A Novel MPPT-Based Lithium-Ion Battery Solar Charger for Operation under Fluctuating Irradiance Conditions

Fluctuant irradiance conditions constitute a challenge in front of a proper battery charging process, when originated from a PhotoVoltaic Array (PVA). The behavior of the PVA under such conditions (i.e., reflected by a disturbed PV characteristic curve) increases the complexity of the total available power’s extraction process. This inconvenient fact yields eventually to a decreased overall efficiency of PV systems, especially with the presence of imprecise power-electronics involved circuits. Accordingly, the purpose of this paper is to design a complete battery solar charger, with Maximum Power Point Tracking ability, emerged from a PVA of 1.918 kWp, arranged in Series-Parallel topology. The targeted battery is of Lithium-Ion (Li-I) type, with 24 VDC operating voltage and 150 Ah rated current. The design began by configuring an interleaved synchronous DC-DC converter to produce a desired voltage level, with low inductor ripple current and low output ripple voltage. The DC-DC converter is in turns condemned by a modified Perturb and Observe (P&O) algorithm, to ensure efficient maximum power tracking. Progressively, the design encountered a layout of the bi-directional DC-DC converter to ensure safe current charging values for the battery. Under the same manner, the role of the bi-directional converter was to plug the battery out of the system, in case when the Depth of Discharge (DoD) is below 25%, thus sustaining the life span of the battery. The entire setup of the proposed sub-systems then leads to the relatively fastest, safest, and most reliable battery charging process. Results show an effectiveness (in terms of PV power tracking) ranging from 87% to 100% under four swiftly changing irradiance conditions. Moreover, this paper suggested the design’s future industrialization process, leading to an effective PV solar charger prototype.