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 (I 2R) 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 different homes now due to its
application and it also reduces cost expense during usage and
can be found in homes, in hospitals and even in dry cleaning
centers etc.

CHAPTER ONE
INTRODUCTION
Ironing is the use of a heated tool (an iron) to remove wrinkles
from fabric.[1] The heating is commonly done to a temperature of
180220 Celsius, depending on the fabric. [2] Ironing works by
loosening the bonds between the long-chain polymer molecules in
the fibers of the material. While the molecules are hot, the fibers
are straightened by the weight of the iron, and they hold their
new shape as they cool. Some fabrics, such as cotton, require the
addition of water to loosen the intermolecular bonds. Many
modern fabrics (developed in or after the mid-twentieth century)
are advertised as needing little or no ironing. Permanent press
clothing was developed to reduce the ironing necessary by
combining wrinkle-resistant polyester with cotton.

1 Background study

Recently, 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 AC power source to DC technology.
This technology required 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 Statement of problem

Difficulties 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 Lessing stress and power consumption.
The design of a solar power dc pressing iron is a system use to
encounter Pressing Iron issues as it helps to deliver current which
a low powered pressing iron uses in doing work.
3 Aim and objectives
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

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

principal of operation of various ways of implementing it.
4 Scope of the project
In this project, a student should be able to know the processes
of designing and constructing a DC solar pressing Iron, how it
works, its recommendation and different stages to produce a
working solar dc pressing iron.
5 Project limitations
A. This design can only be used in Dc supply
B. It cannot last for more than an hour or two before running
down.
C. It has a fast dc current discharge rate
D. For a high time duration it needs more than 10amps solar
making it cost expensive
6 Definition of important terms
A. Coil: this is a wire loop wounding at a given space.
B. Bipolar cable: a wire that linked the iron to a dc source
C. Solar Panel: a device that convert sunlight to electrical
energy
D. Solar controller: A devices that controls the amount of
current coming out from the solar panel.

7 Project report organizations

The organization of the project report is well detailed and vast

in its coverage. It covers all the activities encountered during
the research work. The first chapter is the introductory
chapter, which covers the background, project objectives,
project justification, 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 five is the summary and conclusion which includes the
summary of achievements, problems encountered during
project design, recommendation and suggestion for further
improvement.

CHAPTER TWO
LITERATURE REVIWE

2.1 Origin of the project

A clothes iron, also called a flatiron or simply an iron, is a small
appliance: a handheld piece of equipment with a flat, roughly
triangular surface that, when heated, is used to press clothes to
remove creases. It is named for the metal of which the device is
commonly made, and the use of it is generally called ironing.
Ironing works by loosening the ties between the long chains of
molecules that exist in polymer fiber materials. With the heat and
the weight of the ironing plate, the fibers are stretched and the
fabric maintains its new shape when cool. Some materials, such
as cotton, require the use of water to loosen the intermolecular
bonds. Many materials developed in the twentieth century are
advertised as needing little or no ironing.
The electric iron was invented in 1884 by Henry W. Seeley, a New
York inventor. Seeley patented his "electric flatiron" on June 6,
1882.[1] His iron weighed almost 15 pounds and took a long time

to warm up. Other electric irons had also been invented, including
one from France (1882), but it used a carbon arc to heat the iron,
a method which was dangerous

2.2 Historical review

History and development of flatirons

A charcoal iron

Typical English irons of the 1800s (Collection Tranby House,

Australia). The shape was used by Victorian antiquaries to
describe a style of medieval shield, termed by analogy heater
shield.

Flat iron (Minalin, Pampanga, Philippines Museum).

A 1950s Morphy Richards iron with original box

Metal pans filled with hot coals were used for smoothing fabrics in
China in the 1st century BC.[2] From the 17th century, sadirons or
sad irons (from an old word meaning solid

[vague]

) began to be used.

They were thick slabs of cast iron, delta-shaped and with a

handle, heated in a fire. These were also called flat irons. A later
design consisted of an iron box which could be filled with hot
coals, which had to be periodically aerated by attaching a
bellows. In Kerala in India, 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
frequent. Other box irons had heated metal inserts instead of hot
coals.

Another solution was to employ a cluster of solid irons that were

heated from a single source: As the iron currently in use cooled
down, it could be quickly replaced by a hot one. In 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 equipped with a system of
pipes for distributing natural gas or carbide gas to different rooms
in order to operate appliances such as irons, in addition to lights.
Despite the risk of fire, liquid-fuel irons were sold in U.S. rural
areas up through World War II.
In the industrialized 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 off to maintain the
selected temperature. The invention of the resistively heated
electric iron is credited to Henry W. Seeley of New York in 1882. In
the same year an iron heated by a carbon arc was introduced in

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

irons had no easy way to control their temperature, and the first
thermostatically controlled electric iron appeared in the 1920s.
Later, steam was used to iron clothing. Credit for the invention of
the steam iron goes to Thomas Sears. The first commercially
available electric steam iron was introduced in 1926 by a New
York drying and cleaning company, Eldec, but was not a
commercial success. The $10 Steam-O-Matic of 1938 was the first
steam iron to achieve any degree of popularity, and led the way
to more widespread use of the electric steam iron during the
1940s and 1950s.
Types and names
Historically, irons have had several variations and have thus been
called by many names:
Flatiron or smoothing iron
The general name for a hand-held iron consisting simply of a
handle and a solid, flat, metal base, and named for the flat
ironing face used to smooth clothes.

 Sad iron or sadiron[2]

Mentioned 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 "flatiron".
Box iron, ironing box, charcoal iron, ox-tongue iron or slug
iron[2]
Mentioned 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 ox-tongue iron is named for the particular
shape of the insert, referred to as an ox-tongue slug.
Goose, tailor's goose or, in Scottish, gusing iron [2]
A type of flat iron or sad iron named for the goose-like curve
in its neck, and (in the case of "tailor's goose") its usage by
tailors.
Goffering iron

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

oriented horizontally on a stand. It was used to iron ruffs and
collars.[3][4]
Features
Modern irons for home use can have the following features:
A design that allows the iron to be set down, usually
standing on its end, without the hot soleplate touching
anything that could be damaged;
A

thermostat

ensuring

maintenance

of

constant

temperature;
A temperature control dial allowing the user to select the
operating temperatures (usually marked with types of cloth
rather than temperatures: "silk", "wool", "cotton", "linen",
etc.);
An

electrical

insulation;

cord

with

heat-resistant

silicone

rubber

 Injection of steam through the fabric during the ironing

process;
o A water reservoir inside the iron used for steam
generation;
o An indicator showing the amount of water left in the
reservoir,
o Constant steam: constantly sends steam through the
hot part of the iron into the clothes;
o Steam burst: 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) Anti-drip system;
Cord control: 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 fires, is more
convenient, etc.);

 A retractable cord for easy storage;

(advanced feature) non-stick coating along the sole plate to
help the iron glide across the fabric
(advanced feature) Anti-burn control: if the iron is left flat
(possibly touching clothes) for too long, the iron shuts off to
prevent scorching and fires;
(advanced feature) Energy saving control: if the iron is left
undisturbed for several (10 or 15) minutes, the iron shuts off
to save energy and prevent fires.
Cordless irons: 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. Battery
power is not viable for irons as they require more power than
practical batteries can provide.
(advanced feature) 3-way automatic shut-off
(advanced feature) self-cleaning

 (Advanced 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.
2.3 Comparison with the already existing on
In comparison with an existing one, there is no much difference,
but when considering strength and durability, the already existing
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 I made w used a copper wire which in turns
makes it more reliable and more lasting in terms of cost value.
2.4 How it works
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.

CHAPTER THREE: DESIGN METHODOLOGY

3.1 Project specification
This is designed and construction of a solar dc iron which in this
project we are to illustrate the various stages of the design, HOW
THE INDUCTION COIL RESISTANCE brought about the heating of
the coil. How to connect with the solar panel and battery for
charging.
3.2 Concept review
From the existing 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 10turns SWG of 20guage to be able to carry
a current of 7.2amps 12V for at list 10Mins when fully charged by
the solar panel.

Note: 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.
3.3 Analysis of operations
Form the analysis of the existing 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 3hours 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.

3.4 Block diagram of the project

Fig 3.1 Block diagram of a dc solar pressing Iron

3.4.1 Functions of each block

A. Wound Coil: this is a 12Volts 7.2 Amps Carrying current
20gauge 100turns winding 10 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. the thermostat: this is a heat sensitive switch which when it
the heat on the iron goes to high will automatically kicks off the
voltage from the battery till the heat is down.
C. DC Battery:

this supplies current to the coil when being

connected to the pressing iron.

D. Solar Panel:

This converts the rays from the sun to electrical energy which
then goes to the battery during charging.

CHAPTER FOUR: DESIGN IMPLEMENTATION AND TESTING

4.1 Design procedures
4.1.1 Information gathering
The knowledge of how to design solar dc pressing iron did not just came from
anywhere even due a lot of information came through inspirations of different
ways (bio devices: Magxim Electronics journal on Electronics & psychological
effects 3 Edition 2012 for things to be down there is a source of information via
knowledge which is not only on teachings but also with metal physical
inspiration). Different sources where visited in other to get the clear view of how

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. Others include pea groups
and book reading etc.

4.1.2 Project resource centers

This includes:
a.
b.
c.
d.

internet resource centers

experimental aids and observation
Teachers and lectures
And digital electronics by J.K Mehta

4.1.1 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.

4.2 Circuit diagram of the design

SW2
L1
12u

SW1

SW-SPST-MOM

Thermostat

B1
12V

SOLAR CELL
17V

4.2.1 Circuit diagram analysis

When the devices is powered using a dc 12v battery it starts
heating the wires which as a conventional heat radiates to the
aluminum sheet for pressing cloths.
When the battery has run down the battery has to be connected
to the solar panels and expose to sunlight for recycling the
voltage for future use.
4.3 Design implementation steps

This involves the various steps which was used to archive the
design and implementation of a dc pressing iron.
4.3.1 Component listing
This includes
A. Coil
B. Thermostat
C. DC Battery
D.Solar Panel

4.3.2 Component analysis and descriptions

Here, 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.

4.4 Component gathering

A. Inductors
An inductor, also called a coil or reactor, is a passive twoterminal electrical component which resists changes in electric
current passing through it. It consists of a conductor such as a

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

field in the coil as long as current flows. When the current flowing
through an inductor changes, the time-varying magnetic field
induces a voltage in the conductor, according to Faradays law of
electromagnetic induction. According to Lenz's law the direction of
induced electromotive force (or "e.m.f.") is always such that it
opposes the change in current that created it. As a result,
inductors always oppose a change in current, in the same way
that a flywheel opposes a change in rotational velocity. Care
should be taken not to confuse this with the resistance provided
by a resistor.

Fig4.1 inductors
Windings and taps

Fig 4.2 Diagram of typical coil configurations

The wire or conductor which constitutes the coil is called the
winding.[5] The hole in the center of the coil is called the core
area or magnetic axis.[6] Each loop of wire is called a turn.[2] In
windings in which the turns touch, the wire must be insulated with
a coating of nonconductive insulation such as plastic or enamel to
prevent the current from passing between the wire turns. The
winding is often wrapped around a coil form made of plastic or
other material to hold it in place. [2] The ends of the wire are
brought out and attached to an external circuit. Windings may
have additional electrical connections along their length; these
are called taps.[7] A winding which has a single tap in the center
of its length is called center-tapped.[8]
Coils can have more than one winding, insulated electrically from
each other. When there are two or more windings around a

common magnetic axis, the windings are said to be inductively

coupled or magnetically coupled.[9] A time-varying current
through one winding will create a time-varying magnetic field
which passes through the other winding, which will induce a timevarying voltage in the other windings. This is called a transformer.
[10]

B. Thermostat
A thermostat is a component of which senses the temperature
of a system so that the system's temperature is maintained near
a desired set point. The thermostat does this by switching heating
or cooling devices on or off, or regulating the flow of a heat
transfer fluid as needed, to maintain the correct temperature.
Thermostats are used in any device or system that heats or cools
to a set point temperature, examples include building heating,
central heating, air conditioner, HVAC system, as well as kitchen
equipment including ovens and refrigerators and medical and
scientific incubators.
A thermostat is often the main control unit for a heating or cooling
system, through setting the target temperature. Thermostats can

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. A thermostat is most often an instance of a
"bang-bang controller" as the heating or cooling equipment
interface is not typically controlled in a proportional manner to
the difference between actual temperature and the temperature
set point. Instead, the heating or cooling equipment runs at full
capacity until the set temperature is reached, then shuts off.
Increasing the difference between the thermostat setting and the
desired temperature therefore does not shorten the time to
achieve the desired temperature. A thermostat may have a
maximum switching frequency, or switch heating and cooling
equipment on and off at temperatures either side of the set point.
This reduces the risk of equipment damage from frequent
switching.

Bimetal

Domestic water and steam based central heating systems have

traditionally been controlled by bi-metallic strip thermostats, and
this is dealt with later in this article. Purely mechanical control has
been localized steam or hot-water radiator bi-metallic thermostats
which regulated the individual flow. However, Thermostatic
Radiator Valves (TRV) are now being widely used.
Purely 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

thermostatically controlled valve to regulate the water flow and

temperature to an adjustable level. In older vehicles the
thermostat controls the application of engine vacuum to actuators
that control water valves and flappers to direct the flow of air. In
modern vehicles, the vacuum actuators may be operated by small
solenoids under the control of a central computer .
C. DC Battery
A battery converts chemical energy into electrical energy by a
chemical reaction. Usually the chemicals are kept inside the

battery. It is used in a circuit to power other components. A

battery produces direct current (DC) electricity (electricity that
flows in one direction, and does not switch back and forth).
Using 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. It
is also useful for things that move, such as electric vehicles and
mobile phones.

Fig 4.3 Symbol of a battery

D. Solar panel

Fig 4.4 Solar PV modules on

rooftops
Solar panel refers to a panel designed to absorb the sun's rays
as a source of energy for generating electricity or heating.
A photovoltaic (in short PV) module is a packaged, connected
assembly of typically 610 solar cells. Solar Photovoltaic 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 100 to 365
watts. The efficiency of a module determines the area of a module
given the same rated output an 8% efficient 230 watt module

will have twice the area of a 16% efficient 230 watt module. There
are a few solar panels available that are exceeding 19% efficiency.
A single solar module can produce only a limited amount of
power;

most

installations

contain

multiple

modules.

photovoltaic system typically includes a panel or an array of solar

modules, a solar inverter, and sometimes a battery and/or solar
tracker and interconnection wiring.
4.4.1 Component testing
Before the design I tested the components each and every one of
then to check for accuracy.
4.5 Packaging
I used an iron cast to protect the interior design which makes it
more like an iron.

CHAPTER FIVE: RECOMMENDATION AND CONCLUSION

5.1 Summary
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 expected. But in the long run the result
paid off.
After the complete design of the system, the deviation between the expected result
and the actual result was very close. The performance and efficiency was beyond
expectation and from every ramification, the design of the project was a success.
5.2 Problem encounter

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 require redesigning
and the software debugging also created a bit of a problem because some of the
hardware cannot be stimulated.
One 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.
5.3 Suggestion for further design
It will be more appreciated if the system is designed to a with an AC based coiling
technic which is more efficient as it helps to reduces battery drain during usage of
the system

5.4 Recommendation
a. Avoid water spillage onto of the design.
b. Supply the necessary voltage to the system by using a
12volts battery system with not more than 17amperhour
during usage.
c. Ensure proper placement before running the design.
5.5 Conclusion

Going 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.

Reference
a) Stauffer, H. Brooke (2005). NFPA's Pocket Dictionary of
Electrical

Terms.

Jones

and

Bartlett

Learning.

p. 36.

ISBN 0877655995.
b) Laplante, Phillip A. (1999). Comprehensive Dictionary of
Electrical

Engineering.

Springer.

pp. 114115.

ISBN 3540648356.
c) Arun, P. (2006). Electronics. Alpha Sciences International Ltd.
pp. 7377. ISBN 1842652176.
d) Newnes 2002, p. 129
e) Stauffer 2005, p. 273
f) Amos, S W; Roger Amos (2002). Newnes Dictionary of
Electronics. Newnes. p. 191. ISBN 0080524052.
g) Laplante 1999, p. 633
h) Stauffer 2005, p. 29
i) Newnes 2002, p. 167

j) Newnes 2002, p. 326

k) Laplante, Phillip A. (1998). Comprehensive Dictionary of
Electrical Engineering. Springer. p. 143. ISBN 3540648356.
l) Laplante 1999, p. 346
m)
Laplante 1999, p. 243
n) Laplante 1999, p. 19
o) Newnes 2002, p. 113Appendixes