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ABSTRACT

Constancies of electrical power system is one of the major

problems in our country today, for this reason many alternatives

was invented to help keep our local appliances working and

aiding to our everyday needs.

 This is the design and construction of a Solar Dc pressing iron use

to press clothes when there is no electrical power; this devices

gets its energy from a solar converter energy which is done by the

solar panel and stores it a dc battery which holds the energy till

its consumption time, the iron heating devices is a dc coiled

inductor which as a result of heat loss !"#$ when there is a

passage of current along the coil will create hotness on the

surface of the metal it is in contact with.

 This devices in mostly found in di%erent homes now due to its

application and it also reduces cost e&pense during usage and

can be found in homes, in hospitals and even in dry cleaning

centers etc.

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CHAPTER ONE

INTRODUCTION

Ironing  is the use of a heated tool an iron$ to remove wrinkles

from fabric.'() The heating is commonly done to a temperature of 

(*+""+ -Celsius, depending on the fabric.'")  !roning works by

loosening the bonds between the longchain polymer molecules in

the /bers of the material. 0hile the molecules are hot, the /bers

are straightened by the weight of the iron, and they hold their

new shape as they cool. Some fabrics, such as cotton, re1uire the

addition of water to loosen the intermolecular bonds. 2any

modern fabrics developed in or after the midtwentieth century$

are advertised as needing little or no ironing. 3ermanent press

clothing was developed to reduce the ironing necessary by

combining wrinkleresistant polyester with cotton.

1 Background study

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#ecently, power supply to be able to make use of this devices

is no more for this reason many technology and inventions has

being created to help the continuity of a pressing iron by

converting it from 4C power source to DC technology. This technology re1uired a lot to keep the system going, so it

was interfaced with a solar panels which charges the battery

and also hen the battery is low.

2 Stateent o! "ro#$e

Di5culties encounter as a result poor power supply is much when

compared from using alternative power source, dc powered

devices has become a convenient system use in many developing

countries to 6essing stress and power consumption.

 The design of a solar power dc pressing iron is a system use to

encounter 3ressing !ron issues as it helps to deliver current which

a low powered pressing iron uses in doing work.

% Ai and o#&ecti'es

 The aim of this project is to design and implement a solar Dc

pressing iron which makes use of solar energy and dc supply

as the only source of power to energy the heating element for

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pressing of cloths, and also to have a better idea on the

principal of operation of various ways of implementing it.

( Sco"e o! t)e "ro&ect!n this project, a student should be able to know the processes

of designing and constructing a DC solar pressing !ron, how it

works, its recommendation and di%erent stages to produce a

working solar dc pressing iron.

* Pro&ect $iitations4. This design can only be used in Dc supply7. !t cannot last for more than an hour or two before running

down.C. !t has a fast dc current discharge rateD. 8or a high time duration it needs more than (+amps solar

making it cost e&pensive

+ De,nition o! i"ortant ters4. Coil9 this is a wire loop wounding at a given space.7. 7ipolar cable9 a wire that linked the iron to a dc sourceC. Solar 3anel9 a device that convert sunlight to electrical

energyD.Solar controller9 4 devices that controls the amount of 

current coming out from the solar panel.

- Pro&ect re"ort organi.ations

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 The organi:ation of the project report is well detailed and vast

in its coverage. !t covers all the activities encountered during

the research work. The /rst chapter is the introductory

chapter, which covers the background, project objectives,

project justi/cation, scope of the project, limitations and block

diagram overview of the states. Chapter two presents the

literature reviews. Chapter three covers the system analysis

and design in details. Chapter four presents the system

implementation which entails the component layout, the wiring

schedule, the wiring diagram and also the complete schematic

diagram and testing with integration of the project design.

Chapter /ve is the summary and conclusion which includes the

summary of achievements, problems encountered during

project design, recommendation and suggestion for further

improvement.

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CHAPTER T/O

0ITERATURE REI/E

21 Origin o! t)e "ro&ect

4 clothes iron, also called a atiron or simply an iron, is a small

appliance9 a handheld piece of e1uipment with a at, roughly

triangular surface that, when heated, is used to press clothes to

remove creases. !t is named for the metal of which the device is

commonly made, and the use of it is generally called ironing.

!roning works by loosening the ties between the long chains of 

molecules that e&ist in polymer /ber materials. 0ith the heat and

the weight of the ironing plate, the /bers are stretched and the

fabric maintains its new shape when cool. Some materials, such

as cotton, re1uire the use of water to loosen the intermolecular

bonds. 2any materials developed in the twentieth century are

advertised as needing little or no ironing.

 The electric iron was invented in (**< by =enry 0. Seeley, a >ew

 ?ork inventor. Seeley patented his @electric atiron@ on Aune B,

(**".'() =is iron weighed almost ( pounds and took a long time

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to warm up. ther electric irons had also been invented, including

one from 8rance (**"$, but it used a carbon arc to heat the iron,

a method which was dangerous

 

22 Historica$ re'ie3

History and de'e$o"ent o! 4atirons

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4 charcoal iron

 Typical English irons of the (*++s Collection  Tranby =ouse,

4ustralia$. The shape was used by Fictorian anti1uaries to

describe a style of medieval shield, termed by analogy heater

shield.

8lat iron 2inalin, 3ampanga, 3hilippines 2useum$.

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4 (G+s 2orphy #ichards iron with original bo&

2etal pans /lled with hot coals were used for smoothing fabrics in

China in the (st century 7C.'") 8rom the (Hth century, sadirons or

sad irons from an old word meaning solid 'vague)$ began to be used.

 They were thick slabs of cast iron, deltashaped and with a

handle, heated in a /re. These were also called at irons. 4 later

design consisted of an iron bo& which could be /lled with hot

coals, which had to be periodically aerated by attaching a

bellows. !n Ierala  in !ndia, burning coconut  shells were used

instead of charcoal, as they have a similar heating capacity. This

method is still in use as a backup device, since power outages are

fre1uent. ther bo& irons had heated metal inserts instead of hot

coals.

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4nother solution was to employ a cluster of solid irons that were

heated from a single source9 4s the iron currently in use cooled

down, it could be 1uickly replaced by a hot one. !n the late

nineteenth and early twentieth centuries, there were many irons

in use that were heated by fuels such as kerosene, ethanol, whale

oil, natural gas, carbide gas acetylene, as with carbide lamps$, or

even gasoline. Some houses were e1uipped with a system of 

pipes for distributing natural gas or carbide gas to di%erent rooms

in order to operate appliances such as irons, in addition to lights.

Despite the risk of /re, li1uidfuel irons were sold in J.S. rural

areas up through 0orld 0ar !!.

!n the industriali:ed world, these designs have been superseded

by the electric iron, which uses resistive heating from an electric

current. The hot plate, called the sole plate, is made of aluminium

or stainless steel. The heating element is controlled by a

thermostat that switches the current on and o% to maintain the

selected temperature. The invention of the resistively heated

electric iron is credited to =enry 0. Seeley of >ew ?ork in (**". !n

the same year an iron heated by a carbon arc was introduced in

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8rance, but was too dangerous to be successful. The early electric

irons had no easy way to control their temperature, and the /rst

thermostatically controlled electric iron appeared in the (G"+s.

6ater, steam was used to iron clothing. Credit for the invention of 

the steam iron goes to  Thomas Sears. The /rst commercially

available electric steam iron was introduced in (G"B by a >ew

 ?ork drying and cleaning company, Eldec, but was not a

commercial success. The K(+ Steam2atic of (GL* was the /rst

steam iron to achieve any degree of popularity, and led the way

to more widespread use of the electric steam iron during the

(G<+s and (G+s.

Ty"es and naes

=istorically, irons have had several variations and have thus been

called by many names9

• 8latiron or smoothing iron

 The general name for a handheld iron consisting simply of a

handle and a solid, at, metal base, and named for the at

ironing face used to smooth clothes.

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• Sad iron or sadiron'")

2entioned above, meaning @solid@ or heavy iron, where the

base is a solid block of metal, sometimes used to refer irons

with heavier bases than a typical @atiron@.

• 7o& iron, ironing bo&, charcoal iron, o&tongue iron or slug

iron'")

2entioned above; the base is a container, into which hot

coals or a metal brick or slug can be inserted to keep the

iron heated. The o&tongue iron is named for the particular

shape of the insert, referred to as an o&tongue slug.

• Moose, tailorNs goose or, in Scottish, gusing iron'")

4 type of at iron or sad iron named for the gooselike curve

in its neck, and in the case of @tailorNs goose@$ its usage by

tailors.

• Mo%ering iron

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 This type of iron, now obsolete, consists of a metal cylinder

oriented hori:ontally on a stand. !t was used to iron ru%s and

collars.

'L)'<)

5eatures

2odern irons for home use can have the following features9

• 4 design that allows the iron to be set down, usually

standing on its end, without the hot soleplate touching

anything that could be damaged;

• 4 thermostat  ensuring maintenance of a constant

temperature;

• 4 temperature control dial allowing the user to select the

operating temperatures usually marked with types of cloth

rather than temperatures9 @silk@, @wool@, @cotton@, @linen@,

etc.$;

• 4n electrical cord with heatresistant silicone rubber

insulation;

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• !njection of steam  through the fabric during the ironing

process;

o 4 water reservoir inside the iron used for steam

generation;

o 4n indicator showing the amount of water left in the

reservoir,

o Constant steam9 constantly sends steam through the

hot part of the iron into the clothes;

o Steam burst9 sends a burst of steam through the

clothes when the user presses a button;

o advanced feature$ Dial controlling the amount of 

steam to emit as a constant stream;

o advanced feature$ 4ntidrip system;

• Cord control9 the point at which the cord attaches to the iron

has a spring to hold the cord out of the way while ironing and

likewise when setting down the iron prevents /res, is more

convenient, etc.$;

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• 4 retractable cord for easy storage;

• advanced feature$ nonstick coating along the sole plate to

help the iron glide across the fabric

• advanced feature$ 4ntiburn control9 if the iron is left at

possibly touching clothes$ for too long, the iron shuts o% to

prevent scorching and /res;

• advanced feature$ Energy saving control9 if the iron is left

undisturbed for several (+ or ($ minutes, the iron shuts o% 

to save energy and prevent /res.

• Cordless irons9 the iron is placed on a stand for a short

period to warm up, using thermal mass  to stay hot for a

short period. These are useful for light loads only. 7attery

power is not viable for irons as they re1uire more power than

practical batteries can provide.

• advanced feature$ Lway automatic shuto% 

• advanced feature$ selfcleaning

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• 4dvanced feature$ vertical steam allows you to take out

creases and wrinkles by holding an iron just away from

clothes in vertical manner which will help do ironing fabric

materials like suits and jackets.

2% Co"arison 3it) t)e a$ready e6isting on

 !n comparison with an e&isting one, there is no much di%erence,

but when considering strength and durability, the already e&isting

one was coiled using an aluminum wire which makes it more

fragile and can easily be damage by a high current and voltage

while for this one ! made w used a copper wire which in turns

makes it more reliable and more lasting in terms of cost value.

2( Ho3 it 3orks

0hen the devices is powered by connecting it to the battery

terminals, current moves from the positive to the negative

through the induction coil, due to current movement heat lose

starts which thereby heats up the air coil, the heat is now being

transferred to the aluminum metal sheet which has direct contact

to the material to be ironed until the battery voltage goes down.

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CHAPTER THREE7 DESI8N 9ETHODO0O8: 

%1 Pro&ect s"eci,cation

 This is designed and construction of a solar dc iron which in this

project we are to illustrate the various stages of the design, =0

 T=E !>DJCT!> C!6 #ES!ST4>CE brought about the heating of 

the coil. =ow to connect with the solar panel and battery for

charging.

%2 Conce"t re'ie3

8rom the e&isting technology we have that a pressing iron

contains a heating element which from the power electricity

supply it heats up to transfer heat to the aluminum metal sheet

that has a direct contact to the materials we are to iron, so also in

this system we also employed such technic by wounding a high

resistive coil turns of (+turns S0M of "+guage to be able to carry

a current of H."amps ("F for at list (+2ins when fully charged by

the solar panel.

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>ote9 while charging the battery the pressing iron should be

totally remove from the battery so that it can charger the battery

direct with a load to the drain it during the hour of charging back

the dc voltage.

%% Ana$ysis o! o"erations

8orm the analysis of the e&isting system, we already known that

this technology is new and still has some glitches that makes it

not common in the market today, which is because of the cost of 

solar panels and dc battery that possibly will make the iron to

stay at list for over Lhours in full usage. So when the devices is

powered by connecting it to the battery terminals, current moves

from the positive to the negative through the induction coil, due

to current movement heat lose starts which thereby heats up the

air coil, the heat is now being transferred to the aluminum metal

sheet which has direct contact to the material to be ironed until

the battery voltage goes down.

%( B$ock diagra o! t)e "ro&ect

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5ig %1 B$ock diagra o! a dc so$ar "ressing Iron

%(1 5unctions o! eac) #$ock 

A /ound Coi$7  this is a ("Folts H." 4mps Carrying current

"+gauge (++turns winding (+O on air; this when current passes

across it will trigger the power loss which cause heating on the

surface of the copper wire, this as it is in contact with the

aluminum sheet it will pass the heat to it and make it hot for

ironing cloths mostly light cloths$.

B t)e t)erostat7 this is a heat sensitive switch which when it

the heat on the iron goes to high will automatically kicks o% the

voltage from the battery till the heat is down.

C DC Battery7 this supplies current to the coil when being

connected to the pressing iron.

D So$ar Pane$7

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to design a Solar DC pressing Iron, this ways include internet sites where a lot of 

information of different designs can be archived Come to school premises where

the knowledge is being passed from teachers to students !thers include pea groups

and book reading etc

4.1.2 Project resource centers

This includes:

a. internet resource centersb. e&perimental aids and observationc. Teachers and lecturesd. 4nd digital electronics by A.I 2ehta

"## Choice of Materials

The materials I used were from the information I got from the internet and I have

to develop the work through the source I found online that is treating the same

case

The circuit diagram used is the diagram which was design as a prototype but also

works to revive some information about the circuit analysis of the devices

(2 Circuit diagra o! t)e design

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SOLAR CELL17V

B112V

L1

12u

SW1

Thermostat

SW2

SW-SPST-MOM

(21 Circuit diagra ana$ysis

0hen the devices is powered using a dc ("v battery it starts

heating the wires which as a conventional heat radiates to the

aluminum sheet for pressing cloths.

0hen the battery has run down the battery has to be connected

to the solar panels and e&pose to sunlight for recycling the

voltage for future use.

(% Design i"$eentation ste"s

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 This involves the various steps which was used to archive the

design and implementation of a dc pressing iron.

(%1 Co"onent $isting

 This includes

ACoi$BT)erostatCDC BatteryDSo$ar Pane$

(%2 Co"onent ana$ysis and descri"tions

$ere, the whole components is discussed The choice of component was obtained

from the circuit diagram analysis which visually illustrates the various component

connection between each other, from there the components used was named and

given values form the parameters and so from there we obtained our choice of 

components This is feather analysis in the circuit diagram analysis

(( Co"onent gat)ering

A Inductors

4n inductor, also called a coi$  or reactor, is a passive  two

terminal  electrical component  which resists changes in electric

current passing through it. !t consists of a conductor such as a

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wire, usually wound into a coil. Energy  is stored in a magnetic

/eld in the coil as long as current ows. 0hen the current owing

through an inductor changes, the timevarying magnetic /eld

induces a voltage in the conductor, according to 8aradayPs law of 

electromagnetic induction. 4ccording to 6en:Ns law the direction of 

induced electromotive force or @e.m.f.@$ is always such that it

opposes the change in current that created it. 4s a result,

inductors always oppose a change in current, in the same way

that a ywheel  opposes a change in rotational velocity. Care

should be taken not to confuse this with the resistance provided

by a resistor.

5ig(1 inductors

0indings and taps

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common magnetic a&is, the windings are said to be inducti'e$y

cou"$ed  or agnetica$$y cou"$ed.'G)  4 timevarying current

through one winding will create a timevarying magnetic /eld

which passes through the other winding, which will induce a time

varying voltage in the other windings. This is called a transformer.

'(+)

B T)erostat

4 t)erostat is a component of which senses the temperature

of a system so that the systemNs temperature is maintained near

a desired set point . The thermostat does this by switching heating

or cooling devices on or o%, or regulating the ow of a heat

transfer uid as needed, to maintain the correct temperature.

 Thermostats are used in any device or system that heats or cools

to a set point temperature, e&amples include building heating,

central heating, air conditioner, =F4C system, as well as kitchen

e1uipment including ovens  and refrigerators  and medical and

scienti/c incubators.

4 thermostat is often the main control unit for a heating or cooling

system, through setting the target temperature. Thermostats can

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be constructed in many ways and may use a variety of sensors to

measure the temperature, commonly a thermistor  or bimetallic

strip. The output of the sensor then controls the heating or

cooling apparatus. 4 thermostat is most often an instance of a

@bangbang controller@ as the heating or cooling e1uipment

interface is not typically controlled in a proportional manner to

the di%erence between actual temperature and the temperature

set point. !nstead, the heating or cooling e1uipment runs at full

capacity until the set temperature is reached, then shuts o%.

!ncreasing the di%erence between the thermostat setting and the

desired temperature therefore does not shorten the time to

achieve the desired temperature. 4 thermostat may have a

ma&imum switching fre1uency, or switch heating and cooling

e1uipment on and o% at temperatures either side of the set point.

 This reduces the risk of e1uipment damage from fre1uent

switching.

7imetal

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Domestic water and steam based central heating systems have

traditionally been controlled by bimetallic strip thermostats, and

this is dealt with later in this article. 3urely mechanical control has

been locali:ed steam or hotwater radiator bimetallic thermostats

which regulated  the individual ow. =owever,  Thermostatic

#adiator Falves T#F$ are now being widely used.

3urely mechanical thermostats are used to regulate dampers in

some rooftop turbine vents, reducing building heat loss in cool or

cold periods.

Some automobile passenger heating systems have a

thermostatically controlled valve to regulate the water ow and

temperature to an adjustable level. !n older vehicles the

thermostat controls the application of engine vacuum to actuators

that control water valves and appers to direct the ow of air. !n

modern vehicles, the vacuum actuators may be operated by small

solenoids under the control of a central computer

C DC Battery

4 #attery  converts chemical energy  into electrical energy  by a

chemical reaction. Jsually the chemicals are kept inside the

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battery. !t is used in a circuit  to power other components. 4

battery produces direct current  DC$ electricity electricity that

ows in one direction, and does not switch back and forth$.

Jsing the electricity  from an outlet in a house or building is

cheaper and uses less energy, but a battery can provide

electricity in areas that do not have electric power distribution. !t

is also useful for things that move, such as electric vehicles and

mobile phones.

5ig (% Sy#o$ o! a #attery

D So$ar "ane$

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8ig <.< Solar 3F modules on

rooftops

So$ar "ane$ refers to a panel designed to absorb the sunNs rays

as a source of energy for generating electricity or heating.

4 photovoltaic  in short 3F$ module is a packaged, connected

assembly of typically BQ(+ solar cells. Solar 3hotovoltaic panels

constitute the solar array of a photovoltaic system that generates

and supplies solar electricity  in commercial and residential

applications. Each module is rated by its DC output power under

standard test conditions, and typically ranges from (++ to LB

watts. The e5ciency of a module determines the area of a module

given the same rated output an *R e5cient "L+ watt module

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will have twice the area of a (BR e5cient "L+ watt module. There

are a few solar panels available that are e&ceeding (GR e5ciency.

4 single solar module can produce only a limited amount of 

power; most installations contain multiple modules. 4

photovoltaic system typically includes a panel or an array of solar

modules, a solar inverter, and sometimes a battery andor solar

tracker and interconnection wiring.

((1 Co"onent testing

7efore the design ! tested the components each and every one of 

then to check for accuracy.

(* Packaging

! used an iron cast to protect the interior design which makes it

more like an iron.

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CHPT!" #I$!: "!C%MM!&'TI%& &' C%&C(*I%&

+.1 *ummar,

This section of this project report forms the concluding part of the write up and

takes a look at some of the problems encountered during the progressive job on the

system and also brings in suggestions for further improvement and%or enhancement

for the system design

The design and development of this project has really been challenging, as I have

 been faced with choices far beyond what I e&pected 'ut in the long run the result

 paid off

fter the complete design of the system, the deviation between the e&pected result

and the actual result was very close The performance and efficiency was beyond

e&pectation and from every ramification, the design of the project was a success

+.2 Pro-lem encounter

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During the course of the design of this system, there were series of problems which

came in the way of achieving the design goals of this project, most of them where

over come via share troubleshooting, in some cases some parts re)uire redesigning

and the software debugging also created a bit of a problem because some of the

hardware cannot be stimulated

!ne major setback of this project was coiling a suitable coil resistance for a dc

 battery, which I archived through a resistivity calculations I did during the design

+. *uggestion for further design

It will be more appreciated if the system is designed to a with an C based coiling

technic which is more efficient as it helps to reduces battery drain during usage of 

the system

+.4 "ecommendation

a. 4void water spillage onto of the design.b. Supply the necessary voltage to the system by using a

("volts battery system with not more than (Hamperhour

during usage.c. Ensure proper placement before running the design.

+.+ Conclusion

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*oing through the planning, flow process and the designing of the system had

really been a tough one+ but on the whole it has been a chance to show case a little

 bit of craftsmanship

Re!erence

a$ Stau%er, =. 7rooke "++$. >834Ns 3ocket Dictionary of 

Electrical Terms. Aones and 7artlett 6earning. p. LB.

!S7> +*HHBGG.

b$ 6aplante, 3hillip 4. (GGG$. Comprehensive Dictionary of 

Electrical Engineering. Springer. pp. ((<((.

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