Blake M. Coughenour

Dish-based high concentration PV system with Köhler optics

We present work at the Steward Observatory Solar Lab on a high concentration photovoltaic system in which sunlight focused by a single large paraboloidal mirror powers many small triple-junction cells. The optical system is of the XRX-Köhler type, comprising the primary reflector (X) and a ball lens (R) at the focus that reimages the primary reflector onto an array of small reflectors (X) that apportion the light to the cells. We present a design methodology that provides generous tolerance to mis-pointing, uniform illumination across individual cells, minimal optical loss and even distribution between cells, for efficient series connection. An operational prototype has been constructed with a 3.3m x 3.3m square primary reflector of 2m focal length powering 36 actively cooled triple-junction cells at 1200x concentration (geometric). The measured end-to-end system conversion efficiency is 28%, including the parasitic loss of the active cooling system. Efficiency ~32% is projected for the next system.

Reflectance optimization of second-surface silvered glass mirrors for concentrating solar power and concentrating photovoltaics application

Methods developed to maximize the overall reflectance of the second-surface silvered glass used in concentrating solar power (CSP) and concentrating photovoltaics (CPV) solar systems are reported. The reflectance at shorter wavelengths is increased with the aid of a dielectric enhancing layer between the silver and the glass, while at longer wavelengths it is enhanced by use of glass with negligible iron content. The calculated enhancement of reflectance, compared to unenhanced silver on standard low-iron float glass, corresponds to a 4.5% increase in reflectance averaged across the full solar spectrum, appropriate for CSP, and 3.5% for CPV systems using triple junction cells. An experimental reflector incorporating these improvements, of drawn crown glass and a silvered second-surface with dielectric enhancement, was measured at National Renewable Energy Laboratory to have 95.4% solar weighted reflectance. For comparison, nonenhanced, wet-silvered reflectors of the same 4-mm thickness show reflectance ranging from 91.6% to 94.6%, depending on iron content. A potential drawback of using iron-free drawn glass is reduced concentration in high concentration systems because of the inherent surface errors. This effect is largely mitigated for glass shaped by slumping into a concave mold, rather than by bending. Finally, an experiment capable of determining which junction limits the triple junction cell is demonstrated.

On-sun performance of an improved dish-based HCPV system

The University of Arizona has developed a new dish-based High Concentration Photovoltaic (HCPV) system which is in the process of being commercialized by REhnu, Inc. The basic unit uses a paraboloidal glass reflector 3.1 m x 3.1 m square to bring sunlight to a high power point focus at a concentration of ~20,000x. A unique optical system at the focus reformats the concentrated sunlight so as to uniformly illuminate 36 triple junction cells at 1200x geometric concentration1. The relay optics and cells are integrated with an active cooling system in a self-contained Power Conversion Unit (PCU) suspended above the dish reflector. Only electrical connections are made to the PCU as the active cooling system within is completely sealed. Eight of these reflector/PCU units can be mounted on a single two axis tracking structure2. Our 1st generation prototype reflector/PCU unit consistently generated 2.2 kW of power normalized to 1kW/m2 DNI in over 200 hours of on-sun testing in 20113. Here, we present on-sun performance results for our 2nd generation prototype reflector/PCU unit, which has been in operation since June 2012. This improved system consistently generates 2.7 kW of power normalized to 1kW/m2 DNI and has logged over 100 hours of on-sun testing. This system is currently operating at28% DC net system efficiency with an operating cell temperature of only 20°C above ambient. Having proven this system concept, work on our 3rd generation prototype is underway with a focus on manufacturability, lower cost, and DC efficiency target of 32% or better.

Second-surface silvered glass solar mirrors of very high reflectance

This paper reports methods developed to maximize the overall reflectance second-surface silvered glass. The reflectance at shorter wavelengths is increased with the aid of a dielectric enhancing layer between the silver and the glass, while at longer wavelengths it is enhanced by use of glass with negligible iron content. The calculated enhancement of reflectance, compared to unenhanced silver on standard low-iron float glass, corresponds to a 4.4% increase in reflectance averaged across the full solar spectrum, appropriate for CSP, and 2.7% for CPV systems using triple junction cells. An experimental reflector incorporating these improvements, of drawn crown glass and a silvered second-surface with dielectric boost, was measured at NREL to have 95.4% solar weighted reflectance. For comparison, non-enhanced, wetsilvered reflectors of the same 4 mm thickness show reflectance ranging from 91.6 - 94.6%, depending on iron content. A potential drawback of using iron-free drawn glass is reduced concentration in high concentration systems because of the inherent surface errors. This effect is largely mitigated for glass shaped by slumping into a concave mold, rather than by bending.

Demonstration of a robust curved carbon fiber reinforced polymer deformable mirror with low surface error

Carbon fiber reinforced polymer (CFRP) composites provide several advantages as a substrate for thin-shell adaptive secondary mirrors, including high stiffness-to-weight ratio and low coefficient of thermal expansion (CTE). We have addressed some of these concerns using a prototype CFRP mirror under actuation. Using 4D and Newton interferometry, we present measurements of surface quality at a range of temperatures. Under actuator relaxation at room temperature, its surface error is low (92 nm RMS) and dominated by edge curvature. This error is reduced further under best actuator correction to 43 nm RMS, placing it into consideration for use in near-IR astronomy. The low surface error internal to the outer ring of actuators - 17 nm RMS at 60°F and 33 nm RMS at 20°F - suggests that larger mirrors will have a similar figure quality under actuator correction on ground-based AO systems. Furthermore, the actuator forces required to correct the figure are small compared to the dynamic range of voice coil actuators (~0.1 N). In addition, surface roughness is characterized to address the effects of high spatial frequency errors.

Design, Optimization and Characterization of Secondary Optics for a Dish-Based 1000x HCPV System

This paper presents a novel design of a solar secondary optics used in a dish-based HCPV system at 1000x. Different optimizations were conducted as well as experiments to determine its optimum configuration.

Development and On‐Sun Performance of Dish‐Based HCPV

The paper describes a new system architecture optimized for utility‐scale generation with concentrating photovoltaic cells (CPV). The system concept is optimized to use predominantly low‐cost materials manufactured by methods proven for high volume production. Triple‐junction cells are used to convert 1000x concentrated sunlight into electricity. Compared to silicon panels, these commercially available cells convert at least twice as much of the incident sunlight energy into electricity, and at 1000x optical concentration, they cost one‐tenth as much per watt of power output. The architecture combines three novel elements: large (3.1 m×3.1 m square) paraboloidal glass dish reflectors to collect and concentrate the sunlight; compact receivers at each dish focus, each one incorporating multiple, actively cooled cells; and a lightweight steel spaceframe structure to hold multiple dish/receiver units in co‐alignment and oriented to the sun. A manufacturing process for replicating the reflector dishes is well ...

Freeform lens design to achieve 1000X solar concentration with a parabolic trough reflector

Line-focus parabolic trough mirrors for solar thermal generation cannot produce the high concentration required for concentrating photovoltaic (CPV) systems. We describe a freeform lens array with toroidal symmetry which intercepts the low-concentration line focus to produce a series of elongated, high-concentration foci. The design employs 2D Kӧhler illumination to improve the acceptance angle in one direction. The two-stage concentrator has 1000X average geometric concentration with an acceptance angle of +/-1.49° in the azimuthal direction and +/-0.29° in the elevation direction. Preliminary results of a prototype roll-forming process are shown in thermoplastics and B270 glass.

Tracking-Integrated Optics: Applications in Solar Concentration

Conventional concentrating photovoltaic (CPV) systems track the sun with high precision dual-axis trackers. The emergent field of tracking-integrated optics has the potential to simplify the mechanics of CPV systems by loosening or eliminating the need for dual-axis tracking. In a tracking-integrated scheme, external module tracking is complemented or entirely replaced by miniature tracking within the module. This internal tracking-integration may take the form of active small-motion translation, rotation of arrayed optics, or by passive material property changes induced by the concentrated light. These methods are briefly reviewed. An insolation weighting model is presented which will aid in the design of tracking-integrated optics by quantifying the tradeoff between angular operation range and annual sunlight collection. We demonstrate that when tracking-integrated optics are used to complement external module tracking about a horizontal, North-South oriented axis, truncating the operational range may be advantageous. At Tucson AZ latitude (32.2°N), 15.6% of the angular range may be truncated while only sacrificing 3.6% of the annual insolation. We show that modules tracked about a polar-aligned axis are poorly-suited for truncation.

Freeform solar concentrator with a highly asymmetric acceptance cone

A solar concentrator with a highly asymmetric acceptance cone is investigated. Concentrating photovoltaic systems require dual-axis sun tracking to maintain nominal concentration throughout the day. In addition to collecting direct rays from the solar disk, which subtends ~0.53 degrees, concentrating optics must allow for in-field tracking errors due to mechanical misalignment of the module, wind loading, and control loop biases. The angular range over which the concentrator maintains <90% of on-axis throughput is defined as the optical acceptance angle. Concentrators with substantial rotational symmetry likewise exhibit rotationally symmetric acceptance angles. In the field, this is sometimes a poor match with azimuth-elevation trackers, which have inherently asymmetric tracking performance. Pedestal-mounted trackers with low torsional stiffness about the vertical axis have better elevation tracking than azimuthal tracking. Conversely, trackers which rotate on large-footprint circular tracks are often limited by elevation tracking performance. We show that a line-focus concentrator, composed of a parabolic trough primary reflector and freeform refractive secondary, can be tailored to have a highly asymmetric acceptance angle. The design is suitable for a tracker with excellent tracking accuracy in the elevation direction, and poor accuracy in the azimuthal direction. In the 1000X design given, when trough optical errors (2mrad rms slope deviation) are accounted for, the azimuthal acceptance angle is +/- 1.65°, while the elevation acceptance angle is only +/-0.29°. This acceptance angle does not include the angular width of the sun, which consumes nearly all of the elevation tolerance at this concentration level. By decreasing the average concentration, the elevation acceptance angle can be increased. This is well-suited for a pedestal alt-azimuth tracker with a low cost slew bearing (without anti-backlash features).