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At least 253 records · Page 14

All sources NASA NTRS DOE OSTI

DOE OSTI2022

Row spacing as a controller of solar module temperature and power output in solar farms

We report that when the temperature of solar photovoltaic modules rises, efficiency drops and module degradation accelerates. The spatial arrangement of solar modules can affect convective cooling and, consequently, module temperatures. However, the impact of row spacing on convective cooling in realistic solar farms has not yet been studied. Here, we develop six solar farm arrangements consisting of a fixed number of rows with varying streamwise row spacing. We model the flow and heat transfer of each solar farm using high-resolution large-eddy simulations. Results indicate that increasing row spacing can enhance convective cooling by 14.8%, which reduces module temperature by 6.6 °C and increases power output by 4.0% on average.

14 SOLAR ENERGY↗

DOE OSTI2023

Structural modulation and spin glassiness upon oxidation in oxygen storage material LnFeMnO 4+x for Ln = Y, Lu, and Yb

The mixed valence multiferroic LnFe 2+ Fe 3+ O 4 (where Ln = Y, Lu, and Yb) can reversibly uptake oxygen into its lattice, which is evidenced by a crystallographic phase transition along with the appearance of structural modulations. In this study, we show that the Mn-substituted version of this multiferroic can also be readily oxidized to LnFe 3+ Mn 3+ O 4.5 revealing similar oxygen storage behavior. Through neutron, electron, and synchrotron x-ray diffraction studies, we observe a structural modulation that we attribute to a displacement wave in the fully oxidized compound. This wave exhibits commensurability with a wavevector q = (-2/7, 1/7, 0). Bond valence summation analysis of plausible interstitial oxygen positions suggests that oxygen insertion likely occurs at the middle of the Fe/Mn–O bipyramid layers. The structural modulation of LnFeMnO 4.5 is two-dimensional, propagates along the ab-plane, and is highly symmetric as 12 identical modulation vectors are observed in the diffraction patterns. The nature of the lanthanide, Ln 3+ , does not seem to influence such modulations since we observe identical satellite reflections for all three samples of Ln = Y, Lu, and Yb. Both LnFeMnO 4 and LnFeMnO 4.5 display spin glassy behavior with 2D short-range magnetic ordering being observed in LnFeMnO 4 . Analysis of the neutron diffraction data reveals a correlation length of ~10 nm. Upon oxidation to LnFeMnO 4.5 , the short-range magnetic order is significantly suppressed.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Beam modulation and bump-on-tail effects on Alfvén eigenmode stability in DIII-D

Beam modulation effects on Alfvén eigenmode stability have been investigated in a recent DIII-D experiment and show that variations in neutral beam modulation period can have an impact on the beam driven Alfvén eigenmode spectrum and resultant fast ion transport despite similar time-averaged input power. The experiment was carried out during the current ramp phase of L-mode discharges heated with sub-Alfvénic 50–80 kV deuterium neutral beams that drive a variety of Alfvén eigenmodes unstable. The modulation period of two interleaved beams with different tangency radii was varied from shot to shot in order to modify the relative time dependent mix of the beam pitch angle distribution as well as the persistence of a bump-on-tail feature near the injection energy (a feature confirmed by imaging neutral particle analyzer measurements). As the beam modulation period is varied from 7 ms to 30 ms on/off (typical full energy slowing down time of τ slow ≈ 50 ms at mid-radius), toroidicity-induced Alfvén eigenmodes (TAEs) located in the outer periphery of the plasma become intermittent and coincident with the more tangential beam. Core mode activity changes from reversed shear Alfvén eigenmodes (RSAEs) to a mix of RSAE and beta-induced Alfvén eigenmodes. Discharges with 30 ms on/off period do not have a persistent bump-on-tail feature, have the lowest average mode amplitude and least fast ion transport. Furthermore, detailed analysis of an individual TAE using TRANSP kick modeling (Monte Carlo evolution of the distribution function with probabilistic 'kicks' by the AEs) and the resistive MHD code with kinetic fast ions, MEGA, find no strong role of energy gradient drive due to bump-on-tail features. Instead, the observed TAE modulation with interleaved beams is likely a pitch angle dependent result combined with slowing down of the tangential beam between pulses. For the conditions investigated, bump-on-tail contributions to TAE drive were found to be 5% or less of the total drive at any given time.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2023

D-Egg: a dual PMT optical module for IceCube

The D-Egg, an acronym for "Dual optical sensors in an Ellipsoid Glass for Gen2," is one of the optical modules designed for future extensions of the IceCube experiment at the South Pole. The D-Egg has an elongated-sphere shape to maximize the photon-sensitive effective area while maintaining a narrow diameter to reduce the cost and the time needed for drilling of the deployment holes in the glacial ice for the optical modules at depths up to 2700 m. The D-Egg design is utilized for the IceCube Upgrade, the next stage of the IceCube project also known as IceCube-Gen2 Phase 1, where nearly half of the optical sensors to be deployed are D-Eggs. With two 8-inch high-quantum efficiency photomultiplier tubes (PMTs) per module, D-Eggs offer an increased effective area while retaining the successful design of the IceCube digital optical module (DOM). The convolution of the wavelength-dependent effective area and the Cherenkov emission spectrum provides an effective photodetection sensitivity that is 2.8 times larger than that of IceCube DOMs. The signal of each of the two PMTs is digitized using ultra-low-power 14-bit analog-to-digital converters with a sampling frequency of 240 MSPS, enabling a flexible event triggering, as well as seamless and lossless event recording of single-photon signals to multi-photons exceeding 200 photoelectrons within 10 ns. Mass production of D-Eggs has been completed, with 277 out of the 310 D-Eggs produced to be used in the IceCube Upgrade. In this paper, we report the design of the D-Eggs, as well as the sensitivity and the single to multi-photon detection performance of mass-produced D-Eggs measured in a laboratory using the built-in data acquisition system in each D-Egg optical sensor module.

47 OTHER INSTRUMENTATION↗

DOE OSTI2022

Constraining the charge-, time-, and rigidity-dependence of cosmic-ray solar modulation with AMS-02 observations during Solar Cycle 24

Our basic theoretical understanding of the sources of cosmic rays and their propagation through the interstellar medium is hindered by the Sun, that through the solar wind affects the observed cosmic-ray spectra. This effect is known as solar modulation. Recently released cosmic-ray observations from the Alpha Magnetic Spectrometer (AMS-02) and publicly available measurements of the solar wind properties from the Advanced Composition Explorer and the Wilcox observatory allow us to test the analytical modeling of the time-, charge- and rigidity-dependence of solar modulation. We rely on associating measurements on the local heliospheric magnetic field and the heliospheric current sheet’s tilt angle, to model the time-dependence and amplitude of cosmic-ray solar modulation. We find evidence for the solar modulation’s charge- and rigidity-dependence during the era of solar cycle 24. Our analytic prescription to model solar modulation can explain well the large-scale time evolution of positively charged cosmic-ray fluxes in the range of rigidities from 1 GV to 10 GV. Here, we also find that cosmic-ray electron fluxes measured during the first years of cycle 24 are less trivial to explain, due to the complex and rapidly evolving structure of the heliosphere’s magnetic field that they experienced as they propagated inwards.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2025

Daily modulation of low-energy nuclear recoils from sub-GeV dark matter

At sufficiently low nuclear recoil energy, the scattering of dark matter (DM) in crystals gives rise to single phonon and multiphonon excitations. In anisotropic crystals, the scattering rate into phonons modulates over each sidereal day as the crystal rotates with respect to the DM wind. This gives a potential avenue for directional detection of DM. The daily modulation for single phonons has previously been calculated. Here we calculate the daily modulation for multiphonon excitations from DM in the mass range 1 MeV–1 GeV. We generalize previous multiphonon calculations, which made an isotropic approximation, and implement results in the DarkELF package. We find daily modulation rates up to 1%–10% for an Al 2 O 3 target and DM mass below 30 MeV, depending on the recoil energies probed. We obtain similar results for SiC, while modulation in Si, GaAs, and SiO 2 is negligible. Published by the American Physical Society 2025

Stratman, Connor↗

DOE OSTI2020

Characterization and Analysis of Insulated Metal Substrate-Based SiC Power Module for Traction Application

This paper presents the electrical characterization and drive cycle--based thermal analysis of an insulated metal substrate (IMS)--based silicon carbide power module for high-power traction inverters. The substrate was constructed using a thin layer of polymer--ceramic blend dielectric material with a thick copper core to improve transient thermal performance. The cooling performance of this module has already been validated with promising results. In this paper, an experimental test bed was set up to evaluate the dynamic and static electrical performance of the designed module under a wide range of operating conditions. The characterization results were then used to develop a drive cycle--based thermal model to validate the performance compared to the traditional direct bonded copper--based power module. The results indicate that the IMS-based power module is a suitable solution for high-power traction applications.

Chowdhury, Shajjad↗

DOE OSTI2020

Transient Weighted Moving-Average Model of Photovoltaic Module Back-Surface Temperature

Accurate modeling of photovoltaic (PV) performance requires the precise calculation of module temperature. Currently, most temperature models rely on steady-state assumptions that do not account for the transient climatic conditions and thermal mass of the module. On the other hand, complex physics-based transient models are computationally expensive and difficult to parameterize. In order to address this, a new approach to transient thermal modeling was developed, in which the steady-state predictions from previous timesteps are weighted and averaged to accurately predict the module temperature at finer time scales. This model is informed by 3-D finite-element analyses, which are used to calculate the effect of wind speed and module unit mass on module temperature. The model, in application, serves as an added filter over existing steady-state models that smooths out erroneous values that are a result of intermittency in solar resource. Validation of this moving-average model has shown that it can improve the overall PV energy performance model accuracy by as much as 0.58% over steady-state models based on mean absolute error improvements and can significantly reduce the variability between the model predictions and measured temperature times series data.

14 SOLAR ENERGY↗

DOE OSTI2021

Nanomechanical and Fluorescence Characterizations of Weathered PV Module Encapsulation

Nanoindentation and fluorescence spectroscopy provide spatially resolved mechanical and chemical characterization for degradation of poly (ethylene-co-vinyl acetate) (EVA) encapsulants aged under accelerated weathering and in field deployed photovoltaic (PV) modules. For the accelerated weathering tests, two different EVA formulations in the glass/EVA/glass-laminated coupons were exposed to ultraviolet (UV) light for 180 days at three different temperatures (40, 60, and 80 °C) and UV intensities (0.4, 2.2, and 2.9 W/m2/nm at 340 nm). The fluorescence spectra and moduli were uniform through the cross section of both EVA formulations at the lowest temperature and UV intensity; however, under the highest temperature and UV intensity, the UV irradiated sides showed lower moduli and higher fluorescence compared to the opposite sides. For EVA obtained from PV modules deployed 27 years in Sacramento, CA, USA, changes in fluorescence intensity across the thickness were relatively greater than changes in modulus. On the other hand, for EVA obtained from the same type of module stored in the shed for 27 years, no fluorescence was observed, and a uniform modulus was seen through the EVA layer, but with substantially higher values than those obtained from the field-deployed modules. The different extent of changes between laboratory and field exposures suggests the importance of considering effects of temperature and UV intensity for designing a reliable accelerated testing. This study uniquely demonstrates the capability of microscale characterization using nanoindentation and fluorescence microscopy to monitor mechanical and chemical degradation of EVA encapsulants in PV modules.

14 SOLAR ENERGY↗

DOE OSTI2021

Cracked Solar Cell Performance Depends on Module Temperature

When cells in a crystalline silicon photovoltaic module crack, packaging materials hold the fragments together. Changes in module temperature cause cell fragments to move, allowing cracked metallization to lose and regain contact. We intentionally cracked cells in commercial PV modules and characterized the modules’ temperature-dependent electroluminescence (EL) response. Here we show that (1) metallization makes contact across cracks in a way that is temperature dependent and (2) this contact is not a function of temperature, but is hysteretic. We expect that any electro-optical characterization made at a single temperature will be misleading as to the effects of cracked cells at different temperatures. And we expect that a single temperature sweep cannot fully characterize the temperature dependence of electro-optical performance of modules with cracked cells.

crack↗

DOE OSTI2023

Life-Cycle Analysis of Potentially Longer Life Expectancy CdTe PV Modules

Research on PV module longevity shows that with lower degradation rates and better encapsulation, PV modules can significantly outlast their current life expectancy of 25-30 years. The focus of this study is on alternative CdTe PV module back-contact and encapsulation materials that show the potential of increasing module operation lives from 30 to 40 and 50 years. Life-cycle-analyis shows that some alternative materials may slightly increase cradle-to-gate environmental impacts per m2 of module, but increased operational life more than counterbalances such impacts. The life-cycle carbn footprint of systems operating under average US insolation conditions of 1800 kWh/m2/yr is reduced from 10 gCO2eq/kWh to 6 gCO2eq/kWh when the operation life increases from 30 to 50 yrs. Similar reductions are noted for all life-cycle impact indicators, whereas the EROI of the considered system increases from 67 to 177 as life increases from 30 to 50 yrs.

14 SOLAR ENERGY↗

DOE OSTI2020

Design, Analysis, Comparison, and Experimental Validation of Insulated Metal Substrates for High-Power Wide-Bandgap Power Modules

Direct bonded copper (DBC) substrates used in power modules have limited heat spreading and manufacturing capability due to ceramic properties and manufacturing technology. The ceramic and copper bonding is also subject to high mechanical stress due to coefficient of thermal expansion mismatch between the copper and the ceramic. For wide-bandgap (WBG) devices, it is of interest exploring new substrate technologies that can overcome some of the challenges of direct bonded copper substrates. In this technical paper, the design, analysis, and comparison of insulated metal substrates (IMSs) for high-power wide-bandgap semiconductor-based power modules are discussed. This paper starts with technical description and discussion of state-of-the-art DBC substrates with different ceramic insulators such as aluminum nitride (AlN), Al 2 O 3 , and Si 3 N 4 . Next, an introduction of IMSs and their material properties, and a design approach for SiC (silicon carbide) metal-oxide-semiconductor field-effect transistor (MOSFET)-based power modules for high-power applications is provided. The influence of dielectric thickness on the power handling capability of the substrate are also discussed. The designed IMS and DBC substrates were characterized in terms of steady-state and transient thermal performance using finite element simulation. Finally, the performance of the IMS and DBC are validated in an experimental setup under different loading and cooling temperature conditions. We report the simulation and experimental results showed that the IMS can provide high steady-state thermal performance for high-power modules based on SiC MOSFETs. Furthermore, the IMS provided enhanced transient thermal performance, which provided a reduced junction temperature when the module is operated at low fundamental output frequencies in traction drive systems.

42 ENGINEERING↗

DOE OSTI2025

A Combined Computational and Mathematical Analysis of Interconnect Fatigue Potential in Photovoltaic Modules

A finite element model of a 60-cell monocrystalline silicon glass-polymer photovoltaic module was simulated with ±1.0 kPa and ±2.4 kPa loads applied to the glass to calculate the deformation under load. Cell-to-cell displacements were used to approximate interconnect strain and stress. A mathematical fatigue cycle life relation was fitted to data for the interconnect material (copper), to generate a life prediction at each interconnect location based on the local stress means, reversal extents, and amplitudes. Interconnect stress was found to be significantly asymmetric about zero despite symmetric positive and negative module loads due to laminate thickness offsets about the neutral plane and the effects of module framing. Cycle life results indicated that interconnect fatigue failure was unlikely to occur over a 30-year lifetime of conservative wind and snow load cycles since the typical cell design feature of leaving some unconstrained length between the cell edge and first solder pad increases the effective gauge length and decreases the stress levels below the material endurance limit. Follow-up analyses found that 3.6 mm and 6.4 mm were the minimum unconstrained lengths required to survive the assumed lifetime of wind and snow cycles, respectively, confirming that typical industrial module constructions with 8–15 mm unconstrained lengths should survive conservatively. Notably, large magnitude, low-cycle snow loading was consistently the limiting factor requiring a longer unconstrained interconnect length. Finally, insights and workflows from this study inform module interconnection design limits for survival against mechanical fatigue in deployment environments.

14 SOLAR ENERGY↗

DOE OSTI2022

Thermal Optimization of a Silicon Carbide, Half-Bridge Power Module

This project describes the modeling process to design the packaging and heat exchanger for a half-bridge wide-bandgap (WBG) power semiconductor module. The module uses two silicon carbide, metal-oxide-semiconductor field-effect transistor (MOSFET) devices per switch position that are soldered to an aluminum nitride, direct-bond copper (DBC) substrate. A baseplate cooling configuration (e.g., no thermal grease) is used along with a water-ethylene glycol, jet-impingement-style heat exchanger. The heat exchanger was designed to be fabricated using prototyping equipment from the National Renewable Energy Laboratory, complies with automotive standards (for minimal channel sizes, flow rates, and coolant), and considers reliability aspects (i.e., erosion/corrosion). Device-scale computational fluid dynamics (CFD) is used first to design the slot jet impingement cooling configuration and compute the effective heat transfer coefficient (HTC) of the concept. The computed HTCs are then used as boundary conditions for a finite element study to optimize the package geometry (e.g., device layout and baseplate thickness) to minimize thermal resistance and minimize temperature variation between the module's four devices. Finally, a fluid manifold is designed to generate the slot jets and cool the devices. Module-scale CFD predicts a relatively low junction-to-fluid thermal resistance of 16.7 mm2 K/W, a 1.4 degrees C temperature variation between devices, and a total pressure drop of 5,860 Pa (0.85 psi) for the design. The thermal resistance of the module design is about 67% lower than the 2015 BMW i3 power electronics/modules thermal resistance.

DIRECT ENERGY CONVERSION↗

DOE OSTI2024

Multiphysics Co-Optimization Design and Analysis of Double-Side Cooled Silicon Carbide-Based Power Module: Preprint

With the rapid growth of Electric Vehicles (EVs) and Hybrid Electric Vehicles (HEVs), much more rigorous design targets have been set for automotive power electronics, including high power density, high reliability, and low cost. Novel power module and inverter technologies based on wide bandgap (WEG) semiconductors have been developed to meet these design targets, while providing optimal power semiconductor operating temperature and promising thermomechanical performance. Compared with conventional cooling techniques which are normally applied only on one side of power module, double-side cooling approach is now believed to be the solution to enable high power density and low thermal resistance of WEG semiconductor-based power electronics. In this work, we develop a three-phase power module that is double-sided cooled using dielectric fluid jet impingement. In each phase, four silicon carbide (SiC) power semiconductors are bonded to copper busbars without electrical insulation layers. A finite element analysis (FEA) model is created for thermal and thermomechanical analysis. Based on FEA modeling results, we select particular dimensions for a parametric study to optimize thermal and mechanical performance. Using a multi-objective genetic algorithm (MOGA)-based optimization method, we have minimized the maximum junction temperature and thermal stresses within the power module. The multiphysics co-optimization approach has enabled an efficient design process of power modules with greatly reduced computational cost, as compared to conventional processes that rely on exhaustive numerical simulations and iterations.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2025

Impact of Module Configuration on Lithium-Ion Battery Performance and Degradation: Part I. Energy Throughput, Voltage Spread, and Current Distribution

Batteries are commonly connected in series and parallel to create modules that fulfill the power and energy requirements of specific applications. However, conclusions about battery performance and degradation under different conditions, as well as predictive models, are often derived from single cell cycling results. In this study, we evaluate the performance of six different series-parallel configurations of commercial lithium nickel manganese cobalt cells over hundreds of cycles. Each cell within the modules was individually instrumented for voltage, current, and temperature monitoring. We quantified the impact of module configuration on overall energy throughput, the voltage spread among series-connected cells, and the current heterogeneity in parallel-connected cells. This module cycling study, one of the broadest reported to date, supports systematic evaluation of the performance trade-offs, pack penalty, and safety implications of different module configurations.

25 ENERGY STORAGE↗

DOE OSTI2022

CMEC Module Manager

The CMEC module manager package is designed install and update CMEC modules (https://cmec.llnl.gov/). CMEC modules are independent climate model analysis packages. Individual scripts are provided in the module manager that outline the installation process for each module in a robust way, and a wrapper python script is provided that lets users install a chosen CMEC package with a single command.

Ordonez, AnaC↗

DOE OSTI2021

NEMA-Phase Compliant Traffic Signal Controller Module in SUMO

The controller modules in SUMO use a stage-based control structure. A phase is defined as a stage of all allowed movements at a time instance. However, traffic signal controllers used in North America widely use National Electrical Manufacturers Association (NEMA) phase definition. A NEMA phase is defined by a certain flow movement at an intersection. At one time, more than one NEMA phase could happen together as long as they do not conflict with each other. We can visualize the NEMA phases and timings in Ring-and-Barrier structured NEMA diagrams. For one controller, only one phase from a ring can be activated at a time. Phases from different rings could be activated together as long as they are not from the different sides of a barrier. When a controller is operated in fixed-time control mode, we can model the NEMA phase timing as a corresponding stage-based control timing without any issues. When introducing actuation into the signal control, a Ring-and-Barrier structured traffic signal controller can be more flexible than stage-based controller by allowing different possible phase combinations. We made two efforts in modeling Ring-and-Barrier structured controllers in SUMO. One is to translate a NEMA phases timing into SUMO-readable phases and timings as an additional file for SUMO. This translation worked well for fixed-time control. To model actuated control and coordinated actuated control, we augmented the SUMO source code by adding a Ring-and-Barrier structured controller module. This module could implement traffic signal timing from controllers using NEMA phases. We also augmented TraCI to be able to set new NEMA phase timings during simulations. We examined the Ring-and-Barrier structured traffic signal controller module by both visually observing the simulation animations and the simulation records. The developed control module can model the generalized Ring-and-Barrier structured traffic signal timing that is used in North America. SEE: https://github.com/eclipse/sumo/blob/main/src/microsim/traffic_lights/NEMAController.cpp

Wang, Qichao↗