LOW-COST SILICON SOLAR ARRAY PROJECT Load Tests... · low-cost silicon solar array project 5101-19...

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LOW-COST SILICON SOLAR ARRAY PROJECT

5101-19

CYCLIC PRESSURE-LOAD DEVELOPMENTAL TESTING

OF SOLAR PANELS

.February 28, 1977

Donald Moore

Approved by:

R. G. Ross LSSA Engineering Manager

JET PROPULSION LABORATORY

CALIFORNIA INSTITUTE OF TECHNOLOGY

PASADENA, CALIFOINIA

I . i

-

This work was performed by the Jet Propulsion Laboratory, California

Institute of Technology, under National Aeronautics and Space Administration

Contract NAS7-100, for the U.S. Energy Research and Development Administration

(ERDA), Division of Solar Energy.

The Low-Cost Silicon Solar Array Project is funded by ERDA and forms part

of the ERDA Photovoltaic Conversion Program to initiate a major effort toward the

development of low-cost solar arrays.

ACKNOWLEDGEMENT

The author wishes to express his thanks to the following individuals for

their contributions to this effort. Tom Patrick designed and built the pressure

fill/regulation system and conducted a significant portion of the testing.

Roland Taylor designed and built the automatic panel failure detection circuit.

ii

1.0 BACKGROUND

2.0 PURPOSE AND SCOPE

3.0 TEST APPARATUS

4.0 DESCRIPTION OF PANELS TESTED

5.0 TEST RESULTS

6.0 CONCLUSIONS

CONTENTS

APPENDIX: Summary of Test Data Including Panel Mounting Sketches

1.

2.

3.

4.

5.

FIGURES

Cyclic Pressure Loading Apparatus

Block Diagram, Cyclic Pressure Loading Apparatus

Pressure Application System

Pressure Control System

Cycle Timer/Counter and Failure Monitor System

iii

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ABSTRACT

Nine (9) solar panels of 5 different designs were subjected to

a 50 lb/ft2 uniform load which was alternately applied to the front and back

sides of the panel. The loading rate was slow, consistent with the fact that 1

~ ~ --t..-/.36~J.,, the loading was intended to simulate periodic recurrence of a 100 mph wind _ J_ P v·

-p- 21c )w

over the lifetime of a solar panel. Each of the 5 designs was subjected to

at least 10,000 pressure cycles. No gross structural failures occurred.

One of the designs failed regularly at the cell interconnects. Another

design shorted out one or more cells upon panel flexure. Both problems are

readily explained in terms of design deficiencies in the cell interconnects,

and therefore appear to be easily remedied in future designs.

The cyclic pressure loading apparatus developed as part of this

effort performed extremely well. The unit was relatively trouble-free from

start-up and it applied more than 130,000 cycles to the various panels tested.

V

1.0 Background

In the design of solar panels for a terrestrial environment wind

loading has been identified as an important structural consideration. For the

130 kW procurement an alternating (front and back sides) normal pressure load

2 of 50 lb/ft, corresponding to 100 mph wind, is applied to the panel 100 times

as part of the pre-production acceptance tests.

2.0 Purpose and Scope

This cyclic pressure load was not part of the acceptance test require

ment for the 46 kW procurement. It was decided, however, that some developmental

testing in this area would be mutually beneficial to the panel manufacturers

and ERDA alike. The basic reasons for conducting the subject cyclic pressure

tests using the 46 kW modules are:

1. Identify the problems associated with the design, construction and

operation of a test apparatus to perform the cyclic pressure testing.

2. Determine the sensitivity of a variety of solar panel designs to

the 50 lb/£t2 cyclic pressure loading or fatigue affects therefrom

in the areas of primary structural failures, encapsulant/substrate

delamination, cell breakage, and interconnect failures. This

information to be used in the following way:

a) To understand the kind of problems to expect

b) Determine whether the 130 kW acceptance test requirements

are difficult to satisfy

c) Feed back the nature of panel failures to the panel

manufacturers for corrective action before 130 kW designs

are finalized.

1

,...... .... ,

3.0 Test Apparatus

Design and construction of a simple, reliable means of applying a

uniform pressure load alternately to the front and back sides of the solar

panel being tested was a primary goal of this test effort.

3.1 Functional Requirements

The following requirements were imposed on the apparatus

a) solar panel size - 4 ft x 4 ft or smaller

b) pressure load applied - adjustable--50 lb/ft2

c) pressure applied alternately to front and back sides

d) pressure applied to one side only if desired

e) panel fault detection to ascertain electrical discontinuity

in panel

f) counter - to count the number of cycles to panel failure

g) automatic/untended operation to include -

• automatic cycling of pressure from front to back sides

of panels

adjustable dwell time--that is ability to hold pressure

on one side of panel for desired period of time

adjustable total cycle time

automatic fault (discontinuity) detection

automatic unit shut-down at panel failure

indication of the number of cyles at panel failure retained

h) reliable

i) low-cost

3.2 Description of Apparatus

Figure 1 shows the test apparatus in toto. The top platen is removed

to show the solar panel installation. The top platen and its air mattress are

installed above the solar panel when it is desired to apply load to tne front side

of the panel. Figure 2 is a block diagram representing the interrelationships of

the various key elements of the apparatus.

2

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Detection And Counter Control Application

------ -System System System System

(Electronic) (Timer) (Pneumatic) (Mechanical)

Fig. 5 Fig. 5 Fig. 4 Fig. 3

Figure 2.

Block Diagram Cyclic Pressure Loading Apparatus

Figures 3, 4, and 5 show the above subsystems in greater detail.

3.2.1 Pressure Application System-Fig. 3

The pressure application system is the physical mechanism for applying

pressure to the panels. The solar panel is supported by a 1 in. thick plywood

mask, which is placed between two 1/2 in. plywood platens. Between each platen

and one side of the solar panel an air mattress is inserted. By pressurizing

this air mattress, a uniform pressure load equal to the pressure in the air

mattress is applied to the panel.

A word of caution is appropriate here. The distance between the solar panel and

the reaction platen must be carefully adjusted to insure that the pressure

within the mattress is applied to the panel and not reacted by membrane tensile

forces developed in the mattress itself. To accomplish this, the reaction

platen should be adjusted as close as possible to the solar panel--the air

mattress will not develop tensile stresses when constrained to appreciably less

than its normal inflated thickness. The platen should not, however, be so

close to the solar panel that it can interfere with the deformation of the panel

when the other side of the panel is loaded.

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3.2.2 Pressure Control System--Fig. 4

The function of the pressure control system is to pressurize the

air mattresses to the desired pressure. It also must maintain that pressure

until it receives an external command to pressurize the other side of the panel.

Before describing the operation of the system, note that this system

is completely self-contained except that the 4-way spool valve is controlled

externally by the so-called "cycle-timer" system discussed later. The cycle

timer system cause the pressure controls system to pressurize first one side

of the panel and then th~ other.

Referring to Fig. 4 the operation of the pressure control system

is described below.

a) Consider that we are just starting to pressurize the bottom bag

and its pressure switch is still made (Fig. 3 shows the bottom

bag fully pressurized with its pressure switch open)

b) With the bottom bag pressure switch made the solenoid valve

(innnediately downstream of the course regulator) is open and the

bag is filled from a shop air source regulated to about 25 psig.

The filling source must be at a comparatively high pressure

c)

2 (relative to the desired 50 lb/ft (9.6"H20) in order to fill the

bag in a reasonable length of time.

2 When the pressure in the bag reaches the 47 lb/ft (9"H20) set-point

on the pressure switch, that switch opens and interrupts current

to the solenoid valve, cutting off .the primary 25 psig "fill"

supply air. Having the pressure switch set point at 47 lb/ft2 2 .

rather than the desired 50 lb/ft eliminates "overshoot,"

"hunting" and similar problems often encountered with control

systems of this type.

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3.2.3

d) Now note that a secondary fill source regulated to the desired

50 lb/ft2 that by-passes the solenoid valve is provided. This

secondary fill source is controlled by a precision dead-end

regulation and tops-off the pressure in the air mattress to

the desired 50 lb/ft2• This make-up regulator also makes the

system insensitive to small leaks.

e) To pressurize the other side of the solar panel the 4-way spool

valve is actuated (automatically by the "timer control" system)

and the fill cycle described above (a through d) takes place for

the other air mattress while the first air mattress vents to

atmosphere.

Cycle Timer/Counter System--Fig. 5

The function of the cycle timer/counter system is to alternately

pressurize the front and back sides of the panel at a desired time interval.

This is accomplished by using a function generator which supplies a 28 VDC

square voltage pulse of the desired peripd to the solenoid operator of the

4-way spool valve of the pressure control system. In Fig. 3 if 28 VDC is

applied the top bag will be pressurized and with O VDC applied the bottom bag

will be pressurized. Additionally this 28 VDC signal furnishes the voltage

pulse which actuates an electromechanical counter that indicates the total

number of pressurization cycles applied to the panel.

3.2.4 Fault Detection System--Fig. 5

The function of the fault detection circuit is to automatically

detect an open circuit in the test panel, cause the pressurization system to

shut down, while preserving the total number of cycles at failure. In order

to detect an open circuit in the panel a 5 VDC voltage is placed across the

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panel and a 10012

across the 100 n panel.

resistor in series with the panel. The voltage drop

resistor is taken as a measure of the condition of the

A change in the voltage greater than 10% (either an increase or

decrease) causes automatic system shutdown for subsequent investigation by

the operator to determine the cause for shutdown. Thus, the apparatus stops

cycling and counting. In this way the cycle count is preserved until the

operator can determine the cause of the anomaly--i.e. panel failure or other

condition.

It should be noted, that, in operation discontinuities in the panel

are commonly detected when the back side is loaded and the panel is fully

flexed convex toward the front side. When the back side load is relieved

the continuity of the panel is coDDJ1only restored restarting the system, thus

losing the cycle count at failure. To preclude this possibility a "latching" or

"holding" circuit is incorporated in the fault detection circuit. The "holding"

circuit prevents the system from restarting when panel continuity is restored

as follows. As already mentioned, when the relay receives the 5 VDC anomaly

signal, one set of contacts opens, cutting off the 120 VAC power supply to the

cycle timer system. Additionally, the other set of contacts of the relay close,

putting 4.5 VDC battery in the circuit to hold the relay in the fault position.

Note that the only way the system can be restarted is for the operator to

push the "reset" switch.

4.0 Description of Panels Tested

Five solar panel designs were tested. A brief description of these

panels and the way they were supported in the test apparatus is provided in

Table IV. Additional support details are given in the Appendix.

10

TABLE I DEsctz.1PT1otJ oF 4~l<W .SoLAl2. PA/JELS

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5.0 Test Results

5.1 Comments on the Test Apparatus

The test apparatus performed remarkably well with a minimal number

of teething problems.

a) A few false (not panel failure) shut-downs were experienced.

These were traced to loose wires, line voltage surges, or high

frequency voltage spikes from 120 VAC pressure switch/solenoid

valve circuitry of the pressure control system fed back to the

fault detection circuit. Since this only delayed the testing

until the operator could determine that the cause of shut-down

was not panel failure, this was not considered a serious problem.

b) The pressurization system experienced no tendencies to "hunt" or

"overshoot" as is coDDDon with controls of this type.

c) Each of the two air mattresses used was inflated to 50 lb/sq. ft.

pressure, a total of approximately 130,000 cycles.

5.2 Comments on the Solar Panels

A total of 9 solar panels of 5 different designs were tested. In

general, the solar panels tested proved to be structurally capable of withstanding

the applied cyclic pressure loading. A summary of the raw data obtained is

contained in the Appendix. Certain general observations can be made.

a) All 5 designs proved to be structurally capable of withstanding the

cyclic pressure loading, even though 3 of the designs exhibited

rather large deformations due to the fact that they employed a

plastic or glass reinforced plastic substrate.

12

-

b) All 5 designs used a clear silicone potting compound as a cell

encapsulant. Encapsulant/substrate delamination did not occur

during the course of these tests.

c) Four of the five designs exhibited no failures of any sort

even though the number of cycles applied to a single panel exceeded

35,000 in two of the designs tested.

d) Design Type 4 exhibited a tendency to fail at the cell interconnects.

e)

In some cases it was clear that this failure had occurred during

thermal cycling or humidity tests, but was first noticed in the

cyclic pressure testing, because flexing the panel convex toward

the front side caused the previously cracked interconnects to

open. In some cases the failure occurred in the ribbon type inter

connect approximately midway between cells, and in other cases the

failure occurred where the interconnect was soldered to the top

of the cell.

Design Type 2 exhibited an anomaly which cannot be called failure

because it did not cause panel resistance to drop more than

about 6%. This problem was traced to the expanded metal cell

interconnects. In a few cases cutting out the mesh to produce

the interconnects produced sharp barbs which were unfortunately

located very close to the edge of a cell. Upon panel flexure

these barbs shorted the bottoms of a cell to the top of the same

cell.

13

6.0 Conclusions

6.1 Test Apparatus

a) The design, construction and operation of a device to alternately

apply a uniform pressure load to the front and back sides of

solar panels, automatically shut-down in the event of panel

failure and to retain a count of the number of load cycles in a

straight-forward task.

b) Such a device can be expected to disclose deficiencies (design,

fabrication and material) of solar panels intended for a wind

load environment.

6.2 Solar Panels

A general conclusion of the testing performed here is that design of

solar panels to sustain the 50 lb/ft2 cyclic pressure load is not difficult.

As mentioned previously, no structural failures were encountered even though

the panels tested run the gamut from very flexible (Type 3) to very stiff

(Type 5). It is also encouraging to note that the cell interconnect failure

encountered with the Type 4 panels are readily explainable in terms of

noticeable differences between this design and the other designs which employed

ribbon-type interconnects. The notable differences are:

a) The Type 4 design has very shallow strain relief loops.

b) The solder joint of the ribbon to the top of the cell was very

thick (too much solder and not enough heat).

These problems are considered easily corrected in future designs.

The interconnect anomaly experienced with the Type 2 panels, which

used expanded metal interconnects, also appears to be easily remedied. Careful

14

location of the edges of the cell interconnects with respect to the pattern of

the expanded metal mesh from which they are fabricated will eliminate the

"hangnails" which gave rise to the cell-shorting phenomena reported.

15

APPENDIX

Summary of test data including panel mounting sketches.

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CYCLIC LOADING TEST DATA SUMKAI.Y SHEET .

Type No: --'--------------------Serial No.

Prior Test Hiatory of Panel:

Date(s) of Test

Mounting of Panel (see attached sketch)

Loading (see below) ---- uniform pressure on back side panel

~- uniform pressure on front side panel

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CYCLIC LOADING TEST DATA SUMHilY SHEET

Type No: --'---------------------Serial No.

Prior Test History of Panel:

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CYCLIC LOADING TEST DATA SUMMARY SHEET

Type No: ___ 2 ___________________ _

Serial No. V-14 -A, Prior Test History of Panel:

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--- uniform pressure on front side panel

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46 kW Solar Panela


Type No: ___ 3 ___________________ _

Serial No. 00.9~0

Prior Teat History of Panel:

~o, Pll.&."IOUSL'{ Te.~T~O .

Date(a) of Teat +l~•f,C. , 4/u{ic., 4{ul,<., 1 4'2-"j ,t-Mounting of Panel (see attached sketch)


----- uniform pressure on front side panel 6~

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Panel:

46 kW Solar Panels

CYCLIC LOADING TEST DATA SUMMAltY SHEET

Type No: ___ 3 ____________________ _

Serial No. 00330


· 2000 PU.ssuu c:.1ca.s5(ek1e ~,pa o,.,1.1)-4/21/11,14lz{1c.J4ju{1,/f(u!14,

Date(s) of Test f j 2.1 J ;c. · ~.... . s { 11 J,, Mounting of Panel (see attached sketch)


---- uniform pressure on front side panel

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CYCLIC LOADIRG UST DATA SINtAJ.Y SHEET

Type No: ___ 4 __________________ _ Serial No. 2" I 000 2.


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Date(s) of Test ~f 1ff 7C.. ~ s-/11 f ic.,. Mounting of Panel (see attached sketch) 1~ P~ · A M0"1tiJT UJt. •


~ uniform pressure on front side panel

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A-12

Panel:

46 kW Solar Panels


Type No: ___ 4 __________________ _ Serial No. '" 30040


,. 1G,s H"MJDIT'l e'lc.LES. 2.. SI Tt+e.~AL C'/C:.C..E.S.

Date(s) of Test 5' I 1 '7 f 'J (p ,__J_ 5"118) 7'=> , Mounting of Panel (see attached sketch) TIPe. ,\ MOU'"1TlJG.


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46 k.W Solar Panela

CYCLIC LOADING TEST DATA SUMMAllY SHEET

Type Ho: ___ 4.:...-------------------Serial No. 7" I 000 S-


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2. 4 I THELMA L. c'ICLe\ 3. I 00 T._.E.«MAL C:~CL.E.' •

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20

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46 kW Solar Panels

CYCLIC LOADING TEST DATA SUMIWlY SHEET

Type No: ___ 4_._ _________________ _ Serial No. ,~ 30038


I. I" S"' t'llS. U UM ID IT)\

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Date(s) of Test

Mounting of Panel (see· attached sketch) 'i'IPa A MOUUTl'-1 &


---- uniform pressure on front side panel

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Panel:

46 kW Solar Panels


Type No: ___ 4~-------------------Serial No. 7~ 3004-S-


Date(s) of Test

Mounting of Panel (see attached sketch) l'i p£. 6 MOU~TalJG:t Loading (see below) ---- uniform pressure on back side panel

- uniform pressure on front side panel

Remarks:

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Panel:

46 kW Solar Panels


Type No: __ 5---------------------Serial No. 0S1"2.4


Date(s) of Test



-----uniform pressure on front side panel

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A-19

LOW-COST SILICON SOLAR ARRAY PROJECT Load Tests... · low-cost silicon solar array project 5101-19...

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