its efforts to reduce dependence on fossil fuels and mitigate the effects
of climate change. The country aims to increase its share of renewable energy in the energy
mix to 50% by 2030, with a longer-term goal of achieving 100% renewable energy by 2050.
So we have seen solar installations in residential homes and also in industries as well as in
commercial sectors. However, the efficiency or the amount of power that these solar panels are
able to deliver is reduced due to particles induced by certain factors that tend to settle on these
solar panel surfaces and thus reduce the amount of light that is transmitted onto the solar cells.

The efficiency of solar energy produced by photovoltaic modules can be affected by two main
factors: environmental - such as humidity, wind speed, precipitation, and temperature - and
non-environmental, which takes into account factors such as atmospheric pollution, dust
accumulation, and bird droppings. Among these, the leading factors that negatively affect the
performance of PV cells that lead to the poor functionality of solar panels is the accumulation
of dust and pollutants on the cell surface, which acts as a barrier between PV and irradiation
(Chaichan et al., 2015). Dust impact on PV productivity is one of the most important problems
facing PV utilization in dusty countries. Besides, the amount of dust suspended in the air, which
reduces PV productivity in desert areas, which enjoy high irradiation and large spaces, and
suitable for the construction of PV stations as claimed by (Dida et al., 2020). It is found that
8.41% reduction in the maximum power occurred in dusty PV module compared with cleaned
one. In addition, many contaminants and dirt resulting from human activities are suspended in
the air. All suspended atmospheric substances such as sand, dust, pollutants, smoke, dirt,
pollen, etc. are expressed in most studies as dust and their accumulation on PV deteriorate these
cells’ performance. Also, the dust ingredient have important impact on the reduction in PV

6
power and efficiency as claimed by (Chen et al., 2020). However, many solar panel cleaning
methods have been proposed to improve the efficiency.

This paper “aims to review the importance of cleaning solar panels, classify and discus the
most common significant and recent developments in the solar panel cleaning systems designed
and fabricated to overcome problems associated with dust accumulation. Furthermore, a
comprehensive review of the automatic cleaning systems is conducted. The features of each
system are explained, and the advantages and disadvantages are compared in detail. Leading
indicators of the system, including simplicity, cost, effectiveness and efficiency, safety, water
usage, cleaning time, and human interference, are considered when choosing an optimal
cleaning system.
In general, the main cleaning mechanisms are categorized as follows;
 Natural
 Manual
 Automated.

2.1 Importance of solar panel cleaning include

 Increased efficiency: By removing dirt, dust, and debris from the surface of solar
panels, the cleaning system can improve the efficiency of the panels, leading to an
increase in power output and energy generation.
 Longer lifespan: By regularly cleaning solar panels, the cleaning system can help
to extend the lifespan of the panels by preventing damage from accumulating
debris and contaminants.
 Cost savings: By reducing the need for manual cleaning and maintenance, the
cleaning system can save time and labor costs. Additionally, by increasing the
efficiency of the panels, the system can help to reduce energy costs over time.
 Improved environmental impact: The use of a solar panel cleaning system can
help to reduce the environmental impact of solar energy production by
maximizing the energy generation of each panel and reducing the need for
additional panels to be installed.
 Improved safety: By utilizing an automated cleaning system, the project can
improve the safety of maintenance workers by reducing the need for them to
climb onto rooftops or work in other hazardous conditions

2.2 Natural solar panel cleaning methods

It is the easiest cleaning technique as it utilizes natural elements and phenomena like rain and
wind to naturally clean the modules. Studies indicate that tremendous amounts of rain and wind
with high velocity is an effective technique for cleaning the modules from the accumulated
dust to effectively regain their productivity. These methods can offer advantages, but they also
come with limitations and challenges.
2.2.1 Advantages
 Natural cleaning methods require little to no additional resources, such as water,
cleaning agents, or labor, resulting in cost savings over time.

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  Natural cleaning techniques do not involve the use of chemicals or additional energy,
making them eco-friendly and reducing the environmental impact of solar panel
maintenance.
 Natural cleaning methods are generally gentle and unlikely to cause damage to the solar
panel surface, as they do not involve abrasive tools or high-pressure water jets.
 In some regions, natural cleaning processes are reliable and regular, ensuring a more
consistent cleaning schedule without human intervention and ideal for remote solar
installations where regular manual cleaning may not be practical.
2.2.2 Limitations and Challenges
 With natural cleaning techniques, there is little or no control over when and how the
cleaning process occurs and the efficiency of natural cleaning techniques heavily
depends on the local climate and environmental conditions. In areas with low rainfall
or high levels of airborne pollutants, self-cleaning may be less effective.
 Natural cleaning methods, like rainwater cleaning may be less frequent or ineffective
during dry seasons or periods of reduced precipitation and wind velocity depends on
the installation height and when the velocity of the wind is low it will only add dust
particles to the panel’s surface instead of cleaning it.
 Incomplete cleaning is possible as natural methods may not remove all types of debris,
such as dried bird droppings or stubborn stains, leading to potential efficiency losses.
 Accumulation of minerals that rainwater may contain leave residues on the solar panels
after evaporating, which could impact performance over time.
Therefore, natural cleaning methods are not considered to be an effective and efficient way
of cleaning solar modules. The figure below depicts natural solar panel cleaning method.

Figure 2-1: Natural Solar Panel Cleaning Method

Source (Kumarkhaniya, 2017)

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2.3 Manual solar panel cleaning methods
Employs traditional cleaning methods such as water cleaning, brush cleaning, and manual
wiping. Hence, It is the most common solar panel maintenance technique and it usually requires
water, detergent, hoses, brushes, extension poles and cloth, tools which are available
everywhere. While this approach has been widely used in the past, it comes with its own set of
advantages, limitations, and challenges.
2.3.1 Advantages
 Manual solar panel cleaning technique has a low negative impact on the environment
and the cleaning components are easy to access making it generally more cost-effective
as the initial investment is lower and does not require complex machinery or automation
than automated cleaning systems.
 Manual cleaning is flexible as it allows operators to focus on specific areas that may
need more attention. They can target stubborn stains, bird droppings, or debris
directly, leading to better cleaning results.
 In countries like Zambia with high unemployment rate, manual cleaning can create
employment opportunities for the local communities.

2.3.2 Limitations and Challenges

 Manual cleaning is labor-intensive and time-consuming, especially for large scale
solar installations. It may require a dedicated workforce, which could increase
operational costs.
 Cleaning solar panels manually involves working at heights, which can pose safety
risks for the workers who tend to manually climb up high-rise building roofs where
the modules are mounted and try to wash these panels manually. This calls for
adequate safety measures and training are necessary to mitigate potential accidents.
 Manual cleaning can lead to inconsistent results as the efficiency of manual cleaning
can vary depending on the skill level of the operators. Inconsistent cleaning may lead
to uneven performance of solar panels.
 The use of cleaning agents in manual techniques may lead to the release of pollutants
into the environment if not managed properly.
 Manual cleaning is weather-dependent and can be hindered during adverse weather
conditions such as heavy rain or extreme temperatures and the regularity of cleaning
required depends on the local environmental conditions, which can vary greatly from
one location to another.
 Solar panels installed in remote or difficult-to-reach areas may be challenging to clean
manually. The figure below depicts manual solar panel cleaning method.

9
 Figure 2-2: Manual Solar Panel Cleaning Method
Source (Glenn, 2019)
2.4 Automatic solar panel cleaning methods
As solar technology advances, automated cleaning systems are becoming more prevalent,
offering a solution to some of the challenges associated with manual cleaning. Nevertheless,
the choice between manual and automated cleaning depends on the specific requirements and
characteristics of the solar installation. Existing automated solar panel cleaning technologies
and systems that automate the process of cleaning include robotic systems like, water-based
robots, water-less robots and mechanical cleaning devices like automated sprinklers and other
computer controlled devices.
Currently there exist a number of solutions for eliminating the effect of soiling on solar panels.
The choices for automated cleaning solutions are numerous but impractical for most
applications. The current automated systems, such as, the Kolchar X2 created by Sol-Bright
and the Ecoppia E4, are large and expensive, as shown in figure 03 . These systems are typically
only feasible on massive solar farms where the large number of panels cleaned offsets their
large costs. When it comes to cleaning solar panels on a smaller scale, other less efficient
systems are commonly used.
2.4.1 Advantages
 Automatic cleaning systems can clean solar panels more frequently and consistently
than natural and manual methods, ensuring optimal energy generation and efficiency.
 With automatic cleaning, there is no need for manual labor, which reduces operational
costs and frees up human resources for other tasks making it time and labor saving.
 Automated systems allow for customization of cleaning schedules, allowing operators
to optimize cleaning cycles based on weather conditions and soiling levels.
 Automatic systems eliminate the need for workers to access the rooftop or working at
heights, reducing safety risks associated with manual cleaning.

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  While the initial investment in automatic cleaning systems may be higher, the long-
term cost-effectiveness is often greater due to improved panel performance and
reduced maintenance expenses.
2.4.2 Limitations and Challenges
 The installation of automatic cleaning systems can be costly, especially for small-
scale solar installations.
 Automatic cleaning systems require regular maintenance to ensure their effectiveness.
Any malfunctions or breakdowns could lead to temporary inefficiency or additional
expenses.
 Some automatic systems may consume energy to operate, which could slightly offset
the energy gains from cleaner solar panels.
 More advanced automatic cleaning systems may be complex, requiring specialized
knowledge for operation and maintenance.
 Compatibility with panel technologies: Some automatic cleaning systems may not be
suitable for all types of solar panel technologies, such as thin-film panels or
concentrating solar systems.
 Different regions may require different cleaning mechanisms, therefore automatic
cleaning systems need to be designed to handle various types of soiling and weather
conditions effectively.
 Some automatic systems may use water for cleaning, which could be a concern in
water-scarce regions or may result in mineral deposits on the panels and if cleaning
agents are used in the automatic systems, choosing environmentally-friendly options
is crucial to prevent harm to the environment. The figure below depicts natural solar
panel cleaning method

Figure 2-3: Ecoppia E4 Automated solar panel cleaning machine

Source (Ecoppia)

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 Chapter 3: Methodology
To accomplish the objectives of this project, several methods, approaches and procedures were
undertaken. This involved a wide exploration of all possible designs. The morphological chart
was utilized to generate and record these design options, from which the final concept was
selected. Concept selection was more of a convergent thinking approach as it sought to adopt
one solution from among the many that were generated. In selection, a decision matrix was
employed (Pugh’s matrix); this helped in choosing the most optimal design concept based on
comparisons to a datum (competitor machine) and the set criterion. The matrix further ensured
that the selected concept met the critical customer and functional requirements.
The above approach was further broken down into seven major stages as outlined below
(Torres, 2001). Figure below summarizes the methodologies, approaches and procedures that
were employed during project identification, design and execution.
1. Literature Review
2. Market Analysis
3. Product Design Specification (PDS)
4. Model Detailed Design
5. Material Selection and Specification
6. Prototype Fabrication and Assembly
7. Testing and Performance Evaluation of the Prototype
4.2
3.1 Literature Review
The literature review was a continuous processes that lasted for several weeks. It was a
supportive process as it provided a broad perspective to examine the effects of dust
accumulation on solar module and different types of solar panel cleaning techniques
implemented to mitigate the accumulation of dust. The literature review involved the following
sources and strategies:
1. Research analysis: This involved reviewing relevant and credible academic articles,
books, reports, and dissertations that addressed the research problem and objectives.
The research analysis helped to identify the existing knowledge gaps, the theoretical
frameworks, the research designs, and the findings of previous studies on the topic.
2. Internet search: This involved using online databases, search engines, websites,
blogs, podcasts, and videos to find current and reliable information on the topic. The
internet search helped to access recent data, statistics, trends, opinions, and news
related to the topic. It also helped to find examples of best practices and innovative
solutions for solar panel cleaning.
3. Consultations: This involved seeking advice and feedback from experts, peers,
mentors, and stakeholders who had relevant experience or interest in the topic. The
consultations helped to gain insights, perspectives, suggestions, and recommendations
for the project. They also helped to validate and refine the research questions,
methods, and outcomes.
4. Comparative Case Studies: Examining multiple case studies that compare different
cleaning techniques and their outcomes in similar conditions. This allowed for a

12
 deeper exploration of the varying degrees of success and provided valuable insights
for practical implementation.
5. In-Field Observations: Engaging in direct observations of solar panel installations in
various environments to witness firsthand the effects of dust accumulation and the
methods used for cleaning. This approach provided practical insights and real-time
understanding of the challenges faced.
6. Experimental Prototypes: Designing testing and analyzing small-scale experimental
prototypes of cleaning systems to gain practical insights into their feasibility,
effectiveness, and potential challenges.

3.2 Market Analysis

As solar installations continue to grow, residential homeowners, commercial building owners,
and utility companies are adopting solar energy and the demand for efficient cleaning solutions
is rising. The market is driven by the need for eco-friendly, efficient, cost-effective, and low-
maintenance cleaning systems that enhance solar panel performance.
The choice to pursue the chosen project concept was the outcome of a thorough examination
that included qualitative as well as quantitative approaches. This technique helped in obtaining
a comprehensive grasp of the project's potential and impact.

Qualitative Analysis:
We started by talking to experts and professionals in the field of renewable energy and solar
technology. They shared insights about the challenges of maintaining clean solar panels and
the benefits of an automated cleaning system. We also researched existing information about
solar panel maintenance, environmental impact, and industry trends.

The questionnaire proved to be a helpful tool during the qualitative analysis and some of
questions asked were;
1. Have you experienced a drop in solar panel power output due to dust or dirt?
2. How often do you clean your solar panels
3. What challenges do you face in maintaining the cleanliness of your solar panels?
4. Would you be interested in a system that can automatically clean your solar panels?
5. How much do you think a system like this would be worth to you?
6. Are you aware of any existing solutions for automatic solar panel cleaning?
7. Do you think cleaner solar panels could lead to more energy savings?
8. Are there any specific features you would like to see in an automated cleaning system?
9. How important is environmental impact when considering solar panel maintenance?

The results obtained from the questionnaire can be shown in the pie chart below.

13
 Questionnaire Results
Cleaning Challenges
21%
Approved Semi-
Auto Cleaning
28%

Panel Cleaning
Every 2 Months
11%
Experience Power
loss from Soiling
40%

Figure 3-1: Market Analysis questionnaire results

Source (Author)
A significant number of respondents indicated experiencing a drop in solar power output due
to dust and dirt accumulation. Many mentioned that they currently clean their solar panels
manually, with the frequency ranging from a few times a year to once every few months. The
primary challenges reported included limited accessibility to panels, particularly when installed
on rooftops, the time-consuming nature of manual cleaning and difficulties faced during sunny
or hot days when manual cleaning was attempted. The intense heat and sunlight not only made
the task more physically demanding but also reduced the effectiveness of the cleaning process,
as the panels became hot and dried quickly.

A notable portion of participants displayed keen interest in a system that could automatically
clean their solar panels. The prospect of time savings and consistent maintenance resonated
strongly with respondents. When considering the potential value of such a system, participants
indicated a willingness to invest, with the condition that the solution proves to be effective

While some respondents were aware of existing automated cleaning solutions, there was
uncertainty about their effectiveness and availability in various regions. The majority of
participants recognized the link between cleaner solar panels and increased energy savings,
which aligns with the core motivation behind the project. Additionally, environmental impact
emerged as a significant consideration, with respondents emphasizing the importance of
maintaining optimal panel performance without harming the environment.

3.3 Product Design Specification (PDS)

The product design specification (PDS) helped set the design roadmap as it gave a clearer
conception of what the final machine must look like. It provided an opportunity to educate
customers about the product's functions, uses, advantages, and how it addresses their needs in
order for customers make informed purchasing decisions. This document was dynamic

14
throughout the design process i.e. it kept evolving and thus all the alterations made were
documented. Some of the key aspects considered are documented in the table below.
Performance  Speed
 Loadings
 Rate of working
Environment  Temperature, Pressure and Humidity range
 Shock loading
 Noise levels
 Vibrations
Maintenance  Easy access to spares
 Maintenance intervals
Product Size  Portability and Compactness
 Method of Assembly
 Weight
Materials  Use of Non Toxic Materials
 Corrosion free
Safety  Labelling
 Disposal of Waste
Product Lifespan  Tooling Policy
 Manufacturing Facility

Table 1: Product Design Specifications

Source (Author)
3.4 Model Detailed Design
The machine was broken down into simple functional units in order to lessen and simplify
work, and improve design effectiveness. The table below highlights the functional descriptions
of the developed machine segments.

Functional unit Description

Power transmission mechanism Modes of transmitting power e.g. gear drive, belt drive etc.
Power supply Type of current e.g. Alternating or Direct current
Drive unit Represents the motor and its start
Mounting system Methods of cycle counting e.g. sensor and digital counter
Pumping system Methods of pumping water to the system
Control system Microcontroller
Cleaning mechanism Rolling brush bristles

Table 2: Functional description of machine units

Source (Author)
15
 3.4.1 Morphological chart
The product design specifications were realized into conceptual designs. Several design
solutions were obtained, and using Pugh’s matrix, the best design was chosen. The
morphological chart was also utilized for generating these design concepts. This tool allowed
for divergent thinking in seeking for design solutions. Consolidated concepts were formed
by combining the design options in a column. However, concept crossing was allowed for
optimization. Once these concepts were generated, selection followed.

The table below shows the schematics for developed concepts using the morphological chart.

Function Concept 1 Concept 2 Concept 3

Power Belt and Pulleys Gears Chain Drive
Transmission
Mechanism

Fastening Bolts and Nuts Rivets Screws

Methods

Mounting System Pole-Mount Ground-Mount Roof-Mount

Pumping System Non Submersible Submersible Sprinkler

Table 3: Morphological Chart

Source (Author)
3.4.2 Concept Selection Evaluation
The Pugh chart is a criteria-based decision matrix which uses set criterion to determine which
of several potential design alternatives optimal (Pugh, 1991) is. The technique has become a
standard part of the six sigma methodology.

16
 Below is a simple step by step approach that was followed when using this matrix.

 Identify relevant user requirements or criteria.

 Develop weights for each of the requirements.
 Identify baseline design, usually competitor.
 Evaluate each design alternative against the baseline, scoring it as positive, negative or
equal in meeting the criteria.
 Total the values from each alternative, multiplying each value by its weight if the
optional scoring mechanism was used.
 Combine the best elements of each alternative to create an optimal hybrid solution.

The table below shows the Pugh’s matrix for concept selection evaluation that was developed
and only the top two concepts were considered in the evaluation process in order to come up
with a general conceptual design of the system.

Critical Consideration Weight Datum: R.R Concept 1 Concept 2

Moore
Rating Weighted Rating Weighted Rating Weighted
Score Score Score
Cost of manufacturing 25% 3 0.75 5 1.25 4 1
Energy consumption 8% 3 0.24 5 0.4 4 0.32
Robustness 10% 3 0.3 3 0.3 3 0.3
Cost of maintenance 10% 3 0.3 5 0.5 4 0.4
Easiness of operation 5% 3 0.15 5 0.25 4 0.2
Safe to operation 8% 3 0.24 4 0.32 4 0.32
Running time to specimen failure 15% 3 0.45 2 0.3 1 0.15
Speed of operation 4% 3 0.12 2 0.08 1 0.04
Machine lifespan 10% 3 0.3 3 0.3 3 0.3
Risk of injury 5% 3 0.15 4 0.2 4 0.2

Total Score 3 3.9 3.23

Rank 3 1 2
Procced with Concept? No Yes No

Table 4: Pugh's matrix for concept selection

Source (Author)
The concepts were compared to the datum using the following ratings system:
Where numbers 1, 2, 3, 4, 5 indicated comparisons of much worse, worse, same, better or much
better than reference, respectively. The weighted score was given as Weight X rating.

17
3.5 Material Selection and Specification
The Design for Manufacturing and Assembly (DFMA) material selection criterion was utilized.
In this approach, material selection process involves selecting materials that can meet the
design requirements while also considering manufacturing and assembly considerations. By
selecting appropriate materials and optimizing the design for manufacturing and assembly, it
is possible to create a solar panel cleaning system that is both efficient and cost-effective.
The first step was identification of the design requirements. This involved stating clearly the
objectives and constraints that the design was required to meet. The next step was analysis of
the component for which a material was sought, identifying performance with regard to the
fabrication and assembly requires. The final step involved screening of a database of materials
and their properties, eliminating those that failed to meet the constraints, and ranking those that
remained by their ability to maximize the performance matrices (Cross, 2021).
The figure on the next page summarizes this approach.

Identify the
design
requirements

Determine the
Conduct a manufacturing
final analysis
process

Evaluate
Optimize for
candidate
cost
materials

Consider
assembly
requirements

Figure 5: DFMA Material Selection Process

Source (Author)

The details of materials selection, involved screening of a database of materials and their
properties in identifying the suitable and most economical based upon anticipated production
run. The components of interest involved the cleaning rolling brush and the mounting stand
respectively.

18
The table below shows the Pugh’s matrix for material selection for the mounting stand that was
developed.
Factors Types of Materials
Aluminum Steel Stainless Steel
Durability and Strength -1 +1 +1
Corrosion Resistance +1 -1 +1
Ease of Installation +1 -1 -1
Recyclability +1 -1 -1
Weight +1 -1 -1
Cost -1 +1 +1
Availability -1 +1 +1
Maintenance +1 -1 -1

Sum of Positives (+1) +5 +3 +4

Sum of Positives (-1) -3 -5 -4
Overall Difference +2 -2 0
Rank 1 3 2

Table 5: Pugh’s matrix for material selection for the mounting stand
Source (Author)

Factors Types of Materials

Nylon-bristled brush Polyester-bristled brush Anti-static brush
Durability and Strength +1 -1 -1
Moisture Absorption +1 -1 -1
Quick Drying -1 +1 -1
Availability -1 +1 -1
Cost -1 +1 +1

Sum of Positives (+1) +2 +3 +1

Sum of Positives (-1) -3 -2 -4
Overall Difference -1 +1 -3
Rank 2 1 3

Table 6: Pugh’s matrix for material selection for the rolling brush
Source (Author)
The concepts were compared to the datum using the following ratings system:
 +1 and -1 entail that the concept is better or worse than the datum respectively
According to Table 5. When selecting metals for solar panel mounting stands, it's important to
consider factors such as strength, durability, corrosion resistance, and cost. In the table above,
Aluminum is the best metal for the stand. However, the choice between stainless steel and
19
aluminum depends on the specific requirements of the application. Stainless steel offers
superior strength, corrosion resistance, and aesthetics, making it suitable for applications where
durability and appearance are critical. Aluminum is lightweight, cost-effective, and versatile,
making it ideal for lightweight structures, transportation, and applications where weight
reduction is important.
When choosing a cleaning brush for PV module surfaces, it is important to avoid using abrasive
materials or stiff bristles that could scratch or damage the panels. It is also important to use a
brush that is the appropriate size for the panels being cleaned. Table 6 shows that Polyester-
bristle brush is the best cleaning material for the solar panels.
3.6 Prototype Fabrication and Assembly
This chapter is explained with the head of manufacturing plan. Manufacturing defines the
process of production from raw or semi- raw materials to a finished product ready for sale.
For something to be considered “manufactured”, it must have raw materials that have gone
through a set process and transformed into a final product. The following are the series of
steps in the manufacturing plan
 Cutting
This is the technique used to achieve the desired size of raw material according to the
dimensions. The machine used was Grinding machine
 Welding
This is the technique used to assemble the individual parts after cutting. Welding
machine was used to achieve this task
 Surface finishing
The primary goal of surface finishing is to improve the appearance, durability,
corrosion resistance, and other mechanical properties of the product.
 Drilling
Drilling is a fundamental machining process in manufacturing that involves creating
holes in a workpiece using a rotating cutting tool called a drill bit.

3.7 Testing and Performance Evaluation of the Prototype

A prototype was built to verify that key aspects of the design functioned as expected. It was
essential to identify all the relevant manufacturing processes needed for successfully
completing the prototype. Concepts of design for manufacturing (DFM) and design for
assembly (DFA) were used to minimize as much as possible the cost of manufacturing by
selecting less complex and economical manufacturing processes. The figure below shows the
key considerations in design for manufacturing and assembly (Cross, 2021).
3.7.1 Pump Selection
The determination of the pump selection parameters for the prototype pump mainly focused
on factors like head, flow rate, and pump efficiency.
 Total Dynamic Head (TDH)
TDH is the sum of all the forces that the pump must overcome to move water from the source
to the destination. TDH includes:
• Elevation Head: The height difference between the pump and the panel surface.
• Friction Losses: Due to pipe length, fittings, and flow rate.

20
 • Velocity Head: Energy required to accelerate water to the desired flow rate.
TDH = Elevation Head + Friction Losses + Velocity Head
 Elevation Head
Elevation Head (m) = Height of Pump above Water Datum - Height of Pump above Panel
Surface.
 Friction Losses
This depends on pipe length, pipe diameter, and flow rate.
 Velocity Head
Velocity Head (m) = (Flow Rate (m³/s) / Cross-Sectional Area (m²)
Where;
Cross-Sectional Area = Panel Length (m) * Panel Width (m)
 Total Flow Rate
The flow rate is crucial to the system's operation. By providing effective dust and debris
removal, it directly affects how well the solar panel surface can be cleaned. By balancing the
flow rate, insufficient cleaning or water waste are avoided. This guarantees that the pump
functions successfully without unnecessary power consumption. Determining flow rate also
encourages wise management of water resources, minimizing waste. Additionally, it helps
maintain a cohesive effort to balance restrictions like water availability and pump capacity to
ensure the system effectively fulfills its objective.
Based on the Bernoulli's equation, the following formulae was used to estimate the required
flow rate for pumping water:
πd2
Q= V
4
Where:
• Q is the flow rate (in cubic meters per second, m³/s)
• d is the diameter of the pipe (in meters, m)
• V is the velocity of the water (in meters per second, m/s).
However, a relationship between flow rate, the frequency of cleaning the solar panel, water
velocity and the available water was also established. The relationship can be expressed as
follows:
W
F=
QT
Where:
F is the frequency of cleaning (cleanings per time period)
W is the available water in liters
Q is the flow rate in cubic meters per second
T is the time period (in seconds) between consecutive cleanings

21
 3.7.2 Drive Shaft determination
Determining the appropriate specifications for the rolling brush's shaft was of paramount
importance. The shaft not only supports the movement of the cleaning mechanism but also
ensures effective dust and debris removal. Taking into account factors such as torque,
material strength, and safety margins.
 Required Torque
With key parameters having being the maximum weight of the brush (W) and the radius of
the wheel (r). The required torque was determined using the formula:
Torque (T) = Frictional Force (F) × Radius (r).
 Torsional Strength
Torsional strength, also known as shear strength or torsional resistance, refers to the ability of
a material to withstand twisting or torsional forces without undergoing permanent
deformation or failure. This was determined with reference being the material selected
(aluminum) under the material selection process that was undertaken. The material’s
torsional strength was found to be 165MPa.
 Calculate Shaft Diameter
The diameter was determined using the torsional strength.
Torsional strength = (π/32) × (D^4) × (T/R)
Where,
D is the diameter of the shaft
R is the shaft radius.
 Calculate Shaft Length
The width of the solar panel to be cleaned was the key parameter in determining the shaft
length. However, for effective cleaning, a 10% percentage of overhang on each side was
considered.
Therefore, Shaft length was determined using the formula:
L = Panel Width + 2 × (10% of Overhang)
 Safety Margins
To ensure reliability and account for uncertainties, apply a safety factor was applied to
torque, diameter, and length calculations. A safety factor of 1.5 was chosen, therefore:
• Adjusted Torque = Torque × Safety Factor.
• Adjusted Diameter = Diameter × Safety Factor.
• Adjusted Length = Length × Safety Factor.

22
 3.7.2.1 Solid Edge Analysis of the Drive Shaft
Project space uses a drive shaft that spans the entire width of the device. The purpose of the
drive shaft is to transfer power from the motor to the wheels. The motor is located on one side
of the device where it turns a set of wheels. Another set of wheels needs to be turned by the
motor on the other side of the device, the drive shaft transfers the power to drive the second set
of wheels. The shaft is a ¼” in diameter and is 61.5” in length. Testing has to be done in order
to determine the amount that the shaft will twist due to being powered from only one side.
Excessive torsion will result in plastic deformation.

The shaft was simulated assuming the maximum possible driving torque of the motor. This
was done to determine whether a device malfunction such as becoming stuck while the motor
keeps turning would cause the drive shaft to fail.

The governing equation for the torque applied to the shaft is given in Equation 1. Torque is
proportional to the polar moment of Inertia, JT, and the shear stress, τ, while inversely
proportional to the radius of the cross section, r. It is also worthwhile to note the angular
displacement of a point on the end of the shaft. The angular displacement is a function of the
torque applied, T, the length of the rod, l, the polar moment of inertia of the cross section, J,
and the shear modulus, G. A modeling of the displacement analysis done in Solid Edge can be
seen in Figure 17.

Figure 3-2: Solid Edge driveshaft displacement analysis

Source (Author)

23
 The Mechanical Power Subsystem was tested by ensuring each section worked individually
as well as when interfaced with the other components. After fabrication each pulley was
checked for alignment and to make sure they are aligned across the span of the device.
Once the pulley arrangement were finished, the driving motor was attached to the Chassis
Subsystem with the Mechanical Power Subsystem and used to test the system without the
Cleaning Subsystem. Once it was determined the motor was able to drive the device along a
panel, so the subsystem was combined with the rest of the subsystems.
The results of the analysis on the drive shaft show a maximum deflection at 4.41 degrees. This
deflection will occur at the end farthest away from the motor. The maximum deflection before
the beam plastically deforms was calculated to be roughly 62 degrees. Our analysis shows that
the drive shaft can handle the torque of the motor.

Chapter 4: Findings and Results

The results obtained in this project were broadly divided into the following major categories,
namely; literature review, market analysis, detailed design and machine experimental test
results. The literature review focused on the impacts of soiling on the solar power output and
different mechanism deployed to mitigate its effects. In the market research data, emphasis was
placed on the product need establishment and quality functional deployment. Furthermore, the
detailed design results concentrated on machine component specification and overall system
analysis. The following were the results and findings obtained.

4.3 Literature review and Survey

1. Soiling is the major factor that reduced solar power output and to mitigate the impacts,
in residential homes, industries as well as commercial sectors different solar panel
cleaning methods are deployed especially manual cleaning in maintaining solar panel
efficiency and performance.
2. Automated cleaning systems were identified to be the most viable option to the problem
of soiling compared to manual cleaning methods in terms of cost-effectiveness and
energy yield.
3. The optimal cleaning frequency can vary depending on dust accumulation rates based
on environmental conditions, panel tilt angles, and locations.
4. The material selection for the cleaning brush in an automated solar cleaning system is
of significant importance due to its direct impact on the effectiveness, efficiency, and
safety of the cleaning process. The choice of brush material can influence the cleaning
performance, potential for damage to solar panels, durability, and overall system
reliability.
5. Mounting stands are essential in solar installations. Their importance lies in providing
a secure and stable platform for solar panels, optimizing their performance, ensuring
safety, and facilitating maintenance.
6. Common challenges faced by automated cleaning systems, such as navigation
obstacles, maintenance requirements, and adverse weather conditions were identified.

24
4.4 Market Analysis
We conducted a survey to gather insights and preferences regarding an automated solar panel
cleaning system. The survey aimed to understand participant opinions on cleaning frequency,
mechanisms, control methods, environmental considerations and system maintenance.
The following pie chart report summarizes the responses received.

Survey Results
Cleaning Challenges
Approved Semi- 21%
Auto Cleaning
28%

Panel Cleaning
Every 2 Months Experience Power
11% loss from Soiling
40%

Figure 4-1: Specification preferences results

Source (Author)
The survey results indicate a strong interest in automated solar panel cleaning systems that
offer flexibility, efficiency, and environmental responsibility. Participants expressed
preferences for manual and remote control options, innovative cleaning mechanisms, and
water-conserving solutions. Hence the need for the development of a semi-automated solar
panel cleaning system that meets user needs and expectations.

4.5 Quality Functional Deployment (FQD)

The QFD exercise approach involved a prioritized list of technical parameters that could be
controlled to satisfy the customer needs and requirements to be effectively translated into
design and production specifications provided. The sum of relative weights in figure 4-2 (%
contributions) for the top six requirements showed that these accounted for 89.4% of the total.
Although other requirements were not to be totally ignored, this result implied that focusing
only on these top six parameters would help meet 89.4% of the customer's needs. Clearly, this
reduced the number of design variables, which implied reduction in the cost of manufacturing.

25
 Critical Technical Consideration
120%
100%
80%
60%
40%
20%
0%

Figure 4-2: Technical consideration result

Source (Author)
4.1 Design calculations
The calculations provided in this chapter resulted from the analysis of equations presented in
chapter 3.5. These calculations helped in making informed decisions about component sizing,
material selection, performance expectations, and overall feasibility of the project.
PUMP
 With pipe diameter of 1mm and an average water velocity from analysis and
literature
Hf = 0.001m
 Considering the stand length (0.65m), point of pump submission and panel area of
0.147m2, hence from equation…
TDH=9.2m
 Now the determination of flow required careful analysis of the frequency of
cleaning needed for the system effectiveness.
 Taking into account a cleaning frequency (F) of once every 2weeks (14days).
From analysis, 20litres was taken as the available water quantity (W) and a time
period of 15seconds.
Q= 0.03l/s
The flow rate was adopted because there was need for the panel to get wet for the
debris to get soaked so that the force needed to be exerted by the brushes is
minimum.

26
4.6 Detailed design
The figure below shows the fabricated solar cleaning machine. The number of parts to
perform the same function as standard machines was kept as minimal as possible in order to
minimize manufacturing cost.

Figure 4-3: Detailed design

Source (Author)
4.7 Implementation
The prototype was initially designed to fit the size of the Reggie Power 15W Solar Panel model.
The panel was chosen due to its availability and cost for testing purposes. The length was taken
into consideration when fabricating the Chassis Subsystem. Once all of the subsystems were
completed, the prototype was assembled and prepared for testing.
While assembling the prototype, time was taken to secure the Mechanical Subsystem to the
Cleaning Subsystem. Due to the stress from the brushes on the Cleaning Subsystem and the
small contact area with the pulleys in the Mechanical Subsystem, the connection between these
two subsystems was an area showing higher stress concentrations and the highest possibility
for failure.
To fully secure the subsystem’s together, the pulleys used in the Mechanical Subsystem were
pinned to the shaft of the Cleaning Subsystem to prevent any possible slipping of the shaft
within the gear. Additionally, the remaining pulleys were pinned to their shafts to prevent the
problem from occurring anywhere within the pulley train.
Once the Mechanical Subsystem and Cleaning Subsystem were secured, the rest of the system
was assembled and the prototype was ready for testing.

27
4.8 Testing
Due to the nature of the design project, significant time was taken to test the prototype and
ensure it was successful in reducing the effect of soiling on panels. The system was tested using
two solar panels; one of the panels was a control that was not dirtied and the other panel was
artificially soiled and cleaned using the system. By comparing two panels at the same time, the
results were not affected by the amount of incoming irradiance fluctuating during the time
taken to test. The incoming irradiance was also measured and recorded to use in the analysis
of the data.
In order to test the effectiveness of the device, a panel that was soiled was needed. Since
waiting for a panel to get soiled naturally would have required a large amount of time, a method
was used to artificially soil the panels. The panels were dirtied by spreading naturally found
dirt on the surface of the panel. The dirty remained on the panel in a way that is common on
naturally soiled panels. The efficiency drop of the panel was similar to that found in the
research, around 15%, indicating the process was a good replica of natural soiling.

The data that was collected during the tests was the Maximum Power Point (MPP) of the
solar panels. Since the output voltage and current of a panel are related to each other by the
load across the panel by Ohm’s Law, the load across the panel can change the amount of
power outputted by the panel. Figure 26 shows a typical IV curve of a solar panel and the
combination of current and voltage that generates the MPP of the panel.

Figure 4-4: Typical IV Curve of a Solar Panel Showing MPP

Source (Author)
The MPP was chosen as an indicator of a solar panel’s performance because of its consistent
relation to the actual power that can be delivered by the panel as well as its tie to the power
generated by solar arrays in commercial use. In any application of solar panels for power
generation, the panel system uses a device that tracks the MPP of the panels to output the
maximum energy possible over the course of the day.

28
The MPP was measured using the Solmetric Analyzer software that records the IV curve of a
panel. The device also records different characteristics of the panel such as the MPP, the
voltage and current at the MPP, the open circuit voltage, and the short circuit current. The
Solmetric Analyzer collects the data of a panel in a matter of seconds, allowing the team to
record multiple measurements of both the control and the panel that was tested on within a
very small time frame. Using the Solmetric Analyzer reduced the effect of the time difference
affecting the results.
Figure 27 shows the IV curve that is outputted by the Solmetric Analyzer.

Figure 4-5: IV Curve Collected by Solmetric Analyzer

Source (Author)
4.9 Testing Results
Using the data collected, the percentage increase was calculated. The results showed that the
efficiency increase was directly related to the number of passes the device ran over the panel.
After the device made two passes over the panel, which is one run of the system, a small
increase was found. However, after the device made another run, four passes over the panel in
total, there was an additional increase in panel efficiency. Therefore, results of the test show
that the amount of dirt that is removed is directly related to the number of passes the device
makes over the panel.
4.10 Observations and Proposed Mitigations
Upon analyzing the panel that the system was tested on, a pattern in the dirt left behind by the
device was noticed. There was a large amount of dirt left in the center of the panel suggesting
that the pressure along the length of the Cleaning Subsystem was not enough to hold the brush
against the panel along its entire length. Also, the brushes rotate at a slow rate leaving streak
marks of dirt behind showing where the brushes actually made contact. By increasing the RPM
of the brushes and the pressure along the cleaning subsystem, the amount of dirt taken off per
pass of the device can be increased.

29
 Chapter 5: Conclusion and Recommendations
5.1 Conclusion
The goal of the project was to design and develop a semi-automated solar panel cleaning system
that efficiently and effectively removes dust, dirt, and debris from solar panels, thereby
improving their energy generation efficiency and performance. Specifically, we hoped to create
a device that will increase the efficiency of a soiled by addressing the adverse impact of soiling
on photovoltaic cells with minimal human intervention. Furthermore, a successful design
should be environmental and user friendly by operating without wastage of water and require
only minimal maintenance.
The analysis of experimental data indicated that the developed machine was reliable for solar
panel cleaning. The current apparatus utilizes a brush cleaning system that cleans on set
cleaning cycles. It uses a rolling brush to clean as it horizontally translates across an array of
panels. The device is mounted on a set of powered-motorized wheels. At the end of the panel,
there would be a docking station.
Beyond improving the efficiency, we hope that our design will continue to expand the growth
of solar energy globally. An efficient cleaner would not only help communities’ transition
into using cleaner alternative fuel sources, but help society, as a whole, move closer toward
providing everyone the opportunity to harness reliable energy.

5.2 Recommendations
The current design functions relatively well, however there are several areas for improvement.
1. First and foremost is the cleaning system. The system only improves solar panel
efficiency.
2. Two modifications have been identified that would likely improved system
functionality. The cleaning brush currently spins at 36 RPM which, in testing, has
proven to be too slow to achieve the necessary cleaning effectiveness. To resolve
this issue, a new motor with sufficient RPM or a modified gear train ratio should be
implemented.
3. Another observation of the testing phase was the lack of cleaning effectiveness at
the center point of the brush. The working theory is that the brush is unable to exert
sufficient pressure at that point and requires additional structural reinforcement.
The addition of fixed supports at one or more points along the cleaning brush should
be sufficient to overcome the pressure issue. This may, in turn, require more torque
on the part of the motor, potential requiring a higher performance motor.

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5.3 Proposed Future Works
Discovered that when designing a product for fabrication it is absolutely necessary to plan out
every aspect of the design to the smallest detail. The designer must account for how every
screw, nut, and bolt will fit together and must try and anticipate potential issues that will arise
in the actual assembly of the product. There were several points in our fabrication process
where the areas of the design that were not fully completed caused large issues. This lack of
anticipation cost the team a great deal of time and money in order to correct the resulting design
problems.
Another key takeaway is the need for extensive feasibility testing. In the construction of the
cleaning system the selected brush was subjected to minimal testing. Had we been more
thorough, we would have discovered the brush requires a certain RPM and pressure to operate
efficiently. Correcting this issue required a large amount of redesigning to maintain the targeted
cleaning efficiency.
Finally, we learned the importance of delegation and parallel development. Our initial tendency
was to focus the entire team on one aspect of the design at a time. These smaller portions of
the design did not require the full team and, as a result, wasted time that could have been spent
improving other aspects of the design. If smaller groups had been assigned parts of the design
to work on in parallel, the entire design process would have likely gone much smoother with a
better final product.

31
 References
Akanksha Bhat, M. P., 2022. Estimate PV soiling losses to reduce solar risk with SolarAnywhere.
[Online]
Available at: https://www.solaranywhere.com/2022/estimate-pv-soiling-losses-with-solaranywhere/
[Accessed 20 July 2023].

Althuwaini, Y. E., 2023. Soiling Effect and Remedial Measures of Solar Photovoltaic System
Performance in Kuwait. Journal of Power and and Energy Engineering, 11(4), pp. 20-25.

Anon., 2020. [Online]

Available at: Http://www.brijencapsulants.com
[Accessed 29 July 2023].

Cabanillas, M., 2018. Dust accumulation effect on efficiency of Si photovoltaic, USA: Journal of
Renewable and sustainable energy.

Cook, G., 2019. Photovotaic Fundamentals. Washington DC: Solar Energy Research Institute (SERI).

Dawson, C., 2022. Solar panel Cleaning Systems and their Pros and Cons. Solar Energy, 2(3), pp. 1-20.

Gevorkian, 2018. Solar Power Generation: Technology, New Concepts & Policy.. Chicago: CRC Press.

Glenn, H., 2019. Solar Leaning Center. [Online]

Available at: Http:www.solar.com
[Accessed 17 February 2023].

Kalogirou, S. A., 2017. Solar Energy Engineering: Processes and Systems. 2 ed. Newyork: Academic
Press.

Kimber, M. N. W., 2006. The Effect of Soiling on Large Grid Connected Photovoltaic Systems in
California and the Southwest Region of the United, California: World Conference on Photovoltaic
Energy Conference.

Leon Freris, D. I., 2008. Renewable Energy in Power System. UK: A John Wiley & Sons, Ltd,
Publication.

Masters, G. M., 2015. Renewable and Efficient Electric Power System. Canada: John Wiley & Sons,
Inc., Hoboken, New Jersey.

M, B., 2021. Solar Electricity Handbook. London: Greenstream Publishing.

Pachauri, R., 2017. Performance Analysis of Automatic Cleaning System for Solar PV Modules, India:
Advances in Intelligent Systems and Computing book series.

Sayyah, H. M., 2013. Mitigation of Soiling Losses in Concentrating Solar Collectors, India:
Photovoltaic Specialists Conference.

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 Appendices
Gantt chart

Budget
Items Unit Price (K) Quantity Total Price (K)
Motor 300 1 300
Motor Drive 250 1 250
Pump 200 1 200
PV Module 250 1 250
Supporting Rods 180 1 180
Arduino UNO 300 1 300
Logistics 500 500
Miscellaneous 250 250
K2230

Components Specifications
The table below shows important specifications which were used for the procurement and
manufacturing of the machine components.

Sn Machine component Technical specification

01 Electric motor 373W,2850rpm: Continuous duty induction motor
02 Pump H7p6 fit
03 Arduino UNO Microcontroller DHC5J,4 digit display
04 Motor Drive Inductive: NPN ,12V Dc, 30mA,
05 Pulleys and belt 16mm maximum work diameter, 3 jaw self-centering
06 Mounting Stand 602 & 61802 [30mm & 15mm bores]
07 Bolts M10X40mm & M10X60mm, mild steel bolts

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