The sun is an inexhaustible source of energy, and solar panels are ideal devices which harness this energy and utilize it for different purposes. Basically, a solar panel is an array of solar cells that entrap the solar energy and convert it into electricity. Each year, the earth receives approximately 176 petawatts of solar radiations. If only a fraction of this incoming radiation is captured and converted into a useable form of energy, then the dependency on fossil fuels will be reduced drastically. Moreover, the environment would also not be adversely affected.
 
 
 
Step 1

The first thing that needs to be done is to collect the following raw materials:

• Solar cells
• Plexiglass
• Tin wire
• Solder
• Plywood sheet
• UV protective varnish
• Silicon caulk

Besides the raw materials, the following tools would also be needed:

• Saw
• Glass cutter
• Screw driver
• Soldering gun
• Caulking gun
• Wire cutter
• Voltmeter
• Paint brush
• Screws
• Rosin flux pen
• Glass drilling machine

Step 2

The most important component of the solar panel is the solar cell. Brand new solar cells are the most efficient. However, partially damaged or repaired cells can also be used. About 160 new solar cells would be required to generate 200 watts of electricity. In the case of revamped cells, the power production is comparatively less. Use the voltmeter to check the voltage of each cell, and employ the readings to determine the amount of electricity that would be produced. For instance, if an 18 volt battery has to be charged, then at least 15 cells (each generating 1.25 volts of power) would be needed.

Step 3

Take the plywood sheet and cut it into dimensions large enough to accommodate all the cells. The size of the panel is directly proportional to the amount power that has to be generated, and the amount of solar radiations falling upon it. The shape of the panel is usually rectangular, but it can also be cut into any other suitable shape. After the plywood of appropriate size has been cut, apply UV protective varnish. Set aside the sheet and allow it to dry.

Step 4

With the help of the rosin flux pen, apply flux to the bus strip of the cells. Thereafter, connect the cells to one another with the aid of soldering iron gun. In each cell there will be two unattached wires. Drill two holes in the plywood to feed the wires. Affix the cells to the panel with a little silicon caulk. Also use this caulk to seal all the gaps around the holes.

Step 5

Prepare a frame for the panel and fix it with screws and silicon caulk. Now, fix the plexiglass over the cells. Before attaching the glass, drill two holes to prevent it from cracking. Carefully inspect every inch of the panel and seal off all the gaps, holes and crevices. Moisture should not be allowed to penetrate into the interiors of the panel. At the bottom of the panel, away from all the wirings, drill two holes. These holes will allow the air to circulate within the panel, and proper air circulation will prevent the moisture from building up. As the holes are at the lower side of the panel, rainwater will also not percolate and destroy the cells.

Step 6

Before installing the solar panel, it is essential to ascertain the north and south direction. If the place of installation is in the northern hemisphere, then the panel should face the southern direction. This will help it to capture maximum amount of energy because it will be facing the sun for the maximum amount of time. On the contrary, if the place of installation is in the southern hemisphere, then the solar panel should face the northern direction. The panels are normally attached to the poles. The good thing about solar panels is that they can easily be expanded, modified and refurbished. Furthermore, they can be used for a variety of purposes like distilling and heating water, cooking, air conditioning, running machines and vehicles and so on.

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