Experimental analysis and simulation of a production line for CPV modules: impact of defects, misalignments, and binning of receivers

Abstract

IntroductionThe concentrator photovoltaic (CPV) module performance is governed by its subparts, namely the optical system [1] and the Photovoltaic (PV) solar cells [2], by means of the optical and the electrical efficiencies, respectively [3]. Moreover, the CPV module performance also depends on the accuracy attained in the module assembly which determines the allowed mechanical tolerances for the next manufacturing and installation stages, mainly at the tracker level. In this regard, there are different key points related to module manufacturing that affect the module quality and thus determine its efficiency, among them, the attaching of the secondary optical element (SOE) to the cell, the positioning of the receivers (referred to as the assembly comprising the photovoltaic solar cell, the substrate to which it has been attached also named cell carrier, and the SOE) on the back plate [4], or the attaching and alignment of the parquet of primary optical elements (POEs) to the module chassis [5].In the framework of the European ECOSOLE project, which has received funding from the European Union's Seventh Framework Program, a CPV module, an inverter and a tracker have been designed and manufactured MODELING AND ANALYSISExperimental analysis and simulation of a production line for CPV modules: impact of defects, misalignments, and binning of receivers AbstractAn inherent characteristic of high concentrator photovoltaics (HCPV) modules is a tight mechanical tolerance caused by the narrow angular transmission of the optical system, typically below or close to 1°. Misalignments in the modules caused during the assembly process in the production line will degrade not only the electrical but also the angular performance of the module. Moreover, dispersion in the electrical characteristics of the elementary units comprising a module would lead also to power loss. Quality control and data analysis on the production line is of great significance for adjusting the production line and preserving the angular tolerance and the electrical performance. This is particularly critical during the set-up and tuning of an automated production line. This paper presents the results of a pilot production line for HCPV modules carried out within the European funded ECOSOLE project. Several quality controls were established, which are the binning of the photovoltaic receivers, the measurement of misalignments among the elementary units within every module, and the indoor electrical characterization of the modules. Collected experimental data during the tuning phase of the pilot line were used to validate a module performance model based on production parameters. Monte Carlo method is lately applied to the model to assess the influence of production defects of diverse nature and the adequacy of quality controls, in several manufacturing scenarios beyond the specific constrains of the ECOSOLE experience. together with an automatic high precision module assembly line, equipped with quality control at different manufacturing stages [6,7]. Th...

Relative misalignments estimation in on-tracker CPV modules through image processing

“…In previous works [3], misalignments between lens-receiver units of a module were measured through this image acquisition method by comparing the receivers' areas seen through the optical system of the concentrator (Fig.2.a shows an example of used images). The method was validated against a system called the Module Optical Analyzer (MOA) [4]. The MOA is based on the Luminescence Inverse method [5], that measures (by using a large collimator mirror) the pseudo Lambertian light emitted by the cells (when module is forward biased) to obtain the angular properties of all module units.…”

Challenges in the design of concentrator photovoltaic (CPV) modules to achieve highest efficiencies

“…147 It has been also used to characterize a production line, quantify defects causing misalignments and determine its impact in the system performance. 148 3. Optical design and current distribution in the solar cell in the CPV module a.…”

Vector-Based Advanced Computation for Photovoltaic Devices and Arrays: Numerical Reproduction of Unusual Behaviors of Curved Photovoltaic Devices

“…It is necessary to examine measurement protocols that are not biased against the diversity of curved surfaces, apply various curved surface models to evaluate the measurement method, and perform numerical experiments for verification. The geometric condition of the curved surfaces should express the optical properties of the PV module and the mismatching loss [72][73][74][75][76][77][78].…”