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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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18 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Comparing Methods for Assessing Reliability Uncertainty Based on Pass/Fail Data Collected Over Time

In this paper, we compare statistical methods for analyzing pass/fail data collected over time; some methods are traditional and one (the RADAR or Rationale for Assessing Degradation Arriving at Random) was recently developed. These methods are used to provide uncertainty bounds on reliability. We make observations about the methods' assumptions and properties. Finally, we illustrate the differences between two traditional methods, logistic regression and Weibull failure time analysis, and the RADAR method using a numerical example.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Test and extraction methods for the QC parameters of silicon strip sensors for ATLAS upgrade tracker

The Quality Control (QC) of pre-production strip sensors for the Inner Tracker (ITk) of the ATLAS Inner Detector upgrade has finished, and the collaboration has embarked on the QC test programme for production sensors. This programme will last more than 3 years and comprises the evaluation of approximately 22000 sensors. 8 Types of sensors, 2 barrel and 6 endcap, will be measured at many different collaborating institutes. The sustained throughput requirement of the combined QC processes is around 500 sensors per month in total. Measurement protocols have been established and acceptance criteria have been defined in accordance with the terms agreed with the supplier. For effective monitoring of test results, common data file formats have been agreed upon across the collaboration. To enable evaluation of test results produced by many different test setups at the various collaboration institutes, common algorithms have been developed to collate, evaluate, plot and upload measurement data. This allows for objective application of pass/fail criteria and compilation of corresponding yield data. These scripts have been used to process the data of more than 3000 sensors so far, and have been instrumental for identification of faulty sensors and monitoring of QC testing progress.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2024

Maximizing Efficiency and Quality: Leveraging Automated Testing for Laboratory Commissioning

The traditional commissioning process uses sampling to select equipment for functional acceptance testing when large quantities of equipment are present. Although this approach is generally effective in identifying wide-spread issues, it has several shortcomings: it fails to evaluate equipment not included in the sample, provides only a one-time validation of equipment operation, and the standard documentation is a simple checklist of pass/fail questions. During the construction and commissioning process of the new Research and Innovation Laboratory (RAIL) in Golden, CO, the National Renewable Energy Laboratory team engaged Group14 Engineering to implement a Connected Commissioning process using fault detection and diagnostic software for automated functional acceptance testing. This presentation highlights the advantages offered by automated functional testing in this critical laboratory setting: (1) sampling 100% of BAS-connected equipment during functional testing, (2) testing results backed by data beyond the traditional pass/fail checklist, and (3) an automated test process that can be regularly executed by the building management team for ongoing commissioning throughout the life of the building. The presentation will also cover technical challenges associated with Connected Commissioning and the important conversations with key stakeholders that need to occur well before functional acceptance testing in order to successfully implement the automated testing processes.

automated testing↗
DOE OSTI2023

Maximizing Efficiency and Quality: Leveraging Automated Testing for Laboratory Commissioning

The traditional commissioning process for a building often implements sampling rates to select equipment for functional acceptance testing when large quantities of equipment are present. While this approach is generally effective in identifying wide-spread issues, it has several key shortfalls. (1) It provides a one-time validation of equipment operation in which the standard documentation is a simple checklist of pass/fail questions. (2) It fails to evaluate equipment not included in the sample rate selection. During the construction and commissioning process of the new Research and Innovation Laboratory (RAIL) in Golden, CO, the National Renewable Energy Laboratory team engaged Group14 Engineering to implement a Connected Commissioning process using fault detection and diagnostic software for automated functional acceptance testing. The goal of this presentation will be to highlight the advantages offered by automated functional testing in this critical laboratory setting. These are primarily (1) sampling 100% of BAS-connected equipment during functional testing, (2) testing results backed by data beyond the traditional pass/fail checklist, and (3) an automated test process that can be regularly executed by the building management team for ongoing commissioning throughout the life of the building. The presentation will also cover technical challenges associated with connected commissioning and the important conversations with the key stakeholders that need to occur well before functional acceptance testing in order to successfully implement the automated testing processes.

automated testing↗
DOE OSTI2023

SOLAr Critical Infrastructure Energization (SOLACE): Leveraging Distributed Energy Resources to Provide Local Power

This document is a technical report based on a large-scale DOE-funded project conducted between 2019 and 2022. The project, called SOLAr Critical infrastructure Energization (SOLACE), is aimed at leveraging distributed energy resources (DERs) to provide local power to communities, feeders, or other regions. The project included a particular focus on high-value critical loads such as municipal water supply, telecommunication hubs, and disaster shelters. The key developments of the project were: (1) A comprehensive pre-event power system analysis methodology that identifies and characterizes the viable local power options. (2) A DMS-based example control system for activating and operating the local power solution during a time of crisis. (3) Grid-forming inverter technology to enable isolated local power operation and black-starting. (4) Cyber-security considerations for isolated systems when wider-area communication may be offline. This report describes the overall process that identifies and assesses the viable DER-based local power solutions for a given facility, region, or community. The report documents the process, including the key analysis steps, tools required, data requirements, and recommended pass/fail criteria for each step. It also provides a sample implementation of this process through a test case. Finally, it provides details of how a viable pre-event plan can be selected and activated at go-time when an event has occurred.

14 SOLAR ENERGY↗
DOE OSTI2017

CMM Data Analysis Tool

Due to the increase in the use of Coordinate Measuring Machines (CMMs) to measure fine details and complex geometries in manufacturing, many programs have been made to compile and analyze the data. These programs typically require extensive setup to determine the expected results in order to not only track the pass/fail of a dimension, but also to use statistical process control (SPC). These extra steps and setup times have been addressed through the CMM Data Analysis Tool, which only requires the output of the CMM to provide both pass/fail analysis on all parts run to the same inspection program as well as provide graphs which help visualize where the part measures within the allowed tolerances. This provides feedback not only to the customer for approval of a part during development, but also to machining process engineers to identify when any dimension is drifting towards an out of tolerance condition during production. This program can handle hundreds of parts with complex dimensions and will provide an analysis within minutes.

Source record↗
DOE OSTI2017

Establishment of a PID Pass/Fail Test for Crystalline Silicon Modules by Examining Field Performance for Five Years: Preprint

In an experiment with five module designs and multiple replicas, it is found that crystalline silicon cell modules that can pass a criterion of less than 5 percent power degradation in stress test conditions of 60 degrees Celsius, 85 percent relative humidity (RH), 96 h, and nameplate-rated system voltage bias show no power degradation by potential induced degradation in the range of 4-6 years duration in the Florida, USA environment. This data suggests that this chamber stress level is useful as a pass/fail criterion for PID, and will help ensure against degradation by system voltage stress in Florida, or less stressful climates, for at least 5 years.

14 SOLAR ENERGY↗
DOE OSTI2018

Connectivity and functional verification for the LSST science raft towers

The LSST Camera focal plane will be constructed with 21 144-Mpixel modules (\Raft Tower Module", RTM). An extensive operational test is performed to confirm the integrity of all connections and to verify the basic functionality. Each RTM undergoes at least four connectivity tests. A python script communicates with Java- based control software and performs the test. A python script parses the test data and generates a PDF report. The report includes a summary PASS/FAIL table, several hundred current, voltage and temperature parameters, and images taken with the CCD array at room temperature.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2015

WE-D-BRA-01: FEATURED PRESENTATION and BEST IN PHYSICS (THERAPY): Predicting Potentially Problematic VMAT Treatment Plans Before Patient Specific QA Measurements

Purpose: Several promising IMRT QA tools have been developed in recent years to combat problems found in the lack of sensitivity in planar dose measurements analyzed using consensus gamma analysis criteria. The increased complexity and added information with such devices adds not only increased time, but new challenges in determining endpoints for pass/fail criteria. Using a large cohort of previously measured planar IMRT QA data, it may be possible to correlate potentially problematic plans with calculated plan metrics that can be done a priori, such that these tools can be used only in clinically relevant situations. Methods: 90 previously measured, clinically delivered VMAT plans were exported in DICOM RT format. Using a Matlab program, plan metrics were computed based on a previously developed set of equations (Du et al. 2014). These metrics included MU-weighted beam irregularity, which quantifies an MLC shape’s deviation from that of a circle. Machine delivery parameters such as MU delivered per degree and leaf movement in millimeters per MU were also calculated. Based on a previous analysis of 394 IMRT QA measurements, a “failing” plan was defined as one with less than 85% gamma pass rate when computed at 1% dose difference and 2 mm distance to agreement; 16 of the 90 plans were identified as failing Results: A ROC curve was generated with an AUC of 0.9409. All 16 outliers were detected with a specificity of 85.1% when using a threshold value based on a linear combination of the MU-weighted plan irregularity and the leaf speed in mm/degree (average MU delivered per degree multiplied by average leaf movement in mm per MU). Conclusion: This data supports that potentially problematic VMAT plans can possibly be predicted before measurement by assessing the MU-weighted irregularity of the MLC shapes combined with the averaged leaf speed of the MLC.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2016

Sci-Thur AM: YIS – 08: Automated Imaging Quality Assurance for Image-Guided Small Animal Irradiators

Purpose: To develop quality assurance (QA) standards and tolerance levels for image quality of small animal irradiators. Methods: A fully automated in-house QA software for image analysis of a commercial microCT phantom was created. Quantitative analyses of CT linearity, signal-to-noise ratio (SNR), uniformity and noise, geometric accuracy, modulation transfer function (MTF), and CT number evaluation was performed. Phantom microCT scans from seven institutions acquired with varying parameters (kVp, mA, time, voxel size, and frame rate) and five irradiator units (Xstrahl SARRP, PXI X-RAD 225Cx, PXI X-RAD SmART, GE explore CT/RT 140, and GE Explore CT 120) were analyzed. Multi-institutional data sets were compared using our in-house software to establish pass/fail criteria for each QA test. Results: CT linearity (R2>0.996) was excellent at all but Institution 2. Acceptable SNR (>35) and noise levels (<55HU) were obtained at four of the seven institutions, where failing scans were acquired with less than 120mAs. Acceptable MTF (>1.5 lp/mm for MTF=0.2) was obtained at all but Institution 6 due to the largest scan voxel size (0.35mm). The geometric accuracy passed (<1.5%) at five of the seven institutions. Conclusion: Our QA software can be used to rapidly perform quantitative imaging QA for small animal irradiators, accumulate results over time, and display possible changes in imaging functionality from its original performance and/or from the recommended tolerance levels. This tool will aid researchers in maintaining high image quality, enabling precise conformal dose delivery to small animals.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2022

Improving Solar and Solar+Storage Screening Techniques to Reduce Utility Interconnection Time and Costs (Final Technical Report)

Residential PV installations have increased rapidly over the last decade, and the increased application volume has caused permitting delays and lower overall adoption rates. In this project, we developed and evaluated whether data-driven secondary modeling and screening techniques can help utilities assess customer applications more accurately than traditional screening shortcuts. Secondary topologies are predicted using decision trees and commonly available information, such as service transformer, customer, and street locations. Conductors were predicted using a logistic regression method based on real world object (RWO) types, service transformer ratings, conductor length, and distance to transformer. After developing the combined primary and secondary distribution network model, hosting capacity results were used to train a random forest model to predict the pass/fail likelihood of a customer application. Powerflow based models with predicted secondaries and data-driven methods both increased the screening success rate, relative to common utility heuristics, by as much as 55 percentage points. Data-driven screening techniques were described by one utility as a "right-sized" approach for residential customers given the low-risk of small errors and the high-cost of accurate modeling.

14 SOLAR ENERGY↗
DOE OSTI2015

Benefits of utilizing CellProfiler as a characterization tool for U–10Mo nuclear fuel

Automated image processing techniques have the potential to aid in the performance evaluation of nuclear fuels by eliminating judgment calls that may vary from person-to-person or sample-to-sample. Analysis of in-core fuel performance is required for design and safety evaluations related to almost every aspect of the nuclear fuel cycle. This study presents a methodology for assessing the quality of uranium–molybdenum fuel images and describes image analysis routines designed for the characterization of several important microstructural properties. The analyses are performed in CellProfiler, an open-source program designed to enable biologists without training in computer vision or programming to automatically extract cellular measurements from large image sets. The quality metric scores an image based on three parameters: the illumination gradient across the image, the overall focus of the image, and the fraction of the image that contains scratches. The metric presents the user with the ability to ‘pass’ or ‘fail’ an image based on a reproducible quality score. Passable images may then be characterized through a separate CellProfiler pipeline, which enlists a variety of common image analysis techniques. The results demonstrate the ability to reliably pass or fail images based on the illumination, focus, and scratch fraction of the image, followed by automatic extraction of morphological data with respect to fission gas voids, interaction layers, and grain boundaries. - Graphical abstract: Display Omitted - Highlights: • A technique is developed to score U–10Mo FIB-SEM image quality using CellProfiler. • The pass/fail metric is based on image illumination, focus, and area scratched. • Automated image analysis is performed in pipeline fashion to characterize images. • Fission gas void, interaction layer, and grain boundary coverage data is extracted. • Preliminary characterization results demonstrate consistency of the algorithm.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Fission Meter Information Barrier Attribute Measurement System - NA-243 FNI/UKC FY2017 Task 1-2 Report

An SNM attribute Information Barrier (IB) system was developed for a 2011 US/UK Exercise. The system was modified and extensively tested in a 2013-2014 US-UK Measurement Campaign. This work demonstrated rapid deployment of an IB system for potential treaty use. The system utilizes an Ortec Fission Meter neutron multiplicity counter and custom computer code. The system demonstrates a proof-of-principle automated Pu-240 mass determination with an information barrier. After a software start command is issued, the system automatically acquires and downloads data, performs an analysis, and displays the results. This system conveys the results of a Pu mass threshold measurements in a way the does not reveal sensitive information. In full IB mode, only the pass/fail result is displayed as a “Mass <= Threshold Amount” or “Mass >= Threshold Amount” as shown in Figure 4. This can easily be adapted to a red/green “lights” display similar to the Detective IB system for Pu isotopics as shown in Figure 6. In test mode, more detailed information is displayed. The code can also read in, analyze, and display results from previously acquired or simulated data. Because the equipment is commercial-off-the-shelf (COTS), the system demonstrates a low-cost short-lead-time technology for treaty SNM attribute measurements. A deployed system will likely require integration of additional authentication and tamper-indicating technologies. This will be discussed for the project in this and future progress reports.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2017

Streamlining and Transparently Automating Complex Waste Determinations at Los Alamos National Laboratory - 17286

Environmental programs at Los Alamos National Laboratory (LANL) generate a large amount of sampling activities that can result in waste that needs to be characterized and properly disposed. Since 2011, sampling results are managed in the cloud-based Environmental Information Management (EIM) database, which contains over 16 million current and historical data records. In many cases, the database's analytical records are used to characterize and dispose waste from environmental operations. Three factors contribute to streamlining of the waste disposition operations: (1) if possible, use of the existing analytical data for waste characterization to avoid additional laboratory analysis; (2) reduction in time spent on data evaluation for various waste acceptance criteria; and (3) choice of the proper and least expensive disposal alternative. Use of the existing analytical data, when allowed by law, creates some paradoxical problems: when chemical analysis is requested with the purpose of characterizing waste, it creates only 100 to 400 analytical records. However, use of exiting analytical data at LANL may lead to evaluation of tens of thousands of analytical records, with many records for each single analyte. This occurs because data were collected for environmental characterization and not waste characterization. To streamline data analysis for waste disposition using existing data, LANL has created a Waste Data Summary (WDS) module in the site's EIM database. Recognizing that waste determination is performed by groups outside the environmental program at LANL, the WDS allows for logically guided data selection for a specific waste determination (solids, liquids, radiological, etc.) and reduces potentially thousands of rows of data into simple formatted data reports that are easy to comprehend and process. This allows the waste evaluators to review data using multiple approaches to make their own determination on the most appropriate disposal method. There are four basic principles of WDS operation: (1) The highest detected analytical result is evaluated for the selected samples (or the lowest undetected result if there are no detected results); (2) All approved disposal pathways are evaluated; (3) Any failures of the Waste Acceptance Criteria are visibly highlighted to focus the attention of the evaluator; and (4) The decision of the disposal path is left to the trained waste evaluator (WDS does not choose or suggest any disposal paths). The summary results are presented as the set of short data reports. These reports can be divided into two groups: general comparison reports and disposal pathway specific forms. The general comparison forms show all Resource Conservation and Recovery Act (RCRA) analytes with pass/fail evaluation and with preference for toxicity characteristic leaching procedure (TCLP) results (or 20x rule) for solid samples, the potential RCRA hazard codes assignment for detected analytes, and all rad results. The detected chemical and radioactivity results are compared to the background values and to Soil Screening and Soil Action limits (SSL/SAL limits). Disposal pathway specific forms follow Waste Acceptance Criteria requirements for all disposal pathways available at LANL. The programming of the WDS tries to maximize existing data by analyte substitutions (like using gross alpha for necessary alpha emitting isotopes) or by making calculations when analytical results do not agree with legal requirements (like total chlordane in the RCRA regulations, which is most often analyzed and reported as individual isomers). All forms may be annotated by the waste evaluator to provide additional information to support decision making. Upon final decision of a disposal path, the complete dataset used in the evaluation and the WDS forms with annotations is 'frozen' as an un-editable PDF export to document the data used in the waste disposal determination. The streamlined process results in less work for waste evaluators and reduces overall labor and analytical costs. By comparison, a full review of a 10,000 record parent dataset may take a waste evaluator over a week to review, whereas with the WDS module, the task can be accomplished in less than one hour with clear, reproducible results. These results can be reviewed and checked at any time by quality assurance personnel, thus ensuring transparency in the decision making process. LANL believes this approach has broad applicability to other sites where waste determination is based on review of existing data collected for more generalized environmental purposes. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

An Authentication Vulnerability Assessment of Connected Lighting Systems

Emerging connected lighting systems (CLS) that incorporate distributed intelligence, network interfaces, and sensors can become data-collection platforms that enable a wide range of valuable new capabilities as well as greater energy savings in buildings and cities. However, CLS technology is currently at an early stage of development, and its increased connectivity introduces cybersecurity risks that are new to the lighting industry and that must be addressed for successful integration with other systems. While a number of existing frameworks, guidelines, and tests for evaluating cybersecurity vulnerability may apply to CLS in whole or in part, there is currently no mandatory requirement for cybersecurity testing or certification. The lighting industry, including technology developers and specification organizations, is currently evaluating the suitability of existing frameworks and guidelines for CLS. To support these efforts, Pacific Northwest National Laboratory (PNNL) is conducting a series of studies intended to educate lighting industry stakeholders on specific cybersecurity practices and characterize their implementation in commercially available CLS with varying system architectures, network-communication technologies, and degrees of maturity. This study demonstrates that tests for authentication vulnerabilities can be developed with objective pass/fail criteria, therby facilitating comparisons between CLS. Based on the limited results of this study, it appears that the CLS that are being brought to market have varying levels of authentication vulnerability. It is hoped that these evaluations will support and perhaps accelerate industry discussions on the risks of specific security vulnerabilities, what vulnerabilities should be addressed by in-development of future lighting-specific best practices, and whether any such practices should be included in voluntary lighting standards.

42 ENGINEERING↗
DOE OSTI2020

Blunt Impact Brain Injury using Cellular Injury Criterion

The Advanced Combat Helmet (\ACH") military specification (\mil-spec") requires a helmeted magnesium (\Mg") Department of Transportation (\DOT") headform be dropped vertically, with an impact speed of 3.1 m/s (10 ft/s), onto a steel hemispherical target. The pass/fail criteria are based on translational acceleration (150 G) alone, absent of any rotational component. Without a rotational component, the specification's injury risk application is limited to skull fracture and peripheral hematomas (subdural, subarachnoid), since this translational acceleration injury risk assessment is based on the Wayne State Tolerance Curve (\WSTC"). To provide a more comprehensive view of injury for the entire brain, an alternative approach is needed. To meet this need, we worked with a larger group called PANTHER, a collaboration between national laboratories, industry, and academia. Collaborations specific to research and results presented here come from efforts led by Mr. Ron Szalkowski and Mr. Sushant Malave, Ms. Alice Fawzi, and Dr. Christian Franck. We have developed a prototypical injury risk criterion based on the neuronal response to abrupt changes in general motion (translation, rotation, or both). The cellular-based mild traumatic brain injury (\cbmTBI") criterion utilizes both the strain and strain rate of brain tissue to account for the stretch and rate of stretch that occurs throughout the brain as a result of blunt impact to the head. We conducted physical experiments of an ACH-fitted magnesium headform, which produced repeatable headform peak accelerations. Then, we developed a simulation of the experiment, and validated the simulation output with the experimental data. We then substituted the magnesium headform with a human headform, consisting of skin, muscle, bone, gray matter, white matter, cerebral-spinal fluid, membranes, vasculature, intravertebral discs, airway and sinus. We quantified brain injury risk using the cbmTBI criterion, using the current mil-spec test and a modified test. The modified mil-spec test used an inclined anvil target that was located posterior to the crown of the helmet in the axial plane. While the current mil-spec test produced brain deformation from head translation alone, the modified test produced brain deformation from head translation and rotation, which is closer to most real world and combat theater impacts (e.g., such as occur in tertiary blast exposure). Compared to the current mil-spec test, the modified test produced elevated strains in the human digital twin. These data, mapped to the cbmTBI criterion, suggest increased injury risk for blunt impacts that cause rotation and translation, rather than just translation alone. Moreover, these data may lead to a rotational performance metric, which is rooted in the biology and pathology of the brain's response to impact and blast, and which should be used to improve next-generation helmet designs.

42 ENGINEERING↗
DOE OSTI2015

SU-E-T-679: Retrospective Analysis of the Sensitivity of Planar Dose Measurements To Gamma Analysis Criteria

Purpose: IMRT QA using planar dose measurements is still a widely used method for checking the accuracy of treatment plans. A pass/fail judgment is made using gamma analysis based on a single endpoint. Using more stringent criteria is a way to increase the sensitivity to planning and delivery errors. Before such implementation, it is necessary to understand how the sensitivity to different gamma criteria settings affects gamma passing rates (GPR). Methods: 752 IMRT QA measurements were re-analyzed with varying distance to agreement (DTA) and dose difference (DD) percentages using a Matlab program. Other quantifying information such as the mean dose difference in the treatment target (defined as points that are greater than 80% of maximal dose) were stored in a relational database for retrospective analysis. Results: The average and standard deviation of GPR (%) fell from 99.84 ± (0.43) to 89.61 ± (6.08) when restricting DD from 5 − 1% respectively, as compared to a drop from 99.15 ± (1.19) to 95.00 ± (4.43), when restricting the DTA from 5 − 1 mm respectively. The mean dose difference (%) in the treatment target between measured and calculated dose was −1.96 ± (0. 83), −0.09 ± (0.98), and 1.44 ± (0. 86) for each of our institution’s three matched linear accelerators (LINAC 1, 2, and 3 respectively). For plans that are approximately 2.7 sigma below the mean GPR, an average of 78.4% of those plans were measured on LINAC 1 or 3, while only 48% of the total plans were run on those machines. Conclusion: The data demonstrates that when restricting gamma criterion, such as the DD, the greatest indicator of reduced GPR in our institution is which matched LINAC the plan was measured on. While small, these differences manifest themselves to levels comparable to other treatment related differences and possibly confound the gamma analysis.

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2018

Correlation of Qualification and Accelerated Testing with Field Degradation

Qualification testing of solar photovoltaic (PV) modules per IEC 61215 standard encompasses a set of well-defined accelerated stress tests (irradiation, environmental, mechanical and electrical) with strict pass/fail criteria based on functionality/performance, electrical and mechanical safety, and visual requirements. The qualification testing does not identify all the possible reliability failures or durability issues witnessed in the actual field. However, it does identify the major/catastrophic design quality issues (infant mortality), which could occur early in a module’s field life. Unfortunately, in the industry, there is no consensus-based standard or protocol available to validate manufacturers’ warranty period claims based on the end-of-life wear-out failure mechanisms. Being able to predict the field degradation rates and lifetime using mode-specific accelerated tests on moderately field-aged modules, for example 10 years, for certain commonly occurring degradation modes would be a powerful contribution to all the stakeholders of the PV industry. There is a need to formulate guidelines to find the correlation of accelerated testing with field degradation for individual degradation modes observed in the field. Potential approaches to fulfill this need were experimented in this project and are presented in this report. Two of the most commonly seen degradation modes – encapsulant browning and solder bond thermomechanical fatigue – are addressed in this report through presenting the accelerated testing methods and physical modelling approaches. Two accelerated test methods (UV and thermal cycling) were designed to induce the wear-out mechanisms in the modules and not infant mortality failures. To focus on the wear-out failure modes, the tests were performed on field-aged modules, instead of fresh modules, with known degradation rates and degradation modes. The degradation rates were measured based on the degradation rates of individual cell parameters (short-circuit current, I sc and series resistance, R s ) instead of the degradation rate of maximum power (P max ) which cannot be used to study any specific/limited degradation mode as the P max degradation could be caused by many different degradation modes. The key characteristic parameter considered for encapsulant discoloration and solder bond degradation is I sc and R s , respectively. The developed physical models/equations relating the testing degradation data and field weather data were utilized to determine the acceleration factor (AF) and to predict the degradation rate for a specific degradation mode of PV modules installed in two different climates, Arizona (hot) and New York (cold). The predicted degradation rates for encapsulant browning and solder bond degradation have also been validated against the actual measured field degradation rates. UV testing cost reduction: To determine acceleration factor, single UV chamber was used for accelerated UV testing at three different temperatures simultaneously, instead of three chambers for three temperatures (or one chamber sequentially which is an extremely time-consuming approach). A passive heating approach was successfully used to achieve and maintain multiple temperatures in the accelerated UV chamber. Foam insulation boards of varying thicknesses were utilized to obtain three different temperatures for UV testing. However, these foam materials tend to disintegrate in the presence of moisture. To alleviate this problem, silicone heating blankets with temperature controls and humidifier can be used if the UV testing is to be performed under hot-humid conditions instead of conventional hot-dry conditions. Thermal cycling testing cost reduction: Single thermal cycling chamber was used for accelerated thermal cycling testing at three different upper temperatures simultaneously, instead of three chambers for three upper temperatures (or one chamber sequentially which is an extremely time-consuming approach). An active heating approach based on silicone heating blankets was successfully used to achieve and maintain multiple upper temperatures in the accelerated thermal cycling chamber. Such blankets provide stable temperature control and thereby more reliable and repeatable for replicate experiments.

14 SOLAR ENERGY↗