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Understanding Testing
Requirements for PV Modules
Hardware and Software Verify
Design of Turbine Drive Train Listen to Issue
Compact, High-Frequency Highlights
Power Transformer
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19
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■ Features ■ Departments
3 Taking Aim at Designing Large and Timeless 1 Research News
Composite Wind Blades 1 The Powerful Role of Wind Turbine
8 Ensuring Wind Turbine Transient Event Placement
Protection
14 Applications
11 Understanding Testing Requirements for 14 Hardware and Software Verify Design of
Photovoltaic Modules Wind Turbine Drive Train
17 Solar Air Heater Cuts Carbon Dioxide
■ Tech Briefs Emissions for R&D Facility
24 New Products
On the Cover:
New technologies will continue to be developed at a
rapid pace in the photovoltaic industry, and testing
these new processes plays a key role in bringing
products to market. Envirotronics PV solar chambers
come in a variety of sizes to accommodate any test
specification. Read more on page 11.
In this video, Dabiri discusses his wind research and aerial footage is shown of the facil-
ity. Click here to view the video.
mentally intrusive turbines — as long as they're by each of the six turbines when placed in a
the right turbines, arranged in the right way. number of different configurations. One turbine
Dabiri and his colleagues have been conduct- was kept in a fixed position for every configura-
ing field tests at an experimental two-acre wind tion; the others were on portable footings that
farm in northern Los Angeles County. The farm, allowed them to be shifted around.
known as the Field Laboratory for Optimized The tests showed that an arrangement in which
Wind Energy (FLOWE), houses 10-meter-tall, all of the turbines in an array were spaced four
1.2-meter-wide vertical-axis wind turbines turbine diameters apart (roughly 5 meters) com-
(VAWTs) — turbines that have vertical rotors. pletely eliminated the aerodynamic interference
Half a dozen turbines were used for field tests between neighboring turbines. By comparison,
over the summer of 2010. removing the aerodynamic interference between
VAWTs can be positioned very close to one HAWTs would require spacing them about 20
another, which lets them capture nearly all of the diameters apart — a distance of over a mile
energy of the blowing wind and even wind ener- between the largest wind turbines now in use.
gy above the farm. Having every turbine turn in The six VAWTs generated from 21 to 47 watts
the opposite direction of its neighbors, the of power per square meter of land area. A simi-
researchers found, also increases their efficiency, larly sized HAWT farm generates just 2 to 3
perhaps because the opposing spins decrease the watts per square meter. Over this past summer
drag on each turbine, allowing it to spin faster. of 2011, Dabiri and colleagues studied a larger
Dabiri got the idea for using this type of construc- array of 18 VAWTs to follow up last year's field
tive interference from studies of schooling fish. study, and progress alerts are available.
In the field tests, Dabiri and his team meas-
ured the rotational speed and power generated View other wind research news.
hile the potential of wind energy has The detailed design and analysis phase pro-
Supporting Optimization
The first topic of this article is
how to enable the rapid gener-
ation of a detailed ply layup.
The starting point is typically a
schematic definition of the lam-
inates as provided by the con-
figuration design study.
Figure 2: This image depicts the finite element model of a wind blade based Many wind blade designers and
on a composite ply definition generated by FiberSIM®. The complete and analysts say that most numeri-
detailed definition enables the stress engineer to capture critical design
cal models of composite blades
details that improve the accuracy of the analysis.
lack the accuracy required to
perform appropriate optimiza-
tion. The blade models used
manufacturing dataset for the factory are gener- during the preliminary design step are lacking
ated and published, and prototyping, pre-pro- some key details found in the actual blades.
duction, and production follow. While there is a trade-off between rapid opti-
The question is, can we ensure that the detailed mization cycle time and sophistication of the
design of a blade will lead to a functioning blade blade definition, a 3D digital approach enables
20 to 30 years from now? And, whatever process more composite details to be taken into account
we come up with, will it be scalable and applicable earlier in the process.
to wind blades that are on the average becoming By developing a 3D CAD model of the compos-
longer and heavier every year? ite layup design of the blades early in the design
While we can’t predict the eventual and com- process, designers and analysts are able to sup-
plete solution, we believe that there are a few port optimization with a refined definition of the
aspects of the process that will be most relevant ply shapes, ply drops, core shapes, core/ply tran-
to developing blades that will continue to rotate sitions, fabric orientations, resin contents, lami-
well into this century. nate offset effects, and other key details.
In order to do so, it is imperative
that the preliminary ply definition
By developing a 3D CAD model of the composite
be fed automatically into 3D CAD-
layup design of the blades early in the design
based composite modeling soft-
process, designers and analysts are able to ware so 3D layup definitions can be
support optimization with a refined definition of generated in a rapid and automat-
the ply shapes, ply drops, core shapes, core/ply ed fashion. As a result, analysts
transitions, fabric orientations, resin contents, can use a more accurate layup def-
laminate offset effects, and other key details. inition that is close to the actual
layup performed in the factory.
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embodies all the details and design intent perti- even more thorough for an automated deposi-
nent to the automated manufacturing process. tion process than it needs to be for manual
Therefore, connecting composite design soft- hand layup.
ware to manufacturing simulation software
adapted for automated blade layup is a prerequi- Unifying Around a 3D Approach
site to achieving a meaningful and seamless data Going 100 percent digital is critical if a wind
transition from the design office to the factory. blade manufacturer wants to participate suc-
Multiple manufacturing challenges and cessfully in this highly competitive industry.
specifics must be addressed by designers so Leading global players have already started to
they can send the appropriate part definition to unify their different processes around 3D-based
the offline software that generates the machine composite design and manufacturing. The need
instructions. While the technicians on the shop to digitize uniformly across the design-to-manu-
floor who layup plies are typically able to cor- facturing process is only going to get more crit-
rect problems that inevitably arise during the ical as we move toward even longer and more
process, automated machines are not as flexi- complex wind blades.
ble yet. Moreover, the design release has to be For more information, visit VISTAGY.
L equipment located
in the field, wind
turbines are constantly ex-
Safe and effective wind turbine operation relies on
measurements made by sensors, which in turn
interface with signal conditioners. The sensors
posed to hazardous condi- are located in the controllers, which are usually
tions including electrical found at the bottom of the wind turbine tower
noise, power surges, and and in the nacelle at the top, with a third controller
transient events such as
sometimes located in the hub of the rotor.
static discharge and light-
ning strikes. Not only do
these conditions pose threats to the wind tur- this equipment is not affected, special protec-
bines themselves, they can also damage control tion is essential. This protection is addressed in
room equipment located miles away. To ensure ANSI/IEEE Standard C37.90.1.
Safe and effective wind
turbine operation relies on
measurements made by
sensors, which in turn inter-
face with signal condition-
ers. The sensors are located
in the controllers, which are
usually found at the bottom
of the wind turbine tower
and in the nacelle at the top,
with a third controller some-
times located in the hub of
the rotor. The sensors meas-
ure up to 500 different
parameters, including gen-
erator voltage and current,
frequency, shaft rotational
Figure 1: Typical oscillatory SWC test wave (open circuit). speed, wind direction, vibra-
tion, hydraulic pressure, and
component temperatures.
As wind turbines function in extremely severe relays and relay systems will withstand a speci-
environments that are always subject to tran- fied surge level, while use of proper grounding
sient events and other hazards, rugged, reliable and shielding techniques when equipment is
signal conditioners are critical for dependable installed will attenuate the actual surge levels
sensor data. that impinge on equipment.
The IEEE Standard for Surge Withstand The oscillatory SWC test became a required
Capability (SWC) Tests for Relays and Relay test for relays and relay systems containing
Systems Associated with Electric Power Apparat- semiconductor devices in 1978. Eleven years
us is specifically designed to provide assurance later, the fast transient test was incorporated
that electronic relays and relay systems will into IEEE Std C37.90.1-1989™.
operate effectively in the harsh environments of As stated in the Introduction included with
substations and switchyards. According to IEEE, IEEE Std C37.90.1-2002™, “The combination of
standard surge tests provide assurance that the fast transient SWC test and the oscillatory
WASHERS
control room equipment from the dangerous
and degrading effects of transient power
surges, noise, internal ground loops, and other
hazardous conditions found in the field. To
provide this protection, Dataforth signal condi-
tioners are manufactured with field inputs and
FFREE
REE CCATALOG
ATALOG outputs protected against transient events as
defined by ANSI/IEEE Standard C37.90.1.
Electrical ruggedness is also exemplified by
compliance to the electrostatic discharge
(ESD) susceptibility and emissions require-
ments of CE standards EN61000-6-2 and
EN61000-6-4. By incorporating these specifi-
cations into the core design of all signal condi-
tioning modules, Dataforth ensures meeting —
1-888-927-4377 • sales@bokers.com
612-729-9365 • FAX 612-729-8910 and even exceeding — the rigorous transient
protections required to safeguard wind turbine
operations.
For more information, visit Dataforth.
WASHERS, SPACERS & SHIMS
WWW.BOKERS.COM/TBG
Understanding Testing
Requirements for Photovoltaic
Modules
Envirotronics, Grand Rapids, MI
olar energy has huge potential to supply panels that are more efficient, cost less, and
Damp Heat Test — Test for 1,000 hours at IEC Test Standards for PV Modules Include:
85°C/85% humidity. IEC 61215: Crystalline Silicon Terrestrial PV
UV Preconditioning Test — Ambient to 90°C, Modules. This standard is a sequence of tests to
wavelengths from 280 to 400 nm with UV irradi- determine the electrical and thermal character-
ation uniformity of +/- 15%. istics of the module and to show that the mod-
Bypass Diode Thermal Test — Means for ule is capable of withstanding prolonged expo-
applying a current equal to 1.25 X the STC sure to the elements.
short-circuit current of the module under test IEC 61646: Thin-film Terrestrial PV Modules.
and means for monitoring the flow of current This standard is also a sequence of tests to
through the module throughout the test. determine the electrical and thermal character-
Water Spray Test — Test for one hour with istics of the module and to show that the mod-
water temperature of 25°C. After exposure, ule is capable of withstanding prolonged expo-
examined for evidence of water penetration to sure to the elements.
and above uninsulated live parts and for evi- IEC 61730: PV Modules. This test standard is
dence of the collection of water in any compart- used to provide a safe electrical and mechanical
ment containing live parts. operation during the lifetime of the module. Specific
topics are provided to assess the prevention of identical package including size and using
electrical shock, fire hazards, and personal injury identical cell process
due to mechanical and environmental stresses. • Qualification of a frameless module after the
IEC 61215, IEC 61646, and IEC 61730 are design has received certification as a framed
designed so that their test sequence can coordi- module
nate and are arranged in an optimal way. • Change in bypass diode
IEC 62108: UV Preconditioning. This standard New techniques, materials, design, and tech-
also addresses the operation of the PV module. nologies will continue to be developed at a rapid
Tests include thermal cycling, damp heat humidi- pace in the photovoltaic module industry.
ty freeze, water spray, and UV conditioning. Testing of all these new processes and materials
will play a key role in bringing products to mar-
The UL and ASTM Standards for PV ket. An environmental test chamber plays a key
Modules Include: role for manufacturers to be certain that their
UL 1703 and ASTM E1171 are also tempera- products are meeting all industry and customer
ture cycling, humidity, humidity freeze, and test standards and specifications.
damp heat tests for PV modules. For more information, visit Envirotronics.
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GPS
Receiver R GPS
Receiver F
Time & PPS
Time & PPS
cRIO master R
Trigger cRIO Master F
LAN
LAN
Ethernet Switch
(Hub) LAN
WiFi cRIO System Fn
Antenna LAN
LAN LAN
WiFi
access point
(Hub) Ethernet switch
(Nacelle)
LAN
LAN
WiFi Router
(Tower)
Host PC
(Tower)
A big challenge is the sample-by-sample data synchronization between different sensor types in the rotating hub and
the nacelle.
measurement platform for drive train testing Alliance Partner in Denmark, helped with the
because of their flexibility, ruggedness, tight design of the architecture and provided the solu-
synchronization, and mixed-sensor connectivity. tion. CIM and Vestas used a structured develop-
CompactRIO has the environmental specifica- ment process to provide detailed design and
tions and small size necessary to deploy the software documentation, which will make it easy
measurement system in the field where temper- to implement, maintain, and modify the meas-
atures range from -20 to 50°C and humidity and urement system in the future.
salt can be a challenge. Additionally, LabVIEW
has proven to be a good development environ- Measurement System Design
ment for large, complex applications like Vestas' CIM helped with the design of a measure-
measurement system. ment system consisting of several CompactRIO
Because of the expected development time systems capable of making hundreds of tem-
and the complexity of the application, CIM perature, vibration, movement, and strain
Industrial Systems A/S, a National Instruments measurements in several places in the gear-
Module
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Host FG Control
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Configura- tion d Handler
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Configuration
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Post Processor
tion file Host configuration data Manager
HOST APPLICATION
A simplified design overview of the complex software design on the host computer.
he aircraft manufacturer Bombardier recent- “In 2008 we analyzed all types of equipment
T ly installed a solar energy retrofit to preheat with a goal of reducing our electric and natural
outdoor air at its 40,000-square-foot research gas consumption,” said Serge Dumont, P.Eng.,
and development facility at the Mirabel Airport plant engineering and tooling manager at the
in Quebec. Bombardier's plant engi-
neering group authorized the instal-
lation of a Lubi™, a wall-mounted
solar air heater that is amidst a two-
year payback for that application.
The Lubi supplements the existing
natural gas-fired make-up air unit by
preheating wintertime outdoor air
for the 52-foot-tall, hangar style
building as required by ASHRAE
Standard 62-mandated commercial
building requirements.
This video shows how the Lubi works, how it is installed, and some typical
installations. Click here to watch the video.
Schematic representation of the fine-tuned hypothesis for the mechanism of Ag-assisted electroless etching.
5 µm
4 µm
Scanning electron microscopy images of selectively etched n-type (a) and p-type (b).
Ag ions are reduced and subsequently, (2) Si is is determined by the arrangement of the Ag
oxidized. An important conclusion is that the nanoparticles. For example, when starting from
deposition of Ag can be tailored by influencing a substrate with little Ag coverage, a small
the relative energy positions of the Si band dia- amount of holes is etched and only porous Si is
gram and the Ag+/Ag redox couple. obtained. A high degree of Ag coverage results
After Ag deposition, the Si sub-
strate is etched. Therefore, the
When starting from a substrate with little Ag
substrate is immersed in an etching
coverage, a small amount of holes is etched
solution composed of HF and H2O2.
By studying the influence of differ- and only porous Si is obtained. A high degree
ent parameters on the etch of Ag coverage results in a larger amount of
process, the reaction mechanism holes and, consequently, of Si nanowires
that explains all the observations between them.
has been fine-tuned: (1) H2O2 oxi-
dizes the Ag particles; and (2) the
dissolved Ag+ are reduced again to metallic sil- in a larger amount of holes and, consequently,
ver while oxidizing the underlying Si. Step (2) of Si nanowires between them. For example, for
was found to determine the rate of the etch p-type Si, Si nanowires with a length of 20 µm
mechanism. can be obtained after 30 minutes etching. After
The results have confirmed a recently two hours of etch the nanowires reach up to 70-
believed hypothesis that etching of Si occurs at µm long.
the Ag sites. Moreover, the etched Si structure For more information, visit Imec.
Figure 1. (a) AFPM topographic map of a 7.5 µm x 7.5 µm OPV array. (b) AFPM current map at 0.0 V applied bias and
(c) AFPM current map at -0.5 V applied bias. In the AFPM current maps, the absolute value of the photocurrent is
depicted.
■ Photovoltaic Backsheet
Bekaert Specialty Films (San Diego, CA) has introduced the Solar
Gard PV T10f backsheet, which combines a Tedlar® membrane
with a new proprietary functionalized surface that delivers superior
adhesion to ethylene-vinyl acetate (EVA). The backsheet has out-
standing peel strength and is available in flexible roll-form to fit a
wide range of solar panel sizes. Solar Gard PV T10f features a
thickness of 12 mil, a dielectric breakdown voltage of 19 kV, and a
partial discharge voltage of 1100 VDC.
■ Etchant/n-Dopant Material
The new VersaEtch™ Etchant/n-Dopant InkJet Etchant & Dopant Combination
InkJet
material from Trident Solar (Brookfield, Heat. Narrow
CT) is for inkjet selective emitter applica- SiNx:H feature etched
and n-dopant
P-T
Tyype Si
difffused.
f
tion of solar front contacts (c-Si). Used n+ n+
n++
n+ n+
with the Trident 256Jet-S printhead, the
VersaEtch Etchant/n-Dopant can match the
enhanced cell efficiency (0.5-1.0%) and
Screen Printing
precise deposition performance (demon-
strated 50 micron print) of other selective
emitter approaches, while also being non-contact, single-step, high-purity, and cost-effective.
Combining the etching and doping processes eliminates the need for very precise alignment of
etchant and dopant in two separate processes.
Y C
N
Accounting/Human Resources Manager ..............Sylvia Ruiz
M .
Office Manager .......................................Alfredo Vasquez
Receptionist ...............................Elizabeth Brache-Torres