MacBlog

This was far more successful than my previous attempt. These glass-encased thin-film cells were far easier to cut. Actually, I should that they were far easier to cut accurately. They certainly were not easier now that I think about it. It’s just that they held their shape a lot better.

Fancy pink tape was used to hold pieces together. Later switched to clear scotch tape. Pink is way too distracting.

For the first test panels I was able to string six cells together in series. Of the six, three of them are full-sized. The rest have been cut to some degree. To shape them I used a Dremmel with a cutting disc and first scored the cut that I wanted to make. Usually, the cell would just break along the score on its own but on occasion I would have to snap it. After that I took the ragged edge to the grinder to smooth things out. I did not end up with the cleanest edges in the world but it got the job done. So now that I had this irregularly shaped panel with odd shaped cells I needed to test it out to see if it would even work.

The pieces of green wire are only in there to get even spacing between each cell. They'll be taken out later.

Turns out it worked pretty well. In the first test, shown above, I managed to get voltages ranging from 10 to 18 with a hand-held lamp. I was honestly expecting much less but this first test is encouraging. I can’t wait to get this outside in the full sunlight without any tape holding it together. One thing that will be of concern is the fact that this sculpture will be tested in the sun. My concern comes from the fact that the sculpture was only a mockup for testing purposes. And how do you put masonite together quickly without any screws or fasteners? Hot glue. And lots of it. And what melts the glue in the first place? Heat. This sculpture is completely black and will be placed directly in the sun for further testing. I only hope that the whole thing does not melt under the sun.

This looks crude right now but once I figure out how to stand the sculpture on a pedestal I plan on securely attaching the panels to it. I don't think I'll be covering every face of the sculpture with a panel. 1) I don't have that many cells and 2) I think it would be overkill.

Um, not so easy.

I bought these Polycrystalline solar cells the other day and was positive I could figure out a way to cut them. My thinking was that I would be able to use one of several ways to do it:

1. Use an exacto blade to make repeated marks on the cell until broke. Result: FAIL

2. Securely clamp solar cell along the cut line and “snap” unwanted piece off. Result: FAIL

3. Use a dremmel on its lowest setting to slowly cut through the solar cell. Result: SUPER FAIL

This was a very frustrating process. I even made a few stabs at cutting them with the laser cutter. No even a laser cutter can touch these things! The solar cells are so brittle. On two different occasions, a fellow classmate stopped by to see what I was doing and while they were handling the cells they broke (the cells, not the people). These cells are super thin and have just about no flexibility. It’s really quite amazing.

This just about killed my idea for cutting solar cells for my sculpture but while I was cursing the solar gods one of those two solar-cell-breaking-classmates brought up some solar cells we had used in our Sustainable Energy class a few semesters back and suggested I use those. These cells are smaller and made of glass-encased thin film cells. I remembered them being not very powerful but it seems I was mistaken. At full sunlight they have been rated at almost 5 volts, over-performing their listed voltage (somewhere around 2.9 volts).

So it’s back to the floor where you find me quietly cutting solar cells or cursing aloud again, damning the solar gods.

Wish me luck.

Yes, I have a plan. Sort of. Well, there are things that I know I have to do, like construct the sculpture that will have the solar cells on it (Which I’ve done). And then there are the materials I need to collect for the other part of my thesis. So, there are a lot of knows and known unknowns, but the unknown unknowns that are a real wrench in the machine. My biggest ambition for my work plan is to leave myself enough time to address any unknowns that land in my lap. The work plan diagram below is more of a visual indicator to me to show me where there is overlap and give me some sense of timing.

Research
At the moment, my research has mostly involved materials and electrical components. For example, I have had to decide on the functionality of my sculpture and research technical solutions to making that happen. Good thing is, there is a lot of documentation on the web for DIY solar projects. For my other part of my thesis, I have found myself looking up sustainable materials as well as non-recyclable materials to help focus my idea.

Design
My goal is to have the design aspects of my thesis locked down in the next few weeks. I am sure there will be slight tweaking along the way but I hope not to spend more than 8 weeks on core designs.

Prototyping
Already begun! I already have most of the materials that I need to continue this part of the process. For the sculpture, I have constructed the structure and shape that will be covered in solar cells. There is a chance that I may be able to land some solar cells that are different from the ones I already have on hand so I may hold off on that part of the process. For my “eco-bricks,” I have the resin I need to make the casts but I have yet to make the molds. Baby steps. Additionally, I still need to gather the non-recyclable materials to mix in with the resin.

Testing
Oh, some day I’ll get there. I need to build it first! One thing that I have been able to do is some preliminary tests of the solar cells that I do have. One other thing that I will have to test are the circuits that need to be made for the sculpture.

Papers
Sigh … my biggest hangup. This will be an ongoing process. I figure this begun after the first day of thesis class and I am sure will continue on to the end (probably last minute).

Presentation
I am not so concerned with this. After spring break I should be far enough along on prototyping and some preliminary testing to really get a good sense of how to present my thesis. Once I have some of the physical objects iin hand it will just be a lot easier for me to articulate the work. For example, it’s hard for me to talk about a sculpture that generates electricity when I don’t know how much it can produce. With some sense of the sculptures capabilities, I will be more able to talk about the different ways in which the energy can be used. Not sure if I am powering a light bulb or a laptop!