Centrica Plc, one of the UK’s largest operators of electric vans, is addressing a major challenge faced by EV fleets nationwide: the widespread issue of “bricking”. This problem occurs when the 12-volt auxiliary battery, which powers essential functions like central locking, fails – leaving the vehicle completely inoperable. With a simple and effective solar solution, Centrica is prolonging battery life and ensuring engineers can get to its customers faster, and more reliably.

 

The company has teamed up with fleet technology specialist, Genie Insights, to have solar panels fitted to the roof of its electric vans.  The solar panels provide a trickle charge to the 12-volt batteries, keeping them operational even during periods of inactivity, or when a so-called “parasitic draw” is being taken by telematics or other ancillary equipment.

 

 

These discreet panels, constructed using CIGS (copper indium gallium selenide) technology, are lightweight, flexible and durable, making them ideal for commercial vehicle applications.  They are also the only CIGS panels to be manufactured in the UK and the panel for this application has been specifically designed, tested and proven to generate the optimal voltage to maintain the battery’s charge.

 

In conjunction with Genie Insights, Centrica is rolling out this cost-effective solution across 2,500 electric vans in its fleet.  This partnership is ensuring that Centrica’s fleet will continue to run smoothly and reliably, furthering their commitment to operational excellence and their customers.

 

Centrica Director of Fleet Rob Simister said: “Vehicle downtime is bad for business, and it’s bad for our customers. We had to find a solution quickly so that we can make sure our engineers can get to our customers exactly when we’re needed most.”

 

 

Centrica Fleet Engineering and Innovation Manager Matt Harris [pictured above] added: “We’re making a huge investment in decarbonising our fleet so we need to make sure we’re addressing issues that affect our ability to serve customers quickly. We explored several options but there was a clear frontrunner. Following the successful tests, this partnership with Genie Insights will equip all 2,500 of our electric commercial vehicles with their solar solution, ensuring the 12v batteries remain charged. As a result, our vans will stay on the road longer, better serving our customers’ needs.”

 

Matt Reeve, Managing Director of Genie Insights said: “By taking this proactive approach to battery maintenance, Centrica is not only pioneering a solution to a widespread issue for fleet operators, but also solidifying its leadership in the UK’s transition to electric vehicles.”

 

Read more about this solar-powered battery maintenance solution and its benefits here.

 

 

 

Transport refrigeration units, essential for transporting temperature-sensitive goods, require reliable power sources to ensure goods reach their destination in perfect condition. One common issue that many refrigerated fleet operators face is untimely draining of fridge batteries. In this blog post, we’ll explore the factors that can cause your fridge battery to drain and lead to deep cycling, which can reduce its lifespan.

 

Understanding Parasitic Draw

 

The culprits behind your fridge battery’s premature drain are often ‘parasitic draws’, which are essentially components or systems that continue to draw power even when your vehicles/trailers are not in operation. Here are some common sources of parasitic draw in temperature-controlled transportation:

 

1. Fridge Controllers: Fridge controllers are essential for maintaining the desired temperature within the refrigeration unit. However, they can continue to draw power to monitor and regulate the temperature even when the trailer is not in use.
2. Fuel Level Sensors: Fuel level sensors are crucial for keeping track of the fuel supply in the refrigeration unit. They constantly monitor fuel levels, leading to a steady power draw.
3. Interior Trailer Lighting: Lighting within the vehicle body/trailer can also be a significant source of parasitic draw. These lights can consume power during loading/unloading or during a safety inspection, for example.
4. Telematics/Temperature Monitoring Systems: Most modern fleets are equipped with systems to monitor their location and/or temperatures. These systems often rely on continuous power, leading to a constant drain on the battery.

 

Impact on the Battery: Deep Cycling

 

These parasitic draws gradually deplete the battery over time. This continual draw can eventually cause the battery to enter a state of ‘deep cycling’ – a situation where the battery is discharged below a safe and recommended level. This not only impacts the battery’s performance but also reduces its lifespan over time.

 

Tips for Preventing Premature Battery Drain

 

While some level of parasitic draw is unavoidable, there are steps you can take to mitigate the issue and extend the life of your fridge battery:

 

1. Regular Maintenance: Schedule regular maintenance checks to identify and address any issues related to the power draw.
2. Disconnect Unnecessary Systems: When the vehicle/trailer is parked for an extended period, consider disconnecting or deactivating non-essential systems.
3. Battery Monitoring: Implement a battery monitoring system to keep a close eye on the battery’s state of charge and voltage. This can help you identify and address issues before they become severe.
4. Solar Trickle Charge: Add a Genie Insights’ solar panel to the roof of your vehicle body/trailer to ‘trickle charge’ the fridge battery to keep it topped up.  This will mitigate against parasitic draw, keeping the battery healthy and prolonging its lifespan.  These easy to fit panels can be installed to new vehicles/trailers at the time of commissioning or retrofitted to your existing fleet during a routine service.

 

Understanding the concept of parasitic draw and taking preventive measures can help you maintain a healthy battery to keep your goods at the right temperature, minimise operational downtime and extend the life of the battery. 

 

Learn more about how a solar panel could improve the reliability of your fleet.

When we first started supplying solar panels in 2020 the perception in the market of solar for transport applications wasn’t great and rightly so.  People in the transport industry said “we’ve tried solar before and it didn’t work” but that’s because it was a totally different technology.  The panels then were monocrystalline or polycrystalline which were silicon based.  They weren’t really suitable for transport applications because they were heavy and inflexible and broke too easily. 

Genie Insights’ solar panels for commercial vehicles are UK manufactured by MIPV using a modern CIGS technology (Copper Indium Gallium Selenide) which is slim, light weight and flexible, making the panels pretty much unbreakable; and they perform much better than the traditional kind. 

In this article we will highlight the many benefits CIGS technology has over other photovoltaic (PV) options on the market:

Superior Light Absorption

By using CIGS, a compound semiconductor, thin-film modules absorb light up to 100 times more effectively than conventional materials such as silicon ensuring maximum energy conversion (Source).

All-Day Energy Production

CIGS panels start producing energy earlier in the morning and continue generating power longer into the evening, therefore allowing for a longer charge period than its monocrystalline equivalent.  This is mainly due to the Open Circuit Voltage (VOC) of CIGS technology being higher than other PV materials.  Read more about the importance of VOC here.

Reliability in All Conditions

Most solar panels only contain a few bypass diodes which significantly limits performance in shaded or cloudy conditions but the Genie Insights system is powered by MIPV technology, which incorporates bypass diodes into every other cell meaning if a pair of cells is shaded, the current is able to move to the next cell, so the only performance loss is from the shaded cells. This means our panel will work efficiently 365 days per year including low light, shading from buildings, cloudy days and if partially damaged or covered (e.g. by snow). If a CIGS panel gets partially damaged it will continue to perform but with a reduced performance, rather than failing completely. 

Check out this video showing just a 10% power loss after a CIGS pane has been penetrated five times by shots from a .22 rifle!:

 

And you can read more about bypass diodes here.

Cool & Safe

Unlike monocrystalline panels, CIGS panels do not generate heat, eliminating the risk of overheating and potential fire hazards.  In a temperature-controlled vehicle, in particular, avoiding additional heat is preferable.

Flexible Design

A CIGS panel is flexible and more robust than traditional alternatives due to the glass and solder free construction. This enables the panel to be fitted easily to a roof’s curvature as it does not require a frame to house the panel.

Lightweight & Streamlined

CIGS panels are just 3mm thick and extremely lightweight so there is no effect on payload or loss of MPG due to drag and the relative thinness means CIGS panels are arguably more aesthetically pleasing.

Non-Invasive Installation

A CIGS panel does not require any mechanical fixings or mounting frames and no punctures are required to apply them. This eliminates the chance of water ingress and protects the manufacturer’s warranty if fitting to a composite roof, for example. Installation costs are also minimised as a result.

In just three years, Genie Insights shattered the misconceptions surrounding solar panels for commercial vehicles. Our MIPV-manufactured CIGS panels have transformed the possibilities of photovoltaic solutions in the transport sector, offering flexibility, superior performance and unrivalled reliability in all weather conditions.

Learn more about our solar range here.

When discussing solar energy’s role in commercial vehicles, the focus often gravitates towards carbon reduction and environmental impact. While it’s undeniable that renewable energy solutions are contributing to a greener future, the carbon reduction aspect might not be the primary driver for fitting solar panels to commercial vehicles. This article explains why solar for commercial vehicles isn’t always about carbon reduction and explores other reasons that make transport solar a sound strategic investment.

 

Battery Maintenance Versus Autonomous Power

 

There are two approaches to managing power with solar energy.

 

Trickle charging involves a low-level flow of power to maintain batteries over an extended period. This approach is typically used to keep batteries at full capacity, ensuring they’re ready for use when needed but doesn’t generate sufficient power for primary energy needs.

 

In contrast, autonomous power generation with solar energy entails directly powering a battery independently, reducing or eliminating the need for batteries altogether.

 

In the case of autonomous power generation, the environmental benefit is obvious since the power generation is diverted from fossil fuel to an entirely renewable source.  However, all too often solar suppliers are promising fuel and CO2 savings from trickle charge systems.  Whilst yes there can be a reduction in fuel usage and therefore CO2, the amount is likely to be minimal.  So, what are the actual benefits of trickle charge solar installations?

 

At Genie Insights, the majority of trickle charge systems we supply are primarily about battery maintenance.  We’ll look at two of our best-selling examples below.

 

Battery Health & Longevity

 

Our solar solution for transport refrigeration units continuously tops up the battery level (during daylight hours) which preserves battery health and extends overall lifespan.  This safeguarding of the battery’s health leads to elimination of flat batteries, costly breakdowns and improved vehicle reliability – challenges that have plagued the refrigerated transport sector since the introduction of newer technologies that take a draw from the battery such as telematics.

 

Whilst this does not provide a significant CO2 saving, it does give a secondary environmental benefit due to fewer batteries being required over the lifetime of the fridge.

 

Critical Accessibility

 

Another example is the incorporation of a solar panel onto electric vans to serve as a crucial supplementary power source, primarily ensuring the uninterrupted access and functionality of the vehicle. The 12-volt battery in electric vans is used in critical functions such as unlocking the van and powering various onboard systems. However, if this battery goes flat, it can lead to an inconvenient and compromising situation where the van becomes inaccessible – the van cannot even be unlocked! By adding a solar panel, the 12-volt battery is trickle charged, reducing the risk of it becoming depleted.  In this scenario, it is unlikely that there is any significant carbon reducing effect of the solar panel.

 

Therefore, while carbon reduction is achievable in some solar applications, the modest savings in a trickle charge application doesn’t warrant the hype that is sometimes advertised.  Instead, the very real operational benefits related to battery health are a much more honest and attractive proposition.

 

If your fleet faces either of these operational challenges, please contact us to find out how Genie Insights’ solar solutions can improve the reliability of your fleet.

 

To find out how Genie Insights’ solar solutions can improve the reliability of your fleet, click here.

In commercial vehicle solar panel installations, efficiency, simplicity, and practicality are paramount. One component that has gained attention is the smart charge controller, acclaimed for its data-rich capabilities. However, we challenge the assumption that ongoing data downloads from these controllers are an absolute necessity. In this article, we explore why data analytics from smart charge controllers may not be required for a commercial vehicle solar panel setup.

What is a Smart Charge Controller?

The primary function of a charge controller is to regulate the charging and discharging of batteries to optimise energy utilisation. The charge controller monitors the state of the batteries, the available energy input from the solar panel and the energy demand in real-time. By doing so, it can adjust the charging parameters dynamically, such as voltage and current levels, to ensure that the batteries are charged optimally while preventing overcharging or over-discharging, which can damage the batteries.

Charge controllers used in solar installations range from basic models with limited capability to more expensive types which have full remote connectivity.  The lower end range can store a limited amount of data and the data is not accessible remotely – either a laptop needs to be plugged in or data can be downloaded to a secondary device via Bluetooth.  At the higher end, the charge controller is permanently connected to the wireless LTE network and so can push real-time data remotely to an online monitoring platform.

The Promise of Smart Charge Controllers Versus the Reality

Smart charge controllers have emerged as game-changers in the solar industry, allowing for real-time, remote monitoring of solar panel systems. These features undoubtedly offer valuable insights into energy production, usage patterns, and system health, but when it comes to commercial vehicle solar panel installations, the practicality of continuous data collection warrants a closer look.

One of the key benefits of a solar panel installation for commercial vehicles is its inherent simplicity. Solar panels harness energy from the sun, which is then used to charge the vehicle’s battery. This simple principle doesn’t require constant monitoring or intervention. Modern solar panels are designed to withstand various environmental conditions, and the need for real-time adjustments is minimal once the system is correctly set up.

During the initial stages of a commercial vehicle solar panel evaluation, an all-singing, all dancing smart charge controller can indeed be invaluable – that we don’t deny. Having access to performance data, such as energy generation, consumption patterns, and efficiency in varying conditions of course proves its success.  However, once the system’s viability is proven, the need for continuous data collection diminishes significantly.  In reality, the only proof required to demonstrate the success of a solar panel is the absence of flat batteries!

Data Overload: The Fleet Manager’s Challenge

Fleet managers responsible for commercial vehicles are already grappling with an influx of data from various sources – vehicle tracking, maintenance records, fuel consumption, driver behaviour, and more. The addition of real-time solar panel data might seem appealing in theory, but it adds yet another layer of complexity to an already intricate web of information.

Cost-Effectiveness

Smart charge controllers with continuous data transmission capabilities come with additional costs, including hardware, software, and potential subscription fees for data hosting. For commercial vehicle solar installations, the return on investment from these ongoing data services may not justify the added expense, especially considering that the initial optimisation phase provides the bulk of the required insights.

While the capabilities of smart charge controllers are undeniably impressive, their relevance in commercial vehicle solar panel installations must be evaluated in the context of real-world practicality. The initial data download to validate the system’s effectiveness is indeed valuable. However, beyond this phase, the benefits of ongoing data collection become outweighed by the complexities, costs, and information overload faced by fleet managers.

At Genie Insights we can and do supply a range of charge controllers dependent on customer needs, up to and including fully live, remote systems, but in many cases the basic model is perfectly adequate.  And with thousands of panels in circulation with no complaints of flat batteries that is all the evidence we need!

To find out how Genie Insights’ solar solutions can improve the reliability of your fleet, click here.

A critical component of solar panel performance that often goes unnoticed is the bypass diode. In this blog, we will explore why the number of bypass diodes is important in a solar panel and how they impact its overall efficiency and reliability.

Understanding Solar Panels

Before explaining the significance of bypass diodes, let’s briefly understand how solar panels work. Solar panels consist of photovoltaic cells that convert sunlight into electricity. When exposed to sunlight, these cells generate a direct current.  But when solar panels are shaded (by buildings, trees or cloud cover) or obstructed (snow/ice, bird droppings, dirt, etc), there can be a decrease in performance.

The Role of Bypass Diodes

This is where bypass diodes come in.  They are like traffic police in a solar panel system – when one route is blocked, the traffic police will set up diversions. In a solar system, this is what a bypass diode does.  The bypass diode’s primary function is to ensure the smooth flow of electrical current by bypassing shaded or obstructed cells, allowing the unshaded cells to continue generating power. These diodes are typically placed in parallel with groups of cells within the solar panel. When a cell or group of cells is partially shaded, the corresponding bypass diode activates, creating an alternative path for the current to follow.

By having multiple bypass diodes, if a part of the solar panel is shaded or obstructed, the diode corresponding to that section activates, allowing the unshaded sections to continue generating electricity at maximum capacity. This helps optimise energy production and ensures that the shaded area does not significantly affect the overall performance of the solar panel.

The Genie Insights Design

Most conventional panels only have three bypass diodes – if one cell is shaded, total power reduces by one-third). In contrast, the Genie Insights’ high-voltage 50-watt panel (powered by MIPV technology), commonly employed in ‘trickle charge systems’ like those used to maintain transport refrigeration units and electric vehicles, boasts 44 cells with 22 bypass diodes. This configuration ensures that in the event of a pair of cells being shaded, the current can seamlessly reroute to adjacent cells, resulting in minimal performance loss solely from the shaded cells.

Bypass diodes may be small components within a solar panel system, but their impact is far from negligible. They play a crucial role in ensuring that solar panels operate efficiently, reliably, and with a long lifespan. The number of bypass diodes matters because it directly influences the panel’s ability to handle shading and varying light conditions, ultimately affecting the overall energy production.

To find out how Genie Insights’ solar solutions can improve the reliability of your fleet, click here.

 

During evaluation of our solar panels, we often find that customers tend to focus on the wattage output compared to other types of solar panel. Yet, a more vital factor that often goes unnoticed is Open Circuit Voltage (VOC). While wattage undeniably matters, at Genie Insights we believe that Open Circuit Voltage deserves the spotlight. This article will explain why VOC is more crucial than the number of watts a solar panel produces.

Many people assume a higher VOC simply means a panel produces a higher voltage. In reality, the biggest advantage is much more practical than that.  A higher VOC allows a solar panel to begin charging earlier in the morning, continue charging later into the evening, and keep producing useful energy in lower light conditions throughout the day.  In other words, it gives your solar panel more time to work.

 

Understanding Open Circuit Voltage (VOC)

 

Wattage, or peak power, is the most advertised measure of solar panels. However, peak power is usually achieved under laboratory conditions, where factors like temperature, shading, and real-world inefficiencies are absent. When panels are installed in the field, these factors can significantly reduce the actual power output, making the peak power a less accurate representation of real-world performance.

Cloud cover, shading, temperature, vehicle orientation and seasonal changes all affect the amount of energy a panel can produce.

 

Open Circuit Voltage (VOC) refers to the voltage a solar panel generates when no load is connected to it. Simply put, it represents the energy potential the panel can generate, waiting to be harvested.  VOC, therefore, provides a more reliable insight into the panel’s potential under varying conditions. It helps to anticipate how the panel will behave when exposed to real-world challenges, enabling better decision-making for system design and performance estimation.

 

The cells in solar panels are connected in a chain-like fashion. When you connect cells in series, it adds up the voltages of each cell. So, the more cells you connect in a row, the higher the voltage your solar panel can produce.  The Genie Insights high voltage panel, which has been developed in conjunction with a UK manufacturer via a special manufacturing process, has more cells in series than a comparable standard panel of the same wattage, which boosts the voltage of the panel.

It’s Not About More Voltage – It’s About More Charging Time

Solar panels don’t suddenly switch on at sunrise and switch off at sunset. Their output gradually increases as daylight intensifies before falling away again towards evening.

During these low-light periods, the available light may be sufficient for a high VOC panel to exceed the minimum operating voltage required by the MPPT charge controller, while a lower-voltage panel may still be below that threshold.

The result is that the higher VOC panel begins charging sooner in the morning, continues charging later into the evening and often performs more effectively throughout overcast conditions.

Rather than simply producing a higher voltage, it harvests useful energy for a longer portion of every day.

Think of it like opening hours.  Imagine two identical shops.  They have the same number of staff, the same floor space and sell exactly the same products.  The only difference is that one opens at 7am and closes at 9pm, while the other trades only between 10am and 4pm.  Which one has the greater opportunity to serve customers?  A higher VOC works in much the same way.  It doesn’t necessarily mean dramatically more power at any one moment; it simply means the panel has more hours during the day when it can do useful work.

 

System Efficiency and Voltage Loss

 

In solar energy systems, energy losses occur at various stages: during conversion from DC to AC (inverter losses), transmission through cables, and due to shading or dirt on the panels. These losses often translate to a drop in voltage along the system. A higher VOC can counteract these losses by starting with a higher initial voltage, ensuring that the usable voltage at the end of the system is still sufficient for effective energy conversion.

 

The number of bypass diodes is also important in managing losses within the system due to shading or obstruction. You can read more on this in our blog ‘How Multiple Bypass Diodes Supercharge Solar Panel Performance’ here.

 

Performance Over Time

 

While higher wattage panels might seem attractive, their performance can degrade faster over time due to factors like temperature stress. Panels with higher VOC tend to age more gracefully as they are designed to withstand higher voltage stress. This means that even after years of use, panels with higher VOC are more likely to retain a higher proportion of their original output, contributing to the system’s overall longevity and efficiency.

 

Open Circuit Voltage (VOC) is often overlooked by operators when selecting a solar panel supplier, with wattage output tending to be the measure of choice. However, the importance of VOC shines through when considering real-world performance and system efficiency.

A higher Voc doesn’t simply provide more voltage.  It allows the panel to start working earlier, keep working later and spend more of the day harvesting energy.   For commercial vehicles, where maintaining battery health and maximising vehicle availability are critical, that additional charging window can make a significant difference.

While wattage undoubtedly matters, VOC provides a more accurate and versatile insight into a solar panel’s potential, making it a vital parameter to consider. So, the next time you evaluate a solar panel, remember, it’s not just about the watts – it’s about the voltage waiting to be unlocked.

 

Find out more about the range of Genie Insights’ solar solutions here.

Imagine this scenario: you leave your electric van parked for an extended period and when you return, you find yourself locked out – you can’t unlock the doors, access the interior, and so can’t even start the van. This is a very real problem that’s becoming an apparent inconvenience for electric van fleet owners, particularly those running ancillary services such as telematics.

 

 

In the rapidly evolving EV sector, electric vans for commercial operators are on the rise. However, just like their fossil fuel powered counterparts, electric vans rely on a 12-volt auxiliary battery for essential functions, such as unlocking the vehicle, operating lights, controlling the infotainment system and running safety features. Essentially, this small battery ensures that your electric van remains operational and accessible.

 

So, what happens if this vital battery goes flat? You might be surprised to learn that without it, you can’t even unlock the van! This is where Genie Insights’ solar panels for electric vans come into play, offering a lifeline for battery maintenance and peace of mind.

 

Genie Insights, a leader in solar solutions for transport, in conjunction with UK manufacturer MiPV, has introduced a solar solution to protect and maintain the 12-volt auxiliary battery in electric vans.  The concept is simple yet effective – a discreet, slimline solar panel is installed on the roof of the van which converts energy from the sun into electricity. This electricity is then directed to the 12-volt battery, keeping it charged and ready for action, even during periods of inactivity.

 

Electric vans are leading the charge toward a more sustainable and environmentally conscious future in transportation but the often overlooked 12-volt auxiliary battery presents a potential stumbling block for van fleet owners. The introduction of Genie Insights’ solar solution for this problem provides peace of mind and aligns with the green values of electric transportation. So, if you’re considering electric vans for your fleet, or you are struggling with keeping the ones you already have operational, contact Genie Insights to add this battery maintenance lifeline. Unlock the full potential of your electric van with this cost-effective and practical solution.

 

Have you ever looked at the problem of flat battery related costs within your refrigerated fleet?  From battery related breakdowns to premature battery replacements and even the indirect costs associated with downtime or poor fleet reliability such as late delivery fees or rejected loads, these costs all add up.

 

Most of our solar customers didn’t even realise they had a problem before investigating the numbers or even worse, they just accepted these costs because they’ve never had a way of mitigating them before now!  By adding a solar panel to the roof of your temperature-controlled trailer, the fridge battery can be ‘trickle charged’ to keep the battery constantly topped up. 

 

As well as the improved fleet uptime and reliability achieved by mitigating breakdowns; battery health is also protected giving a longer battery life and there is an environmental benefit due to less replacement batteries being needed over the fleet’s lifetime.

 

With the installation of a Genie Insights high efficiency 50 watt solar panel adding just a nominal amount to a trailer that costs anywhere between £40k and £60k, depending on the trailer spec, Genie Insights’ customers explain that it is a “no brainer”.

 

We have launched a calculator, which provides operators with an indication of how much they could save over their fleets’ lifetime by installing one of the company’s solar panels.  By inputting just a few details, the calculator provides a total potential saving in battery replacements and in reduced breakdowns. 

 

The calculator shows that an operator with a fleet of 200 refrigerated trailers could potentially save £192,000* over the lifetime of the entire fleet.

 

And it seems operators can benefit no matter what size of fleet they operate.  For example, a fleet of just 10 trailers could save £9,600* and a fleet of 1,000 trailers could potentially save £960,000* over the lifetime of the fleet.

 

 

 

* These calculations are based on the following data:

 

Typical trailer lifespan of 8 years

 

Battery replacement cycle of every 2 years

 

Number of battery related breakdowns per month based on 5% of the total fleet

 

Battery replacement cost of £200

 

Breakdown cost (parts and labour) of £200