Engineering topics

Ross, R. G., Jr.

Publications and source records attributed to Ross, R. G., Jr..

At least 55 records · Page 3

NASA NTRS1986

Flat-plate solar array project. Volume 6: Engineering sciences and reliability

The Flat-Plate Solar Array (FSA) Project activities directed at developing the engineering technology base required to achieve modules that meet the functional, safety, and reliability requirements of large scale terrestrial photovoltaic systems applications are reported. These activities included: (1) development of functional, safety, and reliability requirements for such applications; (2) development of the engineering analytical approaches, test techniques, and design solutions required to meet the requirements; (3) synthesis and procurement of candidate designs for test and evaluation; and (4) performance of extensive testing, evaluation, and failure analysis of define design shortfalls and, thus, areas requiring additional research and development. A summary of the approach and technical outcome of these activities are provided along with a complete bibliography of the published documentation covering the detailed accomplishments and technologies developed.

Ross, R. G., Jr.↗

NASA NTRS1986

Crystalline-silicon photovoltaics summary module design and reliability

The evolution of the design and reliability of solar modules was described. Design requirements involved 14 different considerations, including residential building and material electrical codes, wind-loading, hail impact, operating temperature levels, module flammability, and interfaces for both the array structure and the operation of the system. Reliability research involved in diverse investigations including glass-fracture strength, soiling levels, electrochemical corrosion, and bypass-diode qualification tests. Based on these internationally recognized studies, performance assessments, and failure analyses, the Flat-plate Solar Array Project in its 11-year duration served to nuture the development of 45 different solar module designs from 15 PV manufacturers.

Ross, R. G., Jr.↗

NASA NTRS1986

Long-term stability of amorphous-silicon modules

The Jet Propulsion Laboratory (JPL) program of developing qualification tests necessary for amorphous silicon modules, including appropriate accelerated environmental tests reveal degradation due to illumination. Data were given which showed the results of temperature-controlled field tests and accelerated tests in an environmental chamber.

Ross, R. G., Jr.↗

NASA NTRS1986

Reliability of photovoltaic modules

In order to assess the reliability of photovoltaic modules, four categories of known array failure and degradation mechanisms are discussed, and target reliability allocations have been developed within each category based on the available technology and the life-cycle-cost requirements of future large-scale terrestrial applications. Cell-level failure mechanisms associated with open-circuiting or short-circuiting of individual solar cells generally arise from cell cracking or the fatigue of cell-to-cell interconnects. Power degradation mechanisms considered include gradual power loss in cells, light-induced effects, and module optical degradation. Module-level failure mechanisms and life-limiting wear-out mechanisms are also explored.

Ross, R. G., Jr.↗

NASA NTRS1985

Reliability and Engineering of Thin-Film Photovoltaic Modules. Research forum proceedings

A Research Forum on Reliability and Engineering of Thin Film Photovoltaic Modules, under sponsorship of the Jet Propulsion Laboratory's Flat Plate Solar Array (FSA) Project and the U.S. Department of Energy, was held in Washington, D.C., on March 20, 1985. Reliability attribute investigations of amorphous silicon cells, submodules, and modules were the subjects addressed by most of the Forum presentations. Included among the reliability research investigations reported were: Arrhenius-modeled accelerated stress tests on a Si cells, electrochemical corrosion, light induced effects and their potential effects on stability and reliability measurement methods, laser scribing considerations, and determination of degradation rates and mechanisms from both laboratory and outdoor exposure tests.

Ross, R. G., Jr.↗

NASA NTRS1985

Crystalline-silicon reliability lessons for thin-film modules

The reliability of crystalline silicon modules has been brought to a high level with lifetimes approaching 20 years, and excellent industry credibility and user satisfaction. The transition from crystalline modules to thin film modules is comparable to the transition from discrete transistors to integrated circuits. New cell materials and monolithic structures will require new device processing techniques, but the package function and design will evolve to a lesser extent. Although there will be new encapsulants optimized to take advantage of the mechanical flexibility and low temperature processing features of thin films, the reliability and life degradation stresses and mechanisms will remain mostly unchanged. Key reliability technologies in common between crystalline and thin film modules include hot spot heating, galvanic and electrochemical corrosion, hail impact stresses, glass breakage, mechanical fatigue, photothermal degradation of encapsulants, operating temperature, moisture sorption, circuit design strategies, product safety issues, and the process required to achieve a reliable product from a laboratory prototype.

Ross, R. G., Jr.↗

NASA NTRS1985

FSA future directions: Reliability and engineering sciences FY85-FY86 activities and plans

Objectives were listed for four areas: engineering science, reliability physics, module development, and module performance and failure analysis. The engineering science efforts are to develop module design requirements for large-scale photovoltaic (PV) applications and to develop generic module and array design and construction technology to meet the needed performance, safety, reliability, and system interfaces. The reliability physics effort is to develop the technology for 30-year life modules. The module development efforts are to transfer new technology to PV manufacturers and their products, and to evaluate these advanced modules. The module performance and failure analysis efforts are to determine PV module performance, to identify needed development, and to assess suitability for large-scale use.

Ross, R. G., Jr.↗

NASA NTRS1985

Maximum Outputs of Solar Photovoltaic Arrays

Report presents electrical data for solar photovoltaic arrays operating at different locations in United States. Data useful in designing power-conditioners for matching output of array to load.

Ross, R. G., Jr.↗

NASA NTRS1985

Predicting the Reliability of Solar-Cell Interconnections

The reduction of life expectancy by thermal cycling calculated during design. Connections between solar cells critical parts of solarcell arrays generating electric power. Reliability affects life expectancy of modules, panels, and arrays. Used to predict stress-cycle lifetimes of such structures as arches, walkways, cylindrical ribbing of aircraft fuselages and submarine hulls, and pipeline expansion loops. Testing costs reduced by about 90 percent.

Mon, G. R.↗

NASA NTRS1985

Assessing the Performance of Solar Arrays

Selected environmental conditions more effective than traditional parameters. Report analyzes selection of reference criteria for comparing performances of photovoltaic arrays.

Ross, R. G., Jr.↗

NASA NTRS1985

Development of design criteria and qualification tests for bypass diodes in photovoltaic applications

Design criteria have been developed for bypass diodes in p-n and Schottky barrier in photovoltaic applications. A test method for assessing conformity to the design criteria is described. Junction temperatures are defined in terms of expected worst-case field conditions, including ambient temperature and solar irradiance on the photovoltaic module. The rating criteria address the maximum allowable current and heat-sink characteristics of diodes mounted inside or outside the photovoltaic module. The method establishes worst-case module-to-diode thermal interfaces and may be adapted for laboratory or field-site experiments. A list of the design criteria is given.

Otth, D. H.↗

NASA NTRS1985

Development and testing of advanced fire-resistant photovoltaic modules

The evaluation of back-surface materials flammability in order to identify fire resistant module designs is examined. The fire test apparatus, burning-brand test sequence, and spread-of-flame test sequence are described. Video recordings and time-temperature profiles of module back surfaces are utilized to study the flammability failure mechanism and identify high-temperature materials. A table of flammability test results for various module designs is provided. The data reveals that 2-mil kapton, fiberglass cloth coated or impregnated with a material to plug pores, and metal foil back-surface materials achieve class A and B fire-resistance levels, and are applicable for photovoltaic module designs.

Sugimura, R. S.↗

NASA NTRS1985

Electrochemical degradation of amorphous-silicon photovoltaic modules

Techniques of module electrochemical corrosion research, developed during reliability studies of crystalline-silicon modules (C-Si), have been applied to this new investigation into amorphous-silicon (a-Si) module reliability. Amorphous-Si cells, encapsulated in the polymers polyvinyl butyral (PVB) and ethylene vinyl acetate (EVA), were exposed for more than 1200 hours in a controlled 85 C/85 percent RH environment, with a constant 500 volts applied between the cells and an aluminum frame. Plotting power output reduction versus charge transferred reveals that about 50 percent a-Si cell failures can be expected with the passage of 0.1 to 1.0 Coulomb/cm of cell-frame edge length; this threshold is somewhat less than that determined for C-Si modules.

Mon, G. R.↗

NASA NTRS1985

The block program approach to photovoltaic module development

A series of photovoltaic module development activities, designated Blocks I through V, used increasingly refined requirements together with extensive testing and failure analysis to assist industry in developing the most advanced modules possible. The block program approach is described and the design details are given for all modules developed, highlighting the blockwise improvements. The success of this approach is demonstrated by the fact that most design details of the Block V modules have been adopted internationally. Instrumental to this success have been the steady improvements in design and test specifications that have guided module development. The experience gained since development of the Block-V specification is being incorporated into a Block VI Design and Test Specification, which includes upgraded and revised application-specific requirements. Highlights of this Block VI specification are also described.

Smokler, M. I.↗

NASA NTRS1985

Candidate materials for advanced fire-resistant photovoltaic modules

A cooperative, cost-sharing research effort to develop a technology base required to construct fire-ratable photovoltaic modules has resulted in the identification of several high-temperature, back-surface candidate materials capable of raising the fire-resistance of modules using hydrocarbon encapsulants to Class A and B levels. Advanced experimental module configurations have been developed using back surfaces consisting of Kapton, Tedlar laminates, metal-foils, and fiberglass materials with high-temperature coatings. Test results (October 1984; March 1985; May 1985; and October 1985) indicate that several of these advanced module configurations are capable of achieving Class B fire-resistance levels, while a few configurations can achieve Class A levels. The paper summarizes activities to date, discussing flammability failure mechanisms, time-temperature profiles, and results of Block V environmental exposure tests of a candidate material suitable for both Class B and Class A fire-resistance levels.

Sugimura, R. S.↗

NASA NTRS1985

Effects of temperature and moisture on module leakage currents

Experimental and analytical results are presented that characterize the rate dependency of leakage currents on environmental temperature and humidity level and quantify the influence of module construction features such as rear-surface films and foils, cell-frame gap spacings, and encapsulant resistivity and thickness. The relative roles of surface and bulk resistivity are illuminated together with their differing dependencies on surface moisture, bulk moisture, and temperature.

Mon, G.↗

NASA NTRS1984

Predicting Solar Deficits

Statistical method uses available long term solar irradiance data at selected sites in United States to predict probable deviations from long term monthly averages. Technique useful in sizing solar collectors and backup storage systems to cover solar deficits.

Ross, R. G., Jr.↗

NASA NTRS1984

Solar-cell interconnect design for terrestrial photovoltaic modules

Useful solar cell interconnect reliability design and life prediction algorithms are presented, together with experimental data indicating that the classical strain cycle (fatigue) curve for the interconnect material does not account for the statistical scatter that is required in reliability predictions. This shortcoming is presently addressed by fitting a functional form to experimental cumulative interconnect failure rate data, which thereby yields statistical fatigue curves enabling not only the prediction of cumulative interconnect failures during the design life of an array field, but also the quantitative interpretation of data from accelerated thermal cycling tests. Optimal interconnect cost reliability design algorithms are also derived which may allow the minimization of energy cost over the design life of the array field.

Mon, G. R.↗