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The design, fabrication, test, and qualification of a third generation intermediate load solar cell module are presented. A technical discussion of the detailed module design, preliminary design review, design modifications, and environmental testing are included. A standardized pricing system is utilized to establish the cost competitiveness of this module design.
Restructuring research objectives from a technical readiness demonstration program to an investigation of high risk, high payoff activities associated with producing photovoltaic modules using non-CZ sheet material is reported. Deletion of the module frame in favor of a frameless design, and modification in cell series parallel electrical interconnect configuration are reviewed. A baseline process sequence was identified for the fabrication of modules using the selected dendritic web sheet material, and economic evaluations of the sequence were completed.
This paper examines by analytical methods the power spectral densities of digital modulations (in particular, staggered and unstaggered quadrature modulations) passed through band-limited nonlinear channels. Previously observed (by computer simulation or hardware measurement) behavior of such spectra with regard to the suppression or restoration of its sidelobes after passing through the nonlinearity is verified analytically. Several examples corresponding to specific quadrature modulations and filter-nonlinearity combinations are presented as illustrations of the general results.
The modulation of the anomalous He-4 component is investigated both in time and in space from 1 to 23 AU with the spacecraft network of IMP-8, and Pioneers 10 and 11. The times of appearance and disappearance of the anomalous He-4 are determined, and it is found to have a higher sensitivity to modulation both in time and space than cosmic ray protons and helium of equivalent or lower rigidity. The disappearance of the flux due to modulation progressed radially outward over several months suggests that the source lies in the outer heliosphere, probably beyond 25 AU, and possibly out of the ecliptic.
Continuous particle flux measurements above rigidity thresholds of 1.2, 2.2, 5.5 and 11 GV were made by using the thresholds of two Cerenkov detectors aboard the ISEE-3 spacecraft. The ISEE-3 was launched in August 1978, near the beginning of the current solar cycle's heavy modulation phase, and the data presented represent the first direct measurement made at these energies with such a long time base. The measured long term modulation rigidity spectrum is compared with other data and with the spectrum of Forbush decreases, and it is found that the agreement between electron and positively charged particle results must be considered a constraint on cosmic ray modulation models involving the mechanism of gradient and curvature drift in the interplanetary magnetic field.
There have been differences of opinion regarding the origin and behavior of the solar modulation of galactic cosmic rays. It has been shown that the return to solar maximum intensity levels beginning in early 1978 was dominated by Forbush decreases. These Forbush decreases were caused by radially moving interplanetary shocks resulting from large solar flares. The present investigation is concerned with solar modulation effects which were observed during the previous solar minimum. The effects were associated with high-speed streams in the solar wind. These streams caused the formation of corotating interaction regions with both forward and reverse shocks. The modulation effects seen near earth are intimately connected with these shocks.
During the first four years of the U.S. Department of Energy (DOE) National Photovoltatic Program, the Jet Propulsion Laboratory Low-Cost Solar Array (LSA) Project purchased about 400 kW of photovoltaic modules for test and experiments. In order to identify, report, and analyze test and operational problems with the Block Procurement modules, a problem/failure reporting and analysis system was implemented by the LSA Project with the main purpose of providing manufacturers with feedback from test and field experience needed for the improvement of product performance and reliability. A description of the more significant types of failures is presented, taking into account interconnects, cracked cells, dielectric breakdown, delamination, and corrosion. Current design practices and reliability evaluations are also discussed. The conducted evaluation indicates that current module designs incorporate damage-resistant and fault-tolerant features which address field failure mechanisms observed to date.
A defect-design approach to sizing electrical insulation systems for terrestrial photovoltaic modules is presented. It consists of gathering voltage-breakdown statistics on various thicknesses of candidate insulation films where, for a designated voltage, module failure probabilities for enumerated thickness and number-of-layer film combinations are calculated. Cost analysis then selects the most economical insulation system. A manufacturing yield problem is solved to exemplify the technique. Results for unaged Mylar suggest using fewer layers of thicker films. Defect design incorporates effects of flaws in optimal insulation system selection, and obviates choosing a tolerable failure rate, since the optimization process accomplishes that. Exposure to weathering and voltage stress reduces the voltage-withstanding capability of module insulation films. Defect design, applied to aged polyester films, promises to yield reliable, cost-optimal insulation systems.
Beginning in 1976, Department of Energy field centers have installed and monitored a number of field tests and application experiments using current state-of-the-art photovoltaic modules. On-site observations of module physical and electrical degradation, together with in-depth laboratory analysis of failed modules, permits an overall assessment of the nature and causes of early field failures. Data on failure rates are presented, and key failure mechanisms are analyzed with respect to origin, effect, and prospects for correction. It is concluded that all failure modes identified to date are avoidable or controllable through sound design and production practices.
Several statistical reliability studies have been conducted in areas of photovoltaic component design covering cell failure, interconnect fatigue, glass breakage and electrical insulation breakdown. This paper integrates the results from these various studies and draws general conclusions relative to optimal reliability features for future modules. The described analysis is based on designing for specified low levels of component failures and then controlling the degrading effects of the failures through the use of fault tolerant circuitry and module replacement. Means of selecting the cost-optimal level of component failures, circuit redundancy, and module replacement are described.
System architecture brings order to potentially chaotic situation. New configuration allows many "smart" modules (each containing memory and microprocessor) to be linked by common data channel. Architecture allows each module to carry on operations at own data rate within block of time, while communications between modules occur in strict synchronism.
The essential electrical and mechanical characteristics of block 4 photovoltaic solar cell modules are described. Such module characteristics as power output, nominal operating voltage, current-voltage characteristics, nominal operating cell temperature, and dimensions are tabulated. The limits of the environmental and other stress tests to which the modules are subjected are briefly described.
Safety requirements for photovoltaic module and panel designs and configurations likely to be used in residential, intermediate, and large-scale applications were identified and developed. The National Electrical Code and Building Codes were reviewed with respect to present provisions which may be considered to affect the design of photovoltaic modules. Limited testing, primarily in the roof fire resistance field was conducted. Additional studies and further investigations led to the development of a proposed standard for safety for flat-plate photovoltaic modules and panels. Additional work covered the initial investigation of conceptual approaches and temporary deployment, for concept verification purposes, of a differential dc ground-fault detection circuit suitable as a part of a photovoltaic array safety system.
The IUE satellite was used to observe one of the youngest G stars (GO V) for which Duncan (1981) derives an age of 6 x 10 to the 8th power years from the Li abundance. Rotational modulation was looked for in the emission flux in the chromospheric and transition region lines of this star. Variations in the Ca 11 K-lines profile were studied with the CHF telescope at Mauna Kea. Results show that the same modulation of the emission flux of Ca 11 due to stellar rotation is present in the transition region feature of C IV and probably of He II. For other UV lines the modulation is not apparent, due to a more complex surface distribution of the active areas or supergranulation network, or a shorter lifetime of the conditions which give rise to these features, or to the uncertainities in the measured line strengths. The Mg II emission flux is constant to within + or - 3.4% implying a rather uniform distribution of Mg II emission areas. The Ca II emission not only shows a measurable variation in intensity but also variations in detailed line profile shape when observed at high resolution.
Advances in the theory and observation of cosmic ray modulation and in studies of the anomalous component in cosmic radiation are reviewed from reports that appeared in the open literature during the years 1979 to 1982. Entries, which are primarily the work of American researchers, are cited under the following categories: (1) microscopic diffusion theory; (2) global modulation theory; (3) anomalous component; and (4) general modulation observation.
The design and processing techniques necessary to incorporate bypass diodes within the module encapsulant are presented. The Semicon PN junction diode cells were selected. Diode junction to heat spreader thermal resistance measurements, performed on a variety of mounted diode chip types and sizes, have yielded values which are consistently below 1 deg C per watt, but show some instability when thermally cycled over the temperature range from -40 to 150 deg C. Three representative experimental modules, each incorporating integral bypass diode/heat spreader assemblies of various sizes, were designed. Thermal testing of these modules enabled the formulation of a recommended heat spreader plate sizing relationship. The production cost of three encapsulated bypass diode/heat spreader assemblies were compared with similarly rated externally mounted packaged diodes. It is concluded that, when proper designed and installed, these bypass diode devices will improve the overall reliability of a terrestrial array over a 20 year design lifetime.
Statistical models developed to define the most likely sources of photovoltaic (PV) array failures and the optimum method of allowing for the defects in order to achieve a 20 yr lifetime with acceptable performance degradation are summarized. Significant parameters were the cost of energy, annual power output, initial cost, replacement cost, rate of module replacement, the discount rate, and the plant lifetime. Acceptable degradation allocations were calculated to be 0.0001 cell failures/yr, 0.005 module failures/yr, 0.05 power loss/yr, a 0.01 rate of power loss/yr, and a 25 yr module wear-out length. Circuit redundancy techniques were determined to offset cell failures using fault tolerant designs such as series/parallel and bypass diode arrangements. Screening processes have been devised to eliminate cells that will crack in operation, and multiple electrical contacts at each cell compensate for the cells which escape the screening test and then crack when installed. The 20 yr array lifetime is expected to be achieved in the near-term.
Experimental and theoretical studies of cosmic-ray-modulation phenomena reported in the open literature by US researchers during the 1979-1982 period are reviewed. Areas covered include microscopic diffusion theory, gradient and curvature drift, global modulation theory, the anomalous component, and general modulation observations (such as the Pioneer-10 Forbush-decrease-propagation observations and studies on the time variation of the electron-to-proton ratio). An impressionistic overview of current and future trends in this area of study is also provided.