250 kW Solar String Inverter Using Silicon Carbide (SiC) Modular Architecture and Grid Support Functionality FINAL REPORT
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A power source was developed to support testing for the Space Station Freedom Power Management and Distribution (PMAD) DC Testbed. The intent was to simulate as closely as possible the steady-state and transient responses of a solar array. Several breadboards and one thermal prototype were built and tested. Responses were successfully verified and improved upon during successive breadboards. The completed 90-string simulator consists of four power MOSFETs, four 25 watt source resistors, and four 250 watt drain source bypass resistors per string, in addition to the control circuitry.
A power source was developed to support testing for the Space Station Freedom Power Management and Distribution (PMAD) DC Testbed. The intent was to simulate as closely as possible the steady-state and transient responses of a solar array. Several breadboards and one thermal prototype were built and tested. Responses were successfully verified and improved upon during successive breadboards. The completed 90-string simulator consists of four power MOSFETs, four 25-watt source resistors, and four 250-watt drain source bypass resistors per string, in addition to the control circuitry.
Wire-based metallization and stringing techniques for solar cells, and the resulting solar cells, modules, and equipment, are described. In an example, a string of solar cells includes a plurality of back-contact solar cells, wherein each of the plurality of back-contact solar cells includes P-type and N-type doped diffusion regions. A plurality of conductive wires is disposed over a back surface of each of the plurality of solar cells, wherein each of the plurality of conductive wires is substantially parallel to the P-type and N-type doped diffusion regions of each of the plurality of solar cells. One or more of the plurality of conductive wires adjoins a pair of adjacent solar cells of the plurality of solar cells and has a relief feature between the pair of adjacent solar cells.
Wire-based metallization and stringing techniques for solar cells, and the resulting solar cells, modules, and equipment, are described. In an example, a substrate has a surface. A plurality of N-type and P-type semiconductor regions is disposed in or above the surface of the substrate. A conductive contact structure is disposed on the plurality of N-type and P-type semiconductor regions. The conductive contact structure includes a plurality of conductive wires, each conductive wire of the plurality of conductive wires essentially continuously bonded directly to a corresponding one of the N-type and P-type semiconductor regions.
Wire-based metallization and stringing techniques for solar cells, and the resulting solar cells, modules, and equipment, are described. In an example, a substrate has a surface. A plurality of N-type and P-type semiconductor regions is disposed in or above the surface of the substrate. A conductive contact structure is disposed on the plurality of N-type and P-type semiconductor regions. The conductive contact structure includes a plurality of conductive wires, each conductive wire of the plurality of conductive wires essentially continuously bonded directly to a corresponding one of the N-type and P-type semiconductor regions.
Vacuum "lance" picks up assembled chain of solar cells from string conveyor without disturbing cells or interconnecting tabs. Lance has 2 vacuum pickups per cell, for total of up to 32 pickups. Positions and number of pickups can be varied. Lance can be adjusted for range of cell sizes, shapes, and spacings.
String bonder for solar-cell arrays eliminates tedious manual assembly procedure that could damage cell face. Vacuum arm picks up face-down cell from cell-inverting work station and transfers it to string conveyor without changing cell orientation. Arm is activated by signal from microprocessor.
String-conveyor portion of solar-array assembly line holds silicon solar cells while assembled into strings and tested. Cells are transported collector-side-down, while uniform cell spacing and registration are maintained. Microprocessor on machine controls indexing of cells.
Microprocessor-controlled dc-to-dc power converters devised to maximize power transferred from solar photovoltaic strings to storage batteries and other electrical loads. Converters help in utilizing large solar photovoltaic arrays most effectively with respect to cost, size, and weight. Main points of invention are: single controller used to control and optimize any number of "dumb" tracker units and strings independently; power maximized out of converters; and controller in system is microprocessor.
Metallization and stringing methods for back-contact solar cells, and resulting solar cells, are described. In an example, in one embodiment, a method involves aligning conductive wires over the back sides of adjacent solar cells, wherein the wires are aligned substantially parallel to P-type and N-type doped diffusion regions of the solar cells. The method involves bonding the wires to the back side of each of the solar cells over the P-type and N-type doped diffusion regions. The method further includes cutting every other one of the wires between each adjacent pair of the solar cells.
In one or more embodiments, the present disclosure teaches a method for reconfiguring a solar array. The method involves providing, for the solar array, at least one string of solar cells. The method further involves deactivating at least a portion of at least one of the strings of solar cells of the solar array when power produced by the solar array reaches a maximum power allowance threshold. In addition, the method involves activating at least a portion of at least one of the strings of the solar cells in the solar array when the power produced by the solar array reaches a minimum power allowance threshold.
The methodology used to assess the probability of no impact of space debris and meteoroids on a spacecraft structure is applied to the Space Station solar array assembly. Starting with space debris and meteoroid flux models, the projected surface area of the solar cell string circuit of the solar array panel and the mast longeron, and the design lifetime, the possibility of no impact on the solar mast and solar cell string circuits was determined as a function of particle size. The probability of no impact on the cell string circuits was used to derive the probability of no open circuit panel. The probability of meeting a certain power requirement at the end of the design lifetime was then calculated as a function of impacting particle size. Coupled with a penetration and damage models/correlations which relate the particle size to penetration depth and damage, the results of this analysis can be used to determine the probability of meeting the lower power requirement given a degree of redundancy, and the probability of no impact on the solar array mast.
The methodology used to assess the probability of no impact of space debris and meteoroids on a spacecraft structure is applied to the Space Station solar array assembly. Starting with the space debris and meteoroids flux models, the projected surface area of the solar cell string circuit of the solar array panel and the mast longeron, and the design lifetime, the possibility of no impact on the solar array mast and solar cell string circuits was determined as a function of particle size. The probability of no impact on the cell string circuits was used to derive the probability of no open circuit panel. The probability of meeting a certain power requirement at the end of the design lifetime was then calculated as a function of impacting particle size. Coupled with a penetration and damage models/correlations which relate the particle size to the penetration depth and damage, the results of this analysis can be used to determine the probability of meeting the lower power requirement given a degree of redundancy, and the probability of no impact on the solar array mast.
Solar cell devices as well as method and apparatus for producing solar cell devices are disclosed. Aspects of the disclosure provide a solar cell device that includes a string of solar cells. The string of solar cells are conductively connected in series and arranged in a shingled manner with sides of adjacent solar cells being overlapped. A first metal ribbon segment is conductively bonded to a front surface of an end cell, the front surface being configured to face a light incoming direction to receive energy from a light source.
Solar cell devices as well as method and apparatus for producing solar cell devices are disclosed. Aspects of the disclosure provide a solar cell device that includes a string of solar cells. The string of solar cells are conductively connected in series and arranged in a shingled manner with sides of adjacent solar cells being overlapped. A first metal ribbon segment is conductively bonded to a front surface of an end cell, the front surface being configured to face a light incoming direction to receive energy from a light source.
Work station for transferring entire strings of solar cells places successive strings alined, with offset, or reversed end for end. Thus, various solar module formats can be accommodated. Two vacuum cups hold each solar cell in string being transferred.