Charge controller #2

[WindJuggler]

Hello,

I have been designing a charge controller for windmill, solar panel and other.

The older post can be found here.

It is possible that some files are no longer accessible.

My newest design has some modifications and is nearly finished.

This is how it should be set up.





It should have these features:

Measure

• Generator current
  
  
• Generator voltage
  
  
• Battery voltage
  
  
• Current in/out of the battery
  
  
• windmill speed (RPM)
  
  

Other

• Use combinations of those above to get power and energy numbers.
  
  
• Show the data on a display like a doc wattson
  
  
• Log all the above data
  
  
• Use proper charge cycles => different battery types
  
  
• For multiple sources: Wind, Hydro, Solar
  
  
• Use of multiple dumploads => 1st is warm water then switch to something else
  
  
• Easy configurable by computer
  
  
• Firmware updates via the computer
  
  
• 12V, 24V, 48V system voltages
  
  
• 50A current rating
  
  
• Energy preservation mode => switch of devices that consume to much power.
  
  
• Expansion board => Only board with FETs that can double the current rating. (switched with the other FETs)
  
  

But I have still some questions:

• What would be the best way to measure high currents?
  
  
  
  
  
  • Is it best to use the Shunt resistors or would the ACS75x series from Allegro be better?
    
    
  • How would I measure the correct current with the second board?
    
    
  
  
  
• Are there any other (critical) features that I overlooked?
  
  
• What would be the best way to connect the wires with high current to the board?
  
  
• What would be the best way for the users of this controller to connect multiple alternative energy sources(at the same time)?
  
  

Wim

[naveenck]

Hello Win,

I am quite new to the forum and need some help building a hybrid charge controller circuit to accommodate Wind/Pedalling, Solar and AC Grid power supplies. I think your design would be a good starting point. However, I am not able to access the PDF of your "newest design" where it is hosted currently.

Request you to kindly email the same to my email ID as mentioned below.

naveen_ck<at>mindtree<dot>com

It would be a great help and appreciate the same !

Thanks in advance,
Naveen

I fixed you guys emails with some antispam protection because i did not want to hear about it later when some spammer picks up your emails and starts sending you phishing emails using fieldlines and otherpower in the email to try to rope you in. that is what has happened in the past when people post there emails unprotected on this board.
Kurt

[zander1976]

Hey, I wasn't able to see it either but I am very interested in the design.

Can you email it to me as well. benwoodhead<at>hotmail<dot>com

I am working on a handheld device for recording and displaying data being transmitted from the solar and wind by bluetooth or RF.

Ben

[vawtwindy]

the error message on that page is


"Pagina niet gevonden

Onze excuses, die pagina die je zocht werd niet gevonden."

"Page not found Sorry, the page you were looking for was not found"

[Bruce S]

Ben and Naveen;
  Just a quick note to say it really ins't a good idea to have your full email addresses out in the open. Break them up with things that can or will make it harder for SPAM-BOTs to grab your email address.
Use stuff like <dot> and <AT> inplace of real (.) and (@).

Just a lesson learned from the past  .

Cheers
Bruce S

[BrianSmith]

The ACS75x is a better choice for current measurement since it provides galvanic isolation if needed/wanted and it has good bandwidth for measuring current cycles, etc.

[naveenck]

Bruce,

Thanks much for the input ! I will ensure using the methods you mentioned henceforth.

Regards,
Naveen

[WindJuggler]

Sorry that it took me this long to respond.

I stopped development of my design. There were some mistakes and I have to redevelop some parts of the design.
I'm actually thinking of making it modular:

• A central processing unit that is able to log data and measure everything.
• Another part to regulate the loading current and voltage which is controlled by the central unit
• Possibly some other parts

[Bruce S]

WindJuggler;
 Modular can be a very good way to go.I developing stuff makes it easier to troubleshoot and keeps the whole thing from becoming a beast.
Best Of Luck!! update us when you can
  Cheers
Bruce  S