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In this article, we explore the influence of module size on the rate of interconnecting solder bond thermomechanical fatigue (TMF) damage. Structural mechanics models of crystalline silicon PV models are created to solve with the finite-element method. Results conclusively demonstrate that the rate of solder bond TMF damage is independent of module size, interconnect location across the cell and cell location across the module.
Dynamic Mechanical Loading (DML) of photovoltaic modules is explored as a route to quickly fatigue copper interconnect ribbons. Results indicate that most of the interconnect ribbons may be strained through module mechanical loading to a level that will result in failure in a few hundred to thousands of cycles. Considering the speed at which DML may be applied, this translates into a few hours o testing. To evaluate the equivalence of DML to thermal cycling, parallel tests were conducted with thermal cycling. Preliminary analysis suggests that one +/-1 kPa DML cycle is roughly equivalent to one standard accelerated thermal cycle and approximately 175 of these cycles are equivalent to a 25-year exposure in Golden Colorado for the mechanism of module ribbon fatigue.
High efficiency multijunction solar cells in terrestrial concentrator photovoltaic (CPV) modules are becoming an increasingly cost effective and viable option in utility scale power generation. As with other utility scale photovoltaics, CPV modules need to guarantee operational lifetimes of at least 25 years. The reliability of optical elements in CPV modules poses a unique materials challenge due to the increased UV irradiance and enhanced temperature cycling associated with concentrated solar flux. The polymeric and thin film materials used in the optical elements are especially susceptible to UV damage, diurnal temperature cycling and active chemical species from the environment. We used fracture mechanics approaches to study the degradation modes including: the adhesion between the encapsulant and the cell or secondary optical element; and the cohesion of the encapsulant itself. Understanding the underlying mechanisms of materials degradation under elevated stress conditions is critical for commercialization of CPV technology and can offer unique insights into degradation modes in similar encapsulants used in other photovoltaic modules.
In this work, we explore the influence of module size on the rate of interconnect solder bond thermomechanical fatigue (TMF) damage and the probability of cell fracture. For the solder bond TMF damage evaluation, structural mechanics models of crystalline silicon PV models are created to solve with the Finite Element Method. For the probability of cell fracture evaluation, Weibull analysis and weakest link theory are employed to resolve the probability of crystalline silicon PV cell fracture when measured as bare cells and when stressed in reduced- and full-sized modules. Results conclusively demonstrate that the rate of solder bond TMF damage is independent of module size, interconnect location across the cell and cell location across the module and that smaller, representative, modules must be loaded to a much higher level than their parent full-sized modules to achieve an equivalent driving force for cell fracture.
In this work, we present a novel method to evaluate the fracture and fatigue-like behavior of crystalline silicon PV cell metallization. Initial results demonstrate that silver metal gridlines are capable of bridging a ~10–20 µm gap prior to becoming electrically open and do demonstrate fatigue-like behavior under cyclic straining conditions. This later phenomenon was well fit with a traditional power law equation for high cycle fatigue and enabled the development of a damage mechanics model for gridline failure.
The ITER international project design teams are working to produce an engineering design for construction of this large tokamak fusion experiment. One of the design issues is ensuring proper control of the fusion plasma. In-vessel magnet coils may be needed for plasma control, especially the control of edge localized modes (ELMs) and plasma vertical stabilization (VS). These coils will be lifetime components that reside inside the ITER vacuum vessel behind the blanket modules. As such, their reliability is an important design issue since access will be time consuming if any type of repair were necessary. The following chapters give the research results and estimates of failure rates for the coil conductor and jacket materials to be used for the in-vessel coils. Copper and CuCrZr conductors, and stainless steel and Inconel jackets are examined.
We inspected two 6.2 kW systems of CdTe modules that had been deployed for approximately eight years. The report summarizes the findings, lists the observed defects and links one of these defects to a significant loss in performance in some modules.
US Manufacturer Nishati provided three prototype, 72-cell photovoltaic modules to Sandia for characterization under the US Department of Energy Small Business Voucher program. Nishati is developing the Endurance © product to address the stringent requirements associated with PV system installations sited near airports and military bases. These prototype modules are uniquely constructed of a polymeric matrix and an internal honeycomb structural element. Target features of the module design are reduced reflectivity from the front surface and reduced weight. Sandia applied a variety of in-house characterization methods to these modules with the goal of validating performance and identifying any areas for improvement. Reflectance testing revealed extremely low specular reflection, dramatically surpassing the performance of industry standard PV panels. Electrical performance testing validated performance in line with expectations for similar size and power class modules. Complimentary to reflection testing, outdoor angle of incidence testing indicated performance far exceeding expectations for industry standard PV panels. It is possible that the extremely low reflectance properties of these modules will convey an advantage in annual energy production in comparison to industry standard modules. Detailed performance modeling and experimental field validation would be required to verify this possible advantage. During the course of this testing, no obvious deficiencies in this module design were discovered. It is recommended that Nishati and Sandia proceed to the final Task associated with the SBV award. This final task will involve fielding modules at Sandia for reliability and energy production validation.
Electronic component testing of high-shock FM TRANSMITTERS
Differentiation circuits for amplitude modulated signal envelopes
Metallic coating directly sprayed on electronic modules provides simple and reliable lightweight protection against radio frequency interference. A plasma arc may be used. Aluminum and copper are the most effective metals.
Silicon solar cell module fabrication, improvements, and reliability
The radio frequency communications subsystem for a space station is considered, with respect to onboard checkout requirements. The subsystem comprises all equipment necessary for transmitting and receiving, tracking and ranging, command, multiple voice and television information, and broadband experiment data. The communications subsystem provides a radio frequency interface between the space station and ground stations, either directly or indirectly, through a data relay satellite system, independent free-flying experiment modules, and logistics vehicles. Reliability, maintenance, and failure analyses are discussed, and computer programming techniques are presented.
An unusual insect-like vehicle designed for planetary surface exploration is made the occasion for a discussion of control concepts in path selection, hazard detection, obstacle negotiation, and soil sampling. A control scheme which actively articulates the pitching motion between a single-loop front module and a dual loop rear module leads to near optimal behavior in soft soil; at the same time the vehicle's front module acts as a reliable tactile forward probe with a detection range much longer than the stopping distance. Some optimal control strategies are discussed, and the photos of a working scale model are displayed.
Work reported was performed during the period from August 1977 to December 1978. The program objective was to continue the development of electrostatic bonding (ESB) as an encapsulation technique for terrestrial cells. Economic analyses shows that this process can be a cost-effective method of producing reliable, long lifetime solar modules. When considered in sufficient volume, both material and equipment costs are competitive with conventional encapsulation systems. In addition, the possibility of integrating cell fabrication into the encapsulation process, as in the case of the preformed cell contacts discussed in this report, offers the potential of significant overall systems cost reduction.
A computer model including an integration routine was developed and demonstrated to simulate, in principle, the chemical changes which may occur in the photooxidation of hydrocarbons, using as input data a set of elementary reactions, corresponding rate constants and appropriate starting conditions. Application of this model to the photooxidation of pottant and plastic materials used in the LSA module designs provides a reliable predictive capability regarding the useful lifetime of these materials. An earlier mechanism consisting of 46 reactions was simplified considerably by reducing the number of formal termination steps since it became apparent that the major termination process goes via the peroxy radicals. In addition, new reactions of oxygen with acryl radicals (from Norrish type I) to form peracids, which then decompose to form carbon dioxide are included.
Constricted double-heterojunction (CDH) lasers are presented as the class of single-mode nonplanar-substrate devices for which the lasing cavity is on the least resistive electrical path between the contact and the substrate. Various types of CDH structures are considered under three general topics: liquid-phase epitaxy over channeled substrates, lateral mode control, and current control in nonplanar-substrate devices. Ridge-guide CDH lasers have positive-index lateral-mode confinement and provide: single-mode CW operation to 7 mW/facet at room temperature and to 3 mW/facet at 150 C; light-current characteristics with second-harmonic distortion as low as -57 dB below the fundamental level; threshold-current temperature coefficients, as high as 375 C (pulsed) and 310 C (CW); constant external differential quantum efficiency to 100 C; and lasing operation to 170 C CW and 280 C pulsed. Semileakyguide CDH lasers have an asymmetric leaky cavity for lateral-mode confinement and provide single-mode operation to 15 to 20 mW/facet CW and to 50 mW/facet at 50% duty cycle. Modulation characteristics and preliminary reliability data are discussed.
The system and program requirements for a space operations center as defined by systems analysis studies are presented as a guide for future study and systems definition. Topics covered include general requirements for safety, maintainability, and reliability, service and habitat modules, the health maintenance facility; logistics modules; the docking tunnel; and subsystem requirements (structures, electrical power, environmental control/life support; extravehicular activity; data management; communications and tracking; docking/berthing; flight control/propulsion; and crew support). Facilities for flight support, construction, satellite and mission servicing, and fluid storage are included as well as general purpose support equipment.