AES-EPO study program, volume I Final study report
Conceptual study of possible solutions to long- term and time-critical reliability problems affecting Apollo command module guidance and control computer
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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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Activation Energy for Solder Bond Degradation: Thermal Cycling of Field-aged Modules at Multiple Upper Temperatures
The reliability of solder joints in the solar cell metallization-interconnect system influences the lifetime of photovoltaic modules. Two field-aged modules-one with Sn 62 Pb 36 Ag 2 solder at the solder joints (Solarex MSX 60), and the other with the standard Sn 60 Pb 40 solder (Siemens M55)-were subjected to a modified thermal cycling (TC) test of IEC 61215. Three sections in each module were maintained at 85 degrees C, 95 degrees C, and 105 degrees C during the 15-minute high temperature dwell time. Current equivalent to the module short-circuit current was injected through the module when the chamber temperature was above 25 degrees C to simulate regular field operation. This novel approach aims to induce thermomechanical fatigue (TMF) at the solder joints and intermetallic compound (IMC) formation at the metal/solder interfaces. The activation energy (E a ) for solder bond degradation was calculated based on the series resistance (R s ) increase in TC testing rather than power drop to avoid the effect of confounding variables. Module-level R s increase in MSX 60 module after TC800 cycles and in M55 module after TC400 cycles was 1.22% and 183.7%, respectively. The E a determined for the module with 2wt% Ag is 0.24 eV and for that with the standard solder is 0.27 eV. The solder bond degradation seems to have been driven by TMF rather than IMC formation for both modules.
14 SOLAR ENERGY↗
Predictive Models and Novel Accelerated Tests for the Reliability of Cell Metallization and Solder Joints in Photovoltaic Modules
Interconnect, solder, and metallization-related failures are the primary reason for premature Si-based photovoltaic panel failure [1, 2] and can lead to a cascade of other failures, including thermal events. This combination of high severity and high occurrence means that understanding interconnect-related failures is key to the long-term health of the photovoltaic industry, and it is crucial that the industry adopt efficient and effective tests that aid in design-for-reliability and manufacturing quality control.
14 SOLAR ENERGY↗
Center punched solar cell module development effort
The results are given of an advanced module development program with the objective of providing a low cost solar cell mechanical interconnect design. The design approach, which avoids soldering or welding operations, lends itself to automated assembly techniques thus supporting the Low-Cost Silicon Solar Array Project goals. The first group of six modules contained aluminum contact cells and the second group of six modules contained silver-titanium-palladium contact cells. Extensive component and environmental testing at the module level showed that reliable cell mechanical interconnection can be achieved when utilizing the proper electrical contact materials and pressures. A discussion is given of the module design, manufacturing procedure, test program, significant problem areas and solutions, and conclusions and recommendations as formulated and conducted by XEOS.
Ross, R. E.↗
Mission Reliability Estimation for Repairable Robot Teams
A mission reliability estimation method has been designed to translate mission requirements into choices of robot modules in order to configure a multi-robot team to have high reliability at minimal cost. In order to build cost-effective robot teams for long-term missions, one must be able to compare alternative design paradigms in a principled way by comparing the reliability of different robot models and robot team configurations. Core modules have been created including: a probabilistic module with reliability-cost characteristics, a method for combining the characteristics of multiple modules to determine an overall reliability-cost characteristic, and a method for the generation of legitimate module combinations based on mission specifications and the selection of the best of the resulting combinations from a cost-reliability standpoint. The developed methodology can be used to predict the probability of a mission being completed, given information about the components used to build the robots, as well as information about the mission tasks. In the research for this innovation, sample robot missions were examined and compared to the performance of robot teams with different numbers of robots and different numbers of spare components. Data that a mission designer would need was factored in, such as whether it would be better to have a spare robot versus an equivalent number of spare parts, or if mission cost can be reduced while maintaining reliability using spares. This analytical model was applied to an example robot mission, examining the cost-reliability tradeoffs among different team configurations. Particularly scrutinized were teams using either redundancy (spare robots) or repairability (spare components). Using conservative estimates of the cost-reliability relationship, results show that it is possible to significantly reduce the cost of a robotic mission by using cheaper, lower-reliability components and providing spares. This suggests that the current design paradigm of building a minimal number of highly robust robots may not be the best way to design robots for extended missions.
Trebi-Ollennu, Ashitey↗
Integrating a reservoir regulation scheme into a spatially distributed hydrological model
During the past several decades, numerous reservoirs have been built across the world for a variety of purposes such as flood control, irrigation, municipal/industrial water supplies, and hydropower generation. Consequently, natural streamflow timing and magnitude have been altered significantly by reservoir operations. In addition, the hydrological cycle can be modified by land use/land cover and climate changes. To understand the fine scale feedback between hydrological processes and water management decisions, a distributed hydrological model embedded with a reservoir component is of desire. In this study, a multi-purpose reservoir module with predefined complex operational rules was integrated into the Distributed Hydrology Soil Vegetation Model (DHSVM). Conditional operating rules, which are designed to reduce flood risk and enhance water supply reliability, were adopted in this module. The performance of the integrated model was tested over the upper Brazos River Basin in Texas, where two U.S. Army Corps of Engineers reservoirs, Lake Whitney and Aquilla Lake, are located. The integrated DHSVM model was calibrated and validated using observed reservoir inflow, outflow, and storage data. The error statistics were summarized for both reservoirs on a daily, weekly, and monthly basis. Using the weekly reservoir storage for Lake Whitney as an example, the coefficients of determination (R2) and the Nash-Sutcliff Efficiency (NSE) are 0.85 and 0.75, respectively. These results suggest that this reservoir module has promise for use in sub-monthly hydrological simulations. Enabled with the new reservoir component, the DHSVM model provides a platform to support adaptive water resources management under the impacts of evolving anthropogenic activities and substantial environmental changes.
Zhao, Gang↗
Dynamic Thermal Management for High-Performance Storage Systems
Thermal-aware design of disk drives is important because high temperatures can cause reliability problems. Dynamic Thermal Management (DTM) techniques have been proposed to operate the disk at the average case temperature, rather than at the worse case by modulating the activities to avoid thermal emergencies. The thermal emergencies can be caused by unexpected events, such as fan-breaks, increased inlet air temperature, etc. One of the DTM techniques is a delay-based approach that adjusts the disk seek activities, cooling down the disk drives. Even if such a DTM approach could overcome thermal emergencies without stopping disk activity, it suffers from long delays when servicing the requests. Thus, in this chapter, we investigate the possibility of using a multispeed disk-drive (called dynamic rotations per minute (DRPM)) that dynamically modulates the rotational speed of the platter for implementing the DTM technique. Using a detailed performance and thermal simulator of a storage system, we evaluate two possible DTM policies (- time-based and watermark-based) with a DRPM disk-drive and observe that dynamic RPM modulation is effective in avoiding thermal emergencies. However, we find that the time taken to transition between different rotational speeds of the disk is critical for the effectiveness of the DRPM based DTM techniques.
99 GENERAL AND MISCELLANEOUS↗
Investigation of Failure Modes, Mechanisms and Driving Forces for Electrically Conductive Adhesives as Interconnects in PV Modules
In this work we describe our current progress into investigating the reliability of ECA interconnects for PV modules. Preliminary thermal cycling experiments demonstrated that both cohesive and adhesive failure of the ECA joint are relevant failure modes that result in an increase of the joints electrical resistance. A thorough viscoelastic characterization of the candidate ECA was conducted to enable accurate numerical modeling of the joint’s response to thermal cycling. Combined with critical and subcritical fracture measurements, the numerical model elucidates that an additional fatigue mechanism exists which can result in fracture well below subcritical debonding threshold values. It is also demonstrated that fracture of the ECA is more sensitive to humidity than temperature and subcritical debonding mechanisms do exist which are again more sensitive to humidity.
41 EE - Solar Energy Technologies Office (EE-4S)↗
Modeling the irradiance and temperature dependence of photovoltaic modules in PVsyst
In order to reliably simulate the energy yield of photovoltaic (PV) systems, it is necessary to have an accurate model of how the PV modules perform with respect to irradiance and cell temperature. Building on previous work that addresses the irradiance dependence, two approaches to fit the temperature dependence of module power in PVsyst have been developed and are applied here to recent multi-irradiance and -temperature data for a standard Yingli Solar PV module type. The results demonstrate that it is possible to match the measured irradiance and temperature dependence of PV modules in PVsyst. As a result, improvements in energy yield prediction using the optimized models relative to the PVsyst standard model are considered significant for decisions about project financing.
14 SOLAR ENERGY↗
Instrumented Photovoltaic Modules for Environmental Characterization and Simulation Model Validation
Photovoltaic modules are subjected to various mechanical stressors in their deployment environments, ranging from installation handling to wind and snow loads. Damage incurred during these mechanical events has the potential to initiate subsequent degradation mechanisms, reducing useful module lifespan. Thus, characterizing the mechanical state of photovoltaic modules is pertinent to the development of reliable packaging designs. In this work, photovoltaic modules with strain gauges directly incorporated into the module laminate were fabricated and subjected to mechanical loading to characterize internal strains within the module when under load. These experimental measurements were then compared against results obtained by high-fidelity finite-element simulations. The simulation results showed reasonable agreement in the strain values over time; however, there were large discrepancies in the magnitudes of these strains. Both the instrumentation technique and the finite-element simulations have areas where they can improve. These areas of improvement have been documented. Despite the observed discrepancies between the experimental and simulated results, the module instrumentation proved to be a useful gauge in monitoring and characterizing the mechanical state. With some process improvements, this method could potentially be applied to other environments that a photovoltaic module will encounter in its lifetime that are known to cause damage and degrade performance.
14 SOLAR ENERGY↗
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.↗
Breaking the Trend: Are Retro PV Module Designs a Cost-Effective Solution to Glass Reliability?
Explore the source record for details and available documents.
Braid, Jennifer Lee [Sandia National Laboratories ↗
Reliability and performance experience with flat-plate photovoltaic modules
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.
Ross, R. G., Jr.↗
Advanced module development overview
Crystalline silicon solar power modules are examined for reliability and cost effectiveness. A goal of 12% solar energy conversion efficiency is considered feasible at a cost of 12/kWh, and a decision is made to limit consideration to float zone silicon wafer and dendritic web silicone modules. A preliminary module packaging configuration of glass/ethylene vinyl acetate/plastic film is selected. Anticipated module efficiency levels are 12.6% at 25 C and 11.5% at NOCT (Nominal Operating Cell Temperature).
Smokler, M. I.↗
PV Evolution in the Light of Circular Economy: Preprint
An ideal circular economy has no waste, end-of-life resources become new goods, and all production loops are closed. For the photovoltaic industry’s growing waste problem, quantifying the value of lifetime, reliability, repair, reuse, recycling and other options to increase circularity can help identify and prioritize research needs. In this work we capture the evolution of PV module technology, such as improved reliability and increasing market share of glass/glass modules. We then study the material and energy flows for PV production and use, and identify the circular processes and pathways yielding the most impact. We discuss material circularity and energy return on investment as quantitative metrics to define and evaluate circularity.
bifacial↗
Tests Of Amorphous-Silicon Photovoltaic Modules
Progress in identification of strengths and weaknesses of amorphous-silicon technology detailed. Report describes achievements in testing reliability of solar-power modules made of amorphous-silicon photovoltaic cells. Based on investigation of modules made by U.S. manufacturers. Modules subjected to field tests, to accelerated-aging tests in laboratory, and to standard sequence of qualification tests developed for modules of crystalline-silicon cells.
Ross, Ronald G., Jr.↗
Electrochemical Modeling of PID Leakage Current of PV Modules: Steady-State Current, Transient Current, and RC-Equivalent Circuit
Potential-induced degradation (PID) remains a significant reliability concern for photovoltaic (PV) modules, arising when a voltage difference between the module frame and the solar cells drives unintended leakage current through the glass-encapsulant stack. Although PID ultimately manifests as PID-s, PID-p, or PID-c, the underlying behavior of the leakage current-its magnitude and time dependence-requires clearer electrochemical interpretation. Traditional explanations attribute the initial transient current to bulk capacitive elements of the glass, encapsulant, and antireflection coatings, and the steady-state current according to their effective ohmic resistance. More recent studies, however, indicate that electrochemical charge-transfer processes at the encapsulant-metallization interface can play a dominant role in defining the leakage-current path. This paper develops a unified electrochemical framework for modeling PID leakage current. First, an RC-equivalent circuit is formulated by combining conventional RC elements with a Randles-type interface to capture transient leakage current through double-layer capacitance and faradaic processes at ionic-electronic boundaries. Second, the steady-state current-voltage behavior is explained using a linearized Butler-Volmer relationship, showing that the measured ohmic response corresponds to the low-overpotential limit of charge-transfer kinetics. Analytical results demonstrate that, for typical module materials-3.2-mm soda-lime glass and 0.45-mm encapsulant-the dominant modulators to PID leakage current are the glass surface resistance (under dry-surface conditions), the glass bulk capacitance, and the encapsulant resistance (under wet-surface conditions), with soda lime glass surface and EVA/POE encapsulant resistances primarily governing steady-state current. The proposed electrochemical model is validated against measured leakage-current data, showing good agreement in both the magnitude and the time-dependent evolution of PID leakage current.
14 SOLAR ENERGY↗
Energy Yield Loss Due to LETID
This presentation presents an open-source LETID model part of the PVDegradationTools, which can calculate solar modules degradation due to Light and Elevated Temperature (LETID).
degradation↗