Development and Performance Evaluation of an Active Water Injection Cooling System for Solar Panels Using Integrated Digital Thermostat Control

Abstract

The operational temperature of photovoltaic (PV) modules significantly affects their energy conversion efficiency, with high surface temperatures leading to notable performance degradation, particularly in regions with high solar irradiance. This study presents the design, development, and experimental evaluation of an active water injection cooling system for PV panels, equipped with an integrated digital thermostat for automated thermal regulation. The proposed system comprises a DC-powered water pump, precision nozzles, an acrylic manifold, and a closed-loop control mechanism that activates cooling when the panel surface temperature exceeds a predefined threshold. The system was designed using Autodesk Fusion 360 for optimal component integration and fabricated with readily available, cost-effective materials. Experimental tests were conducted under real outdoor conditions in a tropical climate to evaluate the impact of the cooling system on module temperature, electrical power output, and overall energy yield. Results indicate that the active cooling system reduced the panel surface temperature by up to 12.5 °C compared to the uncooled reference, resulting in an average power output increase of 9.3% and a daily energy gain of 8.7%. The findings demonstrate that the proposed water injection cooling method, combined with intelligent temperature control, offers a practical and sustainable solution for enhancing PV performance in hot climates. This work contributes to the advancement of cost-effective thermal management strategies for solar energy systems and provides valuable insights for large-scale PV deployment in regions with high thermal stress.