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NASA NTRS2003

Advanced Rainbow Solar Photovoltaic Arrays

Photovoltaic arrays of the rainbow type, equipped with light-concentrator and spectral-beam-splitter optics, have been investigated in a continuing effort to develop lightweight, high-efficiency solar electric power sources. This investigation has contributed to a revival of the concept of the rainbow photovoltaic array, which originated in the 1950s but proved unrealistic at that time because the selection of solar photovoltaic cells was too limited. Advances in the art of photovoltaic cells since that time have rendered the concept more realistic, thereby prompting the present development effort. A rainbow photovoltaic array comprises side-by-side strings of series-connected photovoltaic cells. The cells in each string have the same bandgap, which differs from the bandgaps of the other strings. Hence, each string operates most efficiently in a unique wavelength band determined by its bandgap. To obtain maximum energy-conversion efficiency and to minimize the size and weight of the array for a given sunlight input aperture, the sunlight incident on the aperture is concentrated, then spectrally dispersed onto the photovoltaic array plane, whereon each string of cells is positioned to intercept the light in its wavelength band of most efficient operation. The number of cells in each string is chosen so that the output potentials of all the strings are the same; this makes it possible to connect the strings together in parallel to maximize the output current of the array. According to the original rainbow photovoltaic concept, the concentrated sunlight was to be split into multiple beams by use of an array of dichroic filters designed so that each beam would contain light in one of the desired wavelength bands. The concept has since been modified to provide for dispersion of the spectrum by use of adjacent prisms. A proposal for an advanced version calls for a unitary concentrator/ spectral-beam-splitter optic in the form of a parabolic curved Fresnel-like prism array with panels of photovoltaic cells on two sides (see figure). The surface supporting the solar cells can be adjusted in length or angle to accommodate the incident spectral pattern. An unoptimized prototype assembly containing ten adjacent prisms and three photovoltaic cells with different bandgaps (InGaP2, GaAs, and InGaAs) was constructed to demonstrate feasibility. The actual array will consist of a lightweight thin-film silicon layer of prisms curved into a parabolic shape. In an initial test under illumination of 1 sun at zero airmass, the energy-conversion efficiency of the assembly was found to be 20 percent. Further analysis of the data from this test led to a projected energy conversion efficiency as high as 41 percent for an array of 6 cells or strings (GaP, AlGaAs, InGaP2, GaAs, and two different InGaAs cells or strings).

Mardesich, Nick↗

NASA NTRS1998

Dark Forward Electrical Test Techniques Developed for Large-Area Photovoltaic Arrays

Spacecraft photovoltaic arrays (PVA's) must be carefully handled during ground integration processing and transportation to the launch site. Care is exercised to avoid damage that could degrade on-orbit electrical performance. Because of this damage risk, however, PVA's are typically deployed and illuminated with a light source so performance characteristics can be measured prior to launch. For large-area arrays, such as the Mir Cooperative Solar Array (2.7- by 18-m) and the International Space Station PVA blankets (4.6- by 31.7-m), this integrity check becomes resource intensive. Large test support structures are needed to offload the array during deployment in 1g, and large-aperture illumination equipment is required to uniformly illuminate array panels. Significant program time, funds, and manpower must be allocated for this kind of test program. Alternatively, launch site electrical performance tests can be bypassed with an attendant increase in risk.

Kerslake, Thomas W.↗

NASA NTRS1994

Solar Radiation on Mars: Tracking Photovoltaic Array

A photovoltaic power source for surface-based operation on Mars can offer many advantages. Detailed information on solar radiation characteristics on Mars and the insolation on various types of collector surfaces are necessary for effective design of future planned photovoltaic systems. In this article we have presented analytical expressions for solar radiation calculation and solar radiation data for single axis (of various types) and two axis tracking surfaces and compared the insulation to horizontal and inclined surfaces. For clear skies (low atmospheric dust load) tracking surfaces resulted in higher insolation than stationary surfaces, whereas for highly dusty atmospheres, the difference is small. The insolation on the different types of stationary and tracking surfaces depend on latitude, season and optical depth of the atmosphere, and the duration of system operation. These insolations have to be compared for each mission.

Appelbaum, Joseph↗

NASA NTRS1987

Ground testing of array modules for the photovoltaic array space power (PASP) experiment

One of the objectives of the PASP experiment is the verification of cost-effective ground simulations of high-voltage solar array/space-environment interactions by comparing the results with flight data. These ground tests consist of electrical characterization, thermal cycling, and plasma chamber simulations. The results of the latter tests are reported. Five array modules which are representative of the flight arrays were tested. The module types are planar silicon, planar gallium arsenide, planar silicon passivated with an integrally deposited cover glass, mini-Cassegrainian concentrator, and SLATS concentrator. The modules were biased to -1000 V in varying plasma densities from 4 x 103 to 2 x 105 e-/cu cm. Each array was tested in both dark and illuminated conditions with a load resistance. In addition to monitoring arcing during the plasma tests, the arrays were visually inspected and electrically characterized before and after exposure in the chamber. The electrical results are tabulated and briefly discussed.

Morris, Robert K.↗

NASA NTRS1992

Photovoltaic Array Space Power flight experiment plus diagnostics (PASP+) modules

The Photovoltaic Array Space Power Plus Diagnostics flight experiment (PASP+) subsumes twelve solar array modules which represent the state of the art in the space photovoltaic array industry. Each of the twelve modules individually feature specific photovoltaic technologies such as advanced semiconductor materials, multi-bandgap structures, lightweight array designs, advanced interconnect technologies, or concentrator array designs. This paper will describe each module in detail including the configuration, components, materials, anticipated on orbit performance, and some of the aspects of each array technology. The layout of each module and the photovoltaic cells or array cross section will be presented graphically. A discussion on the environmental constraints and materials selection will be included as well as a delineation of the differences between the modules and the baseline array configuration in its intended application.

Cooley, William T.↗

NASA NTRS1981

Integrated residential photovoltaic array development

An advanced, universally-mountable, integrated residential photovoltaic array concept was defined based upon an in-depth formulation and evaluation of three candidate approaches which were synthesized from existing or proposed residential array concepts. The impact of module circuitry and process sequence is considered and technology gaps and performance drivers associated with residential photovoltaic array concepts are identified. The actual learning experience gained from the comparison of the problem areas of the hexagonal shingle design with the rectangular module design led to what is considered an advanced array concept. Building the laboratory mockup provided actual experience and the opportunity to uncover additional technology gaps.

Shepard, N. F., Jr.↗

NASA NTRS1978

Evaluations of candidate encapsulation designs and materials for low-cost silicon photovoltaic arrays

Three encapsulation designs for silicon photovoltaic arrays based on cells with silk-screened Ag metallization have been evaluated: transparent polymeric coatings over cells laminated between two films or sheets of polymeric materials; cells adhesively bonded to a glass cover with a polymer pottant and a glass or other substrate component. Silicone and acrylic coatings were assessed, together with acrylic sheet, 0.635 mm fiberglass-reinforced polyester sheet, 0.102 mm polycarbonate/acrylic dual-layer film, 0.127 mm fluorocarbon film, soda-lime glass, borosilicate glass, low-iron glass, and several adhesives. The encapsulation materials were characterized by light transmittance measurements, determination of moisture barrier properties and bond strengths, and by the performance of cells before and after encapsulation. Silicon and acrylic coatings provided inadequate protection. Acrylic and fluorocarbon films displayed good weatherability and acceptable optical transmittance. Borosilicate, low-iron and soda-lime-float glasses were found to be acceptable candidate encapsulants for most environments.

Gaines, G. B.↗

NASA NTRS1989

Photovoltaic array environmental protection program

During the photovoltaic array environmental protection program, a coating material, application technique, and design approach intended to protect flexible solar array blankets during a nominal fifteen-year operating lifetime were developed. Numerous thin-film coatings for protecting the Kapton polyimide material used in the construction of the Space Station Freedom flexible solar array blanket were evaluated. The critical solar array design features and protection measures are discussed with special emphasis on the effects of solar array fabrication and flexible printed circuit manufacturing processes on coating durability. The results of the mechanical and environmental test evaluation, including oxygen plasma, neutral oxygen beam, and UV/charged-particle combined exposure, are discussed. These results led to the selection of a silicon dioxide thin-film coating to protect the solar array blanket from the low-earth-orbit atomic oxygen environment.

Bilger, Kevin M.↗

NASA NTRS1980

Concentrator-enhanced photovoltaic arrays for deep space applications

The useful operational range of photovoltaic solar arrays has been limited to 1.5 AU (Mars orbit) due primarily to solar intensity constraints. Preliminary results indicate that the use of concentrator mirrors in conjunction with solar arrays can extend the practical operating range of photovoltaic space power sources to at least 9.5 AU (Saturn orbit). Various aspects of concentrator-enhanced photovoltaic arrays such as size, structure, thermal characteristics, intensity uniformity, pointing accuracy requirements, deployment methods, power performance and system mass are presented. Based on this information, concentrator-enhanced photovoltaic arrays are superior, with respect to power-to-mass and cost, to existing power sources used for deep space missions. The sensitivity of concentrator-enhanced solar arrays to particulate radiation was also examined for representative deep space missions. Results are presented which show that a radiation-degraded, deep space, concentrator-enhanced solar array's performance exceeds that of existing RTG power sources.

Rockey, D. E.↗

NASA NTRS1982

Photovoltaic array reliability optimization

An overview of the photovoltaic array reliability problem is presented, and a high reliability/minimum cost approach to this problem is presented. Design areas covered are cell failure, interconnect fatigue, and electrical insulation breakdown, and three solution strategies are discussed. The first involves controlling component failures in the solar cell (cell cracking, cell interconnects) and at the module level (must be statistically treated). Second, a fault tolerant circuit is designed which reduces array degradation, improves module yield losses, and controls hot-spot heating. Third, cost optimum module replacement strategies are also effective in reducing array degradation. This can be achieved by minimizing the life-cycle energy cost of the photovoltaic system. The integration of these solutions is aimed at reducing the 0.01% failure rate.

Ross, R. G., Jr.↗

NASA NTRS1981

Integrated residential photovoltaic array development

Sixteen conceptual designs of residential photovoltaic arrays are described. Each design concept was evaluated by an industry advisory panel using a comprehensive set of technical, economic and institutional criteria. Key electrical and mechanical concerns that effect further array subsystem development are also discussed. Three integrated array design concepts were selected by the advisory panel for further optimization and development. From these concepts a single one will be selected for detailed analysis and prototype fabrication. The three concepts selected are: (1) An array of frameless panels/modules sealed in a T shaped zipper locking neoprene gasket grid pressure fitted into an extruded aluminum channel grid fastened across the rafters. (2) An array of frameless modules pressure fitted in a series of zipper locking EPDM rubber extrusions adhesively bonded to the roof. Series string voltage is developed using a set of integral tongue connectors and positioning blocks. (3) An array of frameless modules sealed by a silicone adhesive in a prefabricated grid of rigid tape and sheet metal attached to the roof.

Royal, G. C., III↗

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 NTRS1982

Development of photovoltaic array and module safety requirements

Safety requirements for photovoltaic module and panel designs and configurations likely to be used in residential, intermediate, and large-scale applications were identified and developed. The National Electrical Code and Building Codes were reviewed with respect to present provisions which may be considered to affect the design of photovoltaic modules. Limited testing, primarily in the roof fire resistance field was conducted. Additional studies and further investigations led to the development of a proposed standard for safety for flat-plate photovoltaic modules and panels. Additional work covered the initial investigation of conceptual approaches and temporary deployment, for concept verification purposes, of a differential dc ground-fault detection circuit suitable as a part of a photovoltaic array safety system.

Source record↗

NASA NTRS1982

Characterization of the electrical output of flat-plate photovoltaic arrays

The electric output of flat-plate photovoltaic arrays changes constantly, due primarily to changes in cell temperature and irradiance level. As a result, array loads such as direct-current to alternating-current power conditioners must be able to accommodate widely varying input levels, while maintaining operation at or near the array maximum power point.The results of an extensive computer simulation study that was used to define the parameters necessary for the systematic design of array/power-conditioner interfaces are presented as normalized ratios of power-conditioner parameters to array parameters, to make the results universally applicable to a wide variety of system sizes, sites, and operating modes. The advantages of maximum power tracking and a technique for computing average annual power-conditioner efficiency are discussed.

Gonzalez, C. C.↗

NASA NTRS1993

The application of structural reliability techniques to plume impingement loading of the Space Station Freedom Photovoltaic Array

A new aerospace application of structural reliability techniques is presented, where the applied forces depend on many probabilistic variables. This application is the plume impingement loading of the Space Station Freedom Photovoltaic Arrays. When the space shuttle berths with Space Station Freedom it must brake and maneuver towards the berthing point using its primary jets. The jet exhaust, or plume, may cause high loads on the photovoltaic arrays. The many parameters governing this problem are highly uncertain and random. An approach, using techniques from structural reliability, as opposed to the accepted deterministic methods, is presented which assesses the probability of failure of the array mast due to plume impingement loading. A Monte Carlo simulation of the berthing approach is used to determine the probability distribution of the loading. A probability distribution is also determined for the strength of the array. Structural reliability techniques are then used to assess the array mast design. These techniques are found to be superior to the standard deterministic dynamic transient analysis, for this class of problem. The results show that the probability of failure of the current array mast design, during its 15 year life, is minute.

Yunis, Isam S.↗

NASA NTRS1993

The Application of Structural Reliability Techniques to Plume Impingement Loading of the Space Station Freedom Photovoltaic Array

Yunis, Isam S.↗

NASA NTRS1977

Consideration of encapsulants for photovoltaic arrays in terrestrial applications

Long-term survivability of photovoltaic arrays and components in terrestrial environments will require development of adequate protective systems. Highly considered are polymeric encapsulants, a method which was successfully employed in space and aerospace applications to protect critical electrical circuitry. To be employable, however, the polymer encapsulants must themselves be chemically and mechanically resistant to failure in terrestrial service. Chemical resistance includes stability to the degrading actions of ultraviolet light, oxygen, moisture and elevated temperatures in sun rich areas. Programs are underway to identify and develop chemically stable encapsulant candidates. Chemical considerations aside, mechanical failures of the encapsulants must also be avoided in array designs. This paper discusses design considerations for avoiding mechanical failures of polymeric encapsulants, with emphasis on biaxial properties, thermal fatigue, and anisotropy and nonhomogeneity of material properties. The general principles to be presented evolved from actual failures of polymeric materials in engineering applications. Also included are brief remarks on the permeability of polymer materials to atmospheric gases.

Cuddihy, E. F.↗

NASA NTRS1992

The Photovoltaic Array Space Power plus Diagnostics (PASP Plus) Flight Experiment

An overview of the Photovoltaic Array Space Power Plus Diagnostics (PASP Plus) flight experiment is presented in outline and graphic form. The goal of the experiment is to test a variety of photovoltaic cell and array technologies under various space environmental conditions. Experiment objectives, flight hardware, experiment control and diagnostic instrumentation, and illuminated thermal vacuum testing are addressed.

Piszczor, Michael F.↗