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.
Slauch, Ian S.; Kumar, Rishi K.; Rahman, Farhan R.; Sidawi, Tala S.; Tracy, Jared T.; Meier, Rico M.; Fenning, David F.; Hartley, James Y.; Gambogi, William G.; Bertoni, Mariana B.
Slauch, Ian S.; Vishwakarma, Saurabh V.; Tracy, Jared T.; Gambogi, William G.; Meier, Rico M.; Rahman, Farhan R.; Hartley, James Y.; Bertoni, Mariana B.
Static structural finite element models of an aluminum-framed crystalline silicon (c-Si) photovoltaic (PV) module and a glass-glass thin film PV module were constructed and validated against experimental measurements of deflection under uniform pressure loading. Parametric analyses using Latin Hypercube Sampling (LHS) were performed to propagate simulation input uncertainties related to module material properties, dimensions, and manufacturing tolerances into expected uncertainties in simulated deflection predictions. This exercise verifies the applicability and validity of finite element modeling for predicting mechanical behavior of solar modules across architectures and enables computational models to be used with greater confidence in assessment of module mechanical stressors and design for reliability. Sensitivity analyses were also performed on the uncertainty quantification data sets using linear correlation coefficients to elucidate the key parameters influencing module deformation. This information has implications on which materials or parameters may be optimized to best increase module stiffness and reliability, whether the key optimization parameters change with module architecture or loading magnitudes, and whether parameters such as frame design and racking must be replicated in reduced-scale reliability studies to adequately capture full module mechanical behavior.
Heliostat optical performance can be affected by both wind and gravity induced deflections in the mirror support structure. These effects can result in decreased energy collection efficiency, depending on the magnitude of structural deflections, heliostat orientation and field position, and sun position. This paper presents a coupled modeling approach to evaluate the effects of gravity loading on heliostat optical performance, considering two heliostat designs: The National Solar Thermal Test Facility (NSTTF) heliostat and the Advanced Thermal Systems (ATS) heliostat. Deflections under gravitational loading were determined using finite element analysis (FEA) in ANSYS MECHANICAL, and the resulting deformed heliostat geometry was analyzed using Breault APEX optical engineering software to evaluate changes in beam size and shape. Optical results were validated against images of actual beams produced by each respective heliostat, measured using the Beam Characterization System (BCS) at Sandia National Laboratories. Simulated structural deflections in both heliostats were found to have visible impacts on beam shape, with small but quantifiable changes in beam power distribution. In this paper, the combined FEA and optical analysis method is described and validated, as well as a method for modeling heliostats subjected to gravitational deflection and canted in-field, for which mirror positions may not be known rigorously. Furthermore, a modified, generalized construction method is proposed and analyzed for the ATS heliostat, which was found to give consistent improvements in beam shape and up to a 4.1% increase in annual incident power weighted intercept (AIPWI).
Cavity receivers used in solar power towers and dish concentrators may lose considerable energy by natural convection, which reduces the overall system efficiency. A validated numerical receiver model is desired to better understand convection processes and aid in heat loss minimization efforts. The purpose ofthis investigation was to evaluate heat loss predictions using the commercial computational fluid dynamics (CFD) software packages fluent 13.0 and solidworks flow simulation 2011 against experimentally measured heat losses for a heated cubical cavity receiver model (Kraabel, 1983, "An Experimental Investigation of the Natural Convection From a Side-Facing Cubical Cavity," Proceedings of the ASME JSME Thermal Engineering Joint Conference, Vol. 1, pp. 299-306) and a cylindrical dish receiver model (Taumoefolau et al., 2004, "Experimental Investigation of Natural Convection Heat Loss From a Model Solar Concentrator Cavity Receiver," ASME J. Sol. Energy Eng., 126(2), pp. 801-807). Simulated convective heat loss was underpredicted by 45% for the cubical cavity when experimental wall temperatures were implemented as isothermal boundary conditions and 32% when the experimental power was applied as a uniform heat flux from the cavity walls. Agreement between software packages was generally within 10%. Convective heat loss from the cylindrical dish receiver model was accurately predicted within experimental uncertainties by both simulation codes using both isothermal and constant heat flux wall boundary conditions except when the cavity was inclined at angles below 15 deg and above 75 deg, where losses were under- and overpredicted by fluent and solidworks, respectively. Comparison with empirical correlations for convective heat loss from heated cavities showed that correlations by Kraabel (1983, "An Experimental Investigation of the Natural Convection From a Side-Facing Cubical Cavity," Proceedings ofthe ASME JSME Thermal Engineering Joint Conference, Vol. 1, pp. 299-306) and for individual heated flat plates oriented to the cavity geometry (Pitts and Sissom, 1998, Schaum's Outline of Heat Transfer, 2nd ed., McGraw Hill, New York, p. 227) predicted heat losses from the cubical cavity to within experimental uncertainties. Correlations by Clausing (1987, "Natural Convection From Isothermal Cubical Cavities With a Variety of Side-Facing Apertures," ASME J. Heat Transfer, 109(2), pp. 407-412) and Paitoonsurikarn et al. (2011, "Numerical Investigation of Natural Convection Loss From Cavity Receivers in Solar Dish Applications," ASME J. Sol. Energy Eng. 133(2), p. 021004) were able to do the same for the cylindrical dish receiver. No single correlation was valid for both experimental receivers. The effect ofdifferent turbulence and air-property models within fluent were also investigated and compared in this study. However, no model parameter was found to produce a change large enough to account for the deficient convective heat loss simulated for the cubical cavity receiver case.