PowerLabs

PowerLabs (formerly PowerHouse) is a solar engineering startup based in Beverly, MA. My most recent work focused on leading the development of a next-generation portable solar power system built on a rugged trailer platform. I oversaw the design and integration of the electrical and control systems, ensuring seamless coordination between mechanical and electronic subsystems for reliable, autonomous operation. The following sections highlight earlier stages of this project, including my contributions to the previous prototype design.

Overview

For its primary prototype, PowerLabs developed a solar prototype on a trailer platform, enabling AC power delivery and LiFePO4 battery bank charging through an inverter/charger connected to a deployable array of solar panels. In the initial design, the array of panels was moved with the extension / retraction of two pairs of potentiometer feedback heavy duty linear actuators. After a successful prototype demonstration, the product received additional funding from the United States Navy.

Challenge

The linear actuators used in the design each have a speed difference of ±10 %. Without the presence of a control box to synchronize the actuators, several components would break during deployment. Since there is not a compatible control box available for the selected actuators, I was asked to design a system to provide synchronized control of the two sets of linear actuators for the prototype demonstration.

Electronics

The control box I developed utilizes an Arduino Mega and four H-bridge motor controllers, one for each actuator. Two 24V batteries on the trailer provide power to a 12V bus bar setup, which provides power to the actuators. A 9V battery provides power to the Arduino, and a breadboard is used to provide more connections to the 5V Arduino output and ground.

Software

The actuators are synced both within and between pairs. If one actuator / pair is ahead of the other, its speed will be reduced to allow the other to catch up. Potentiometer readings are obtained and normalized to accurately compare the positions of the actuators. As outlined in the README, an SNES controller is used to calibrate and control the system with unique combinations of button inputs.