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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

HAPPA: A Modular Platform for HPC Application Resilience Analysis with LLMs Embedded

High-performance computing (HPC) systems are increasingly vulnerable to soft errors, which pose significant challenges in maintaining computational accuracy and reliability. Predicting the resilience of HPC applications to these errors is crucial for robust code protection and detailed resilience analysis. In this study, we present HAppA, a modular platform designed for HPC Application Resilience Analysis. Embedding Large Language Models (LLMs), HAppA addresses understanding the context information of long code sequences typical in HPC applications. HAppA implements a novel code representation module that chunks the code into fixed-size segments and aggregates the embeddings of these segments. Three aggregation methods have been explored: MeanPooling, MaxPooling, and LSTM-based techniques. We built a DAtaset for REsilience analysis using Fault Injection (FI), named DARE. Using our DARE dataset, HAppA is trained for regression prediction tasks. Our evaluation results demonstrate the predictive accuracy of HAppA compared to other models, particularly noting that the LSTM-based aggregation method -- HAppA-LSTM -- achieves a mean squared error (MSE) of 0.078 for SDC prediction, surpassing the existing state-of-the-art PARIS model, which recorded an MSE of 0.1172. Additionally, HAppA with the KeyBERT model extracts a list of keywords representing the source code. A comprehensive importance analysis of these keywords further elucidates the code patterns contributing to the error rate. These findings highlight the effectiveness of HAppA in analyzing the resilience of HPC applications and establish a new benchmark for predictive accuracy in resilience.

Jiang, Hailong [Kent State University]↗
DOE OSTI2013

Photovoltaic Module Qualification Plus Testing

This report summarizes a set of test methods that are in the midst of being incorporated into IEC 61215 for certification of a module design or other tests that go beyond certification to establish bankability.

14 SOLAR ENERGY↗
DOE OSTI2015

FIRST NEW SOLAR MODELS WITH OPAS OPACITY TABLES

Stellar seismology appears more and more as a powerful tool for a better determination of the fundamental properties of solar-type stars. However, the particular case of the Sun is still challenging. For about a decade now, the helioseismic sound-speed determination has continued to disagree with the standard solar model (SSM) prediction, questioning the reliability of this model. One of the sources of uncertainty could be in the treatment of the transport of radiation from the solar core to the surface. In this Letter, we use the new OPAS opacity tables, recently available for solar modeling, to address this issue. We discuss first the peculiarities of these tables, then we quantify their impact on the solar sound-speed and density profiles using the reduced OPAS tables taken on the grids of the OPAL ones. We use the two evolution codes, Modules for Experiments in Stellar Astrophysics and Code Liégeois d’Evolution Stellaire, that led to similar conclusions in the solar radiative zone. In comparison to commonly used OPAL opacity tables, the new solar models are computed for the most recent photospheric composition with OPAS tables and present improvements to the location of the base of the convective zone and to the description of the solar radiative zone in comparison to the helioseismic observations, even if the differences in the Rosseland mean opacity do not exceed 6%. We finally carry out a comparison to a solar model computed with the OP opacity tables.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2013

Calibration of measurement sensitivities of multiple micro-cantilever dynamic modes in atomic force microscopy using a contact detection method

An accurate experimental method is proposed for on-spot calibration of the measurement sensitivities of multiple micro-cantilever dynamic modes in atomic force microscopy. One of the key techniques devised for this method is a reliable contact detection mechanism that detects the tip-surface contact instantly. At the contact instant, the oscillation amplitude of the tip deflection, converted to that of the deflection signal in laser reading through the measurement sensitivity, exactly equals to the distance between the sample surface and the cantilever base position. Therefore, the proposed method utilizes the recorded oscillation amplitude of the deflection signal and the base position of the cantilever at the contact instant for the measurement sensitivity calibration. Experimental apparatus along with various signal processing and control modules was realized to enable automatic and rapid acquisition of multiple sets of data, with which the calibration of a single dynamic mode could be completed in less than 1 s to suppress the effect of thermal drift and measurement noise. Calibration of the measurement sensitivities of the first and second dynamic modes of three micro-cantilevers having distinct geometries was successfully demonstrated. The dependence of the measurement sensitivity on laser spot location was also experimentally investigated. Finally, an experiment was performed to validate the calibrated measurement sensitivity of the second dynamic mode of a micro-cantilever.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2018

Advanced High Torque Density Magnetically Geared Generator

The objective of this research project was to investigate the fundamental torque density limitations of multistage flux focusing magnetic gears and magnetically geared direct-drive generators for wind turbines. Magnetic gears create non-contact speed amplification by modulating the air-gap magnetic field harmonics created by magnetic rotors. By integrating a stator into the magnetic gear structure a very high torque density direct-drive generator can be created. Magnetic geared systems offer unique capabilities that are currently not available using existing mechanically geared systems, such as overload protection. Magnetic gears also offer the potential for higher reliability, higher efficiency and quieter operation than is currently achievable using a mechanically geared generator. By increasing reliability and design life magnetic gears could decrease the overall life-cycle costs when compared with equivalent mechanical or direct-drive drivetrains. This research project investigated and experimentally testing two sub-scale magnetic gearboxes (0.12 m diameter) and two large diameter magnetic gearboxes (0.56m and 0.63m diameter). The goal of the project was to demonstrate a torque density >300Nm/L for a multistage magnetic gearbox with integrated stator. A nested multistage magnetic gear structure was first proposed and studied. However, it was shown that the nested design greatly increased mechanical complexity and therefore a two-stage series typology was utilized. A multi-stage magnetic gear with a 59:1 gear ratio was successfully experimentally tested. A peak torque of 4.25 kN·m was measured and this resulted in an overall active region torque density of 141 N·m/L (when including support rings). The torque density was significantly reduced from what was computed using 2-D electromagnetic analysis. This reduction was due to the 3-D edge effects, increased power losses and the inclusion of additional mechanical support rings as well as other mechanical assembly design changes. At large diameters contiguous lamination parts could not be fabricated and so a segmented laminated rotor design had to be used. This reduced the mechanical strength of the design when compared to small diameter magnetic gears and resulted in the need for the addition of mechanical support rings to prevent deflection. The final experimentally tested design also had a high torque ripple and the power loss within the magnetic gear did not change significantly with load. This therefore resulted in the efficiency being high only at peak loads. Despite not experimentally achieving the 2-D calculated high torque density the analysis has shown that the problems encountered with the scaling can be overcome with careful design changes. For example, understanding the unique mechanical deflection requirements during the electromagnetic design of the large diameter magnetic gears is key to achieving both a high torque density based on the electromagnetic analysis and a high torque density based on the mechanical support needs. Furthermore, ensuring that end plates are made of non-conductive material and minimizing other conductive support elements within the magnetic structure is a key requirement for reducing eddy current losses. In summary, if the mechanical design can be made more robust and eddy current loss mitigation strategies are used in the mechanical design phase then the magnetic gear is capable of being scaled up whilst operating at a very high torque density. This will then enable it to be potentially performance and cost competitive with alternative direct-drive and mechanically geared wind turbine drivetrains.

17 WIND ENERGY↗
DOE OSTI2022

Inclusion of a cold hardening scheme to represent frost tolerance is essential to model realistic plant hydraulics in the Arctic–boreal zone in CLM5.0-FATES-Hydro

As temperatures decrease in autumn, vegetation of temperate and boreal ecosystems increases its tolerance to freezing. This process, known as hardening, results in a set of physiological changes at the molecular level that initiate modifications of cell membrane composition and the synthesis of anti-freeze proteins. Together with the freezing of extracellular water, anti-freeze proteins reduce plant water potentials and xylem conductivity. To represent the responses of vegetation to climate change, land surface schemes increasingly employ “hydrodynamic” models that represent the explicit fluxes of water from soil and through plants. The functioning of such schemes under frozen soil conditions, however, is poorly understood. Nonetheless, hydraulic processes are of major importance in the dynamics of these systems, which can suffer from, e.g., winter “frost drought” events. In this study, we implement a scheme that represents hardening into CLM5.0-FATES-Hydro. FATES-Hydro is a plant hydrodynamics module in FATES, a cohort model of vegetation physiology, growth, and dynamics hosted in CLM5.0. We find that, in frozen systems, it is necessary to introduce reductions in plant water loss associated with hardening to prevent winter desiccation. This work makes it possible to use CLM5.0-FATES-Hydro to model realistic impacts from frost droughts on vegetation growth and photosynthesis, leading to more reliable projections of how northern ecosystems respond to climate change.

58 GEOSCIENCES↗
DOE OSTI2014

Modular Undersea Compressed Air Energy Storage (UCAES) System

This project has been devoted to the design, optimization, and cost analysis of a unique power plant with integral energy storage. The proposed facility combines a novel underwater compressed air energy storage (UCAES) system with a customized gas turbine generator, providing exceptional power management and overall efficiency. Unlike conventional CAES, opportunities for underwater storage are plentiful and proximal to the power grid. The UCAES system provides coastal and island communities a practical means for managing the volatility of large-scale wind and solar power resources. The result is higher renewable energy absorption and improved electrical reliability with reduced fossil fuel consumption. The UCAES power plant is composed of three major subsystems: The underwater air containment system (ACS), the air transport pipe (ATP), and the land-based power conversion system (PCS). The underwater ACS is made up of modular concrete shell units, structurally optimized for minimal material usage while employing conventional production methods and equipment. Each shell is designed to receive and control loose fill or gravel, serving as the ballast. The static nature of the final structures make them an asset to marine habitats and includes features intended to permit safe and cost-effective deployment. The ATP Connects the ACS modules to each other and to the on-land power conversion system and utilizes high density polyethylene (HDPE) pipe for low cost and long life. The PCS Houses the turbine-generator ‘expander modules’, with peak capacity of 12.3 MWe each, engineered from existing gas turbine equipment and includes electrically driven commercial 3-stage intercooled centrifugal compressors, each nominally drawing 6.6 MWe when matching the turbine flow requirements. The subsystems listed above are designed with the intent to serve as building-blocks to achieve a peak power output rating in the 40 to 120 MWe range, with 0.25 to 4 hours of energy storage capacity. The modular facility with integral energy storage provides some remarkable transient maneuvers and load-following features unachievable by competing technologies. The system can operate as a dispatchable power plant with a fuel-to-electric efficiency over 41%; substantially better that the average existing Hawaiian peak power generation assets. Optimal efficiency can be maintained while load-following due to modular PCS design and is operable with a range of liquid or gaseous fuels while meeting the most stringent California (CARB) emission standards. The system can operate as a peaking energy plant in discharge mode. Power ramp-up equivalent to 215% of continuous load rating within 1 second accomplished by simply turning off the electric compressor(s). Contrarily, the system can offer energy absorption during periods of grid surplus generation. The electric compressors may be sequenced on to absorb power within seconds. More moderate transitions are easily achieved with standard compressor control functions. The system offers unique features as compared to energy storage systems. ‘Round-trip efficiency’, as calculated by industry standard methods, is in the 90% range. The PCS equipment has a mean-time between overhauls of 80,000 hours, with maintenance costs of less than $0.005/kW-hr of electricity delivered. The underwater ACS structures and piping employ materials and designs specified to achieve a 75 year life. With the underwater containment modules qualified as a marine habitat, there would be no decommissioning costs. In conjunction with the engineering work invested in the design of the UCAES power plant, Brayton Energy has employed a team of manufacturing specialists, marine construction engineers, and power industry experts to create a comprehensive economic model that captures the many site-related variables and configuration options. The cost results and methodology have been validated by suppliers, engineers, and deployment specialists through a detailed case study on Hawaii. While creation of the parametric cost model was based on inputs specific to Hawaii, the proposed construction and deployment steps were chosen to be general enough to allow extrapolation across locations world-wide. Analysis of the proposed system shows it to be a viable option and addresses the principal challenges described by the Department of Energy by offering competitive costs, validated safety and reliability, consideration of the regulatory environment, and utilization of industry accepted practices and equipment. The UCAES system is recommended for immediate consideration in Hawaii. Estimation of time to complete planning, design, and construction of the facility is anticipated to take 3 to 5 years. Other coastal and island communities world-wide should realize similar benefits; as the results presented in this report are considered generally transferable to other locations.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2017

Recent results from a testbed for the reliability of the digital instrumentation and control systems and cybersecurity in nuclear power plants - 392

Transition from analog to digital instrumentation and control systems requires a systematic study of the modifications, and assessment of their reliability. Such studies are often carried out on a test bed. The test bed developed earlier includes a commercially available triple modular redundant (TMR) programmable logic controller (PLC) for testing not only the reliability of the digital I and C but also the cyber-security of the system during plant operation. This paper reports results of our preliminary analyses carried out using the test bed following the injection of faults mimicking faulty sensors. The fault injection tool generates faulty signals in single or multiple sensors located in the primary loop. These scenarios studied under steady-state operation conditions simulate a bad sensor, a cut wire, noise, etc. The faults injected can lead to information being displayed in the main control room (MCR) to not match the conditions in the plant. In addition to a fault injection module, a result analyzer module is also a part of this testbed. Operator actions can be based on information displayed in the MCR, or they can be informed by the result analyzer. Potential operator actions following these single- or multiple faulty signals are assessed. It is concluded that the result analyzer in some cases can be helpful in guiding operators to make the right decisions. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2015

A Combined Experimental and Computational Study on the Stability of Nanofluids Containing Metal Organic Frameworks

Computational studies on nanofluids composed of metal organic frameworks (MOFs) were performed using molecular modeling techniques. Grand Canonical Monte Carlo (GCMC) simulations were used to study adsorption behavior of 1,1,1,3,3-pentafluoropropane (R-245fa) in a MIL-101 MOF at various temperatures. To understand the stability of the nanofluid composed of MIL-101 particles, we performed molecular dynamics simulations to compute potentials of mean force between hypothetical MIL-101 fragments terminated with two different kinds of modulators in R-245fa and water. Our computed potentials of mean force results indicate that the MOF particles tend to disperse better in water than in R-245fa. The reasons for this observation were analyzed and discussed. Our results agree with experimental results indicating that the employed potential models and modeling approaches provide good description of molecular interactions and the reliabilities. Work performed by LXD was supported by the U.S. Department of Energy (DOE), Office of Basic Energy Sciences, Division of Chemical Sciences, Geosciences, and Biosciences. Work performed by HVRA, SKN, RKM, and PBM was supported by the Office of Energy Efficiency and Renewable Energy, Geothermal Technologies Program. Pacific Northwest National Laboratory is a multiprogram national laboratory operated for DOE by Battelle.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Electromagnetic Transient Simulation of Photovoltaic Inverter Using Implicit-Explicit Solver

This paper introduces the implementation of electromagnetic transient (EMT) simulations of a photovoltaic (PV) inverter module using the Implicit-Explicit (ImEx) solver in the Suite of Nonlinear and Differential/Algebraic Equation Solvers (SUNDIALS). This study demonstrates the effectiveness of the ImEx solver in overcoming the challenges inherent in simulating the complex dynamics of PV inverter modules. Furthermore, using SUNDIALS’ ImEx solver module ARKODE for EMT simulation automates key aspects of the process, such as numerical integration, providing substantial benefits including enhanced consistency, faster implementation, reduced human error, and the capability to handle the complexities of advanced numerical integration. By conducting comparative simulations with an implicit method used in commercial software, the research showcases the ImEx solver’s capability in achieving high accuracy and reliability. Results indicate that leveraging the ImEx approach significantly enhances modeling fidelity and reduces simulation setup times, offering a promising tool for the EMT analysis of PV inverter systems in power electronics-dominated power grids.

Choi, Jongchan [ORNL] (ORCID:000000025952455X)↗
DOE OSTI2023

pvOps: a Python package for empirical analysis of photovoltaic field data

The purpose of pvOps is to support empirical evaluations of data collected in the field related to the operations and maintenance (O&M) of photovoltaic (PV) power plants. pvOps presently contains modules that address the diversity of field data, including text-based maintenance logs, current-voltage (IV) curves, and timeseries of production information. The package functions leverage machine learning, visualization, and other techniques to enable cleaning, processing, and fusion of these datasets. These capabilities are intended to facilitate easier evaluation of field patterns and extraction of relevant insights to support reliability-related decision-making for PV sites. The open-source code, examples, and instructions for installing the package through PyPI can be accessed through the GitHub repository.

14 SOLAR ENERGY↗
DOE OSTI2015

DOE SunShot (FY15 Final Technical Report)

Sandia National Laboratories (Sandia) manages four of the five PV Regional Test Centers (RTCs). This report reviews accomplishments made by the four Sandia-managed RTCs during FY2015 (October 1, 2014 to September 30, 2015) as well as some programmatic improvements that apply to all five sites. The report is structured by Site first then by Partner within each site followed by the Current and Potential Partner summary table, the New Business Process, and finally the Plan for FY16 and beyond. Since no official SOPO was ever agreed to for FY15, this report does not include reporting on specific milestones and go/no-go decisions. The RTCs validate new solar technologies and system configurations, demonstrating performance and reliability under field conditions over time. There are five sites representing a range of climate conditions (NREL manages the Colorado site). The RTCs provide technical assistance to solar companies in the US. This program has shifted its focus, along with the industry, from validation of large systems to more targeted studies of small systems designed to compare sub-arrays of different module technologies. In addition, the RTCs are actively seeking partners from both module manufacturers and balance-of-systems producers.

14 SOLAR ENERGY↗
DOE OSTI2016

Spark Plasma Sintering of Ultracapacitors

A solid-state ultracapacitor module to replace standard electrochemical batteries would achieve major performance gains and mass/volume reduction. This report summarizes a project to evaluate an alternative sintering process to produce a solid-state ultracapacitor to overcome the limitations of both the electrochemical batteries presently in use on spacecraft and of currently available electrochemical ultracapacitors. It will provide a robust energy storage device with higher reliability, wider working temperature range, longer lifetime, and less weight and volume than electrochemical batteries. As modern electronics decrease in size, more efficient and robust remote power is needed. Current state-of-the-art rechargeable batteries cannot be rapidly charged, contain harmful chemicals, and suffer from early wear-out mechanisms. Solid-state ultracapacitors are recyclable energy storage devices that offer the promise of higher power and a greater number of charge/discharge cycles than current rechargeable batteries. In addition, the theoretical energy density when compared to current electrochemical batteries indicates that a significant weight savings is possible. This is a project to develop a very high density solid-state ultracapacitor with giant permittivity and acceptable dielectric loss to overcome the energy-density barrier such that it will be a suitable replacement for batteries.

25 ENERGY STORAGE↗
DOE OSTI2024

Exploring the Performance and Reliability of Screen-Printable Fire-Through Copper Paste on PERC Solar Cells

In this work, we present the performance and reliability of a fire-through copper (Cu) paste which has been screen printed on c-Si solar cell with passivated emitter rear contact (PERC). The Cu paste is fired through silicon nitride (SiN) anti-reflection coating at a peak temperature of 630 degrees C . SEM images of the Cu paste show a Cu core with ~200 nm oxide shell around the particles. This conductive oxide layer acts as a diffusion barrier between Cu and Si and prevents the degradation of cell performance during accelerated aging conditions. An efficiency of 19.250% has been achieved with Voc=654mV,FF= 76.68%, Jsc=38.40 m.A/cm 2 for champion PERC cells. Accelerated testing of the PERC mini-modules in damp heat chamber with 85 degrees C and 85% humidity have demonstrated that the devices are operational even after 1,500 hours. Devices with screen printed Ag contacts on the front side have been studied in parallel to the Cu contacts for comparison.

copper↗
DOE OSTI2025

RD53 pixel readout integrated circuits for ATLAS and CMS HL-LHC upgrades

The RD53 collaboration has since 2013 developed new hybrid pixel detector chips with 50 × 50 μm2 pixels for the HL-LHC upgrades of the ATLAS and CMS experiments at CERN. A common architecture, design and verification framework has been developed to enable final pixel chips of different sizes to be designed, verified and tested to handle extreme hit rates of 3 GHz/cm2 (up to 12 GHz per chip) together with an increased trigger rate of 1 MHz and efficient readout of up to 5.12 Gbits/s per pixel chip. Tolerance to an extremely hostile radiation environment with 1 Grad over 10 years and induced SEU (Single Event Upset) rates of up to 100 upsets per second per chip have been major challenges to make reliable pixel chips. Three generations of pixel chips, and many specific mixed signal building blocks and radiation test chips, have been submitted and extensively tested to get to final production chips. The large, complex and high rate pixel chips have been developed with a strong emphasis on low power consumption together with a concurrent development and qualification of novel serial powering at chip, module and system level, to minimize detector material budget.

Alimonti, G↗
DOE OSTI2018

Investigating PID Shunting in Polycrystalline Silicon Modules via Multi-Scale, Multi-Technique Characterization

Here we present a method for calculating the TCO sheet resistance of complete thin film modules using EL imaging. The method uses the characteristic decay of the junction voltage over the width of a cell stripe to derive four simple analytic equations for the TCO sheet resistance and the internal and contact resistances. Experimentally, only the module dark JV curve, Jsc-Voc curve, and electroluminescence imaging is required. Unlike previous methods, the internal and contact resistances of the modules are accounted for, and the method does not require curve fitting. The TCO sheet resistances of four 10cm x 10cm amorphous silicon modules are calculated and show excellent agreement with the experimentally measured values.

14 SOLAR ENERGY↗
DOE OSTI2016

Reconstruction of implanted marker trajectories from cone-beam CT projection images using interdimensional correlation modeling

Purpose: Cone-beam CT (CBCT) is a widely used imaging modality for image-guided radiotherapy. Most vendors provide CBCT systems that are mounted on a linac gantry. Thus, CBCT can be used to estimate the actual 3-dimensional (3D) position of moving respiratory targets in the thoracic/abdominal region using 2D projection images. The authors have developed a method for estimating the 3D trajectory of respiratory-induced target motion from CBCT projection images using interdimensional correlation modeling. Methods: Because the superior–inferior (SI) motion of a target can be easily analyzed on projection images of a gantry-mounted CBCT system, the authors investigated the interdimensional correlation of the SI motion with left–right and anterior–posterior (AP) movements while the gantry is rotating. A simple linear model and a state-augmented model were implemented and applied to the interdimensional correlation analysis, and their performance was compared. The parameters of the interdimensional correlation models were determined by least-square estimation of the 2D error between the actual and estimated projected target position. The method was validated using 160 3D tumor trajectories from 46 thoracic/abdominal cancer patients obtained during CyberKnife treatment. The authors’ simulations assumed two application scenarios: (1) retrospective estimation for the purpose of moving tumor setup used just after volumetric matching with CBCT; and (2) on-the-fly estimation for the purpose of real-time target position estimation during gating or tracking delivery, either for full-rotation volumetric-modulated arc therapy (VMAT) in 60 s or a stationary six-field intensity-modulated radiation therapy (IMRT) with a beam delivery time of 20 s. Results: For the retrospective CBCT simulations, the mean 3D root-mean-square error (RMSE) for all 4893 trajectory segments was 0.41 mm (simple linear model) and 0.35 mm (state-augmented model). In the on-the-fly simulations, prior projections over more than 60° appear to be necessary for reliable estimations. The mean 3D RMSE during beam delivery after the simple linear model had established with a prior 90° projection data was 0.42 mm for VMAT and 0.45 mm for IMRT. Conclusions: The proposed method does not require any internal/external correlation or statistical modeling to estimate the target trajectory and can be used for both retrospective image-guided radiotherapy with CBCT projection images and real-time target position monitoring for respiratory gating or tracking.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2021

Improving solar panel durability through novel panel designs and advanced manufacturing equipment

Work in the project was spread across 4 main themes:1) Improved Understanding of Why Cracks Form and Cause Degradation in Solar Cells: We developed a finite element model which correlated well with experimental determined deflection vs load profiles and which predicted stress profiles vs load level and temperature. These profiles helped to guide brace designs and showed the high stress levels seen in the silicon near the interconnect wire locations as the temperature is cooled below -30C, likely forming "invisible" microcracks. Experiments showed how for polymer backsheet modules, a brief exposure to such low temperatures made modules extremely sensitive to propagation of these microcracks at relatively low load levels, and how thicker and softer encapsulant helped to reduce this crack sensitivity. We showed for some modules that most cracks that are seen under loading had their origin at short, hard to see, V-cracks from soldering damage, and how the shunting from cells with high densities of cracks reduces energy delivery more than Pmax. 2) Improved Durability Testing Methods With Respect to Cracked Cells: We lobbied the PV community throughout the project that IEC 61215 was insufficient to probe the sensitivity of module Pmax degradation due to cracks in that in did not have a test leg that included a crack creation step (static loading) followed by a crack opening step (cyclic loading and/or thermal cycling). We published extensively on how pre- existing cracks opened up with cyclic loading. The new IEC TS 63209-1 ED1 test sequence now include our recommendations, and this should lead to improved module designs and reduced risk for investors. We also published recommendations for a new "Cold Climate Test" sequence to probe the sensitivity of modules to degradation from short microcracks formed when modules see temperatures below -30C followed by front side loading. We participated in several USTAG meetings related to cracked cells, EL testing, and mechanical load testing and provided input to the group to improve new standards under consideration. We also showed how the act of performing an EL test can affect the test results due to heating from the injected current. 3) New Module Designs and Related Manufacturing Methods & Equipment: We demonstrated reduced crack sensitivity on encapsulated cell coupons the benefits of building protective compressive stress into the cells by laminating them in a bent state and then allowing the coupon to flatten out after lamination. Our attempts to scale this to the module level with a more manufacturable sequence did not demonstrate the same positive effects, but we hope that others will follow up with other variations on this bent lamination or bent cooling concept to make more durable modules. 4) New Module Mounting Designs: We explored a range of bracing concepts which pressed on the backsheet to slightly bow the glass outward and place cells in a state of protective compressive stress and to reduce the deflection under front side loads. These successfully reduced cell cracking and crack opening, but high static loads permanently deformed cost-effective braces, after which they provided little benefit. We settled on an elegant & effective solution – the RailPad, where lightweight bracing elements are placed between the mounting rail(s) and the backsheet, and the existing strength of the rails is used to prevent module deflection under load. New construction and retrofit designs were made, and test sites were implemented in FL and MA. We applied for RailPad patent protection.

14 SOLAR ENERGY↗