Solar Panel Manufacturing Research Articles

Real-Time Monitoring and Defect Detection of Laser Scribing Process of CIGS Solar Panels Utilizing Photodiodes

Laser scribing is developing rapidly in industrial applications as a method of material processing, especially in areas that require high levels of precision. This technology provides functionality and efficiency improvements in the manufacturing of solar panels. Due to the premium quality and speed requirements of the laser scribing technology, monitoring of this process in real-time is critical in order to promptly detect defects in the manufacturing process. However, common monitoring systems have been developed for other laser processes, like laser welding, which are noticeably slower than the laser scribing process. The goal of this research was to investigate the possibility of using photodiodes for real-time monitoring of the laser scribing process for Copper Indium Gallium Selenide (CIGS) solar panels. Various monitoring setup configurations were designed, developed, and examined to determine the viable option for implementation as a defect detection platform. Using different photodiode positions, the intensity of the light and the photodiode induced voltage for diffuse and specular reflections were tested, and the practical pros and cons of applying each configuration were analyzed. The capability of the monitoring system to distinct the different layers of the scribed CIGS cell was also examined to assess the penetration depth of the scribe. In addition, by performing several experiments with different scribe thicknesses and analyzing oscilloscope measurements, the optimal placement of the photodiode for accurate tracing of the scribing path was determined and verified. Key aspects of development of such monitoring system for solar panel applications were identified through this research.

Life Cycle Climate Change Impact of a Cost-Optimal HVDC Connection to Import Solar Energy from Australia to Singapore

This paper aims to evaluate the life cycle greenhouse gas (GHG) emissions of importing electrical power into Singapore, generated from a large-scale solar photovoltaic (PV) power plant in Australia, through a long-distance subsea high-voltage direct current (HVDC) cable. A cost optimization model was developed to estimate the capacities of the system components. A comprehensive life cycle assessment model was built to estimate emissions of manufacturing and use of these components. Our evaluation shows that, for covering one fifth of Singapore’s electrical energy needs, a system with an installed capacity of 13GWPV, 17 GWh battery storage and 3.2GW subsea cable is required. The life cycle GHG emissions of such a system are estimated to be 110gCO2eq/kWh, with the majority coming from the manufacturing of solar PV panels. Cable manufacturing does not contribute largely toward GHG emissions. By varying full-load hours and cable lengths, it was assessed that sites closer to Singapore might provide the same energy at same/lower carbon footprint and reduced cost, despite the lower insolation as compared to Australia. However, these sites could cause greater emissions from land use changes than the deserts of Australia, offsetting the advantages of a shorter HVDC cable.

Influence of Cu2+ and Sn2+ ions on optical properties of MgS Nanoparticles: A comparative Analysis

Cu2+ and Sn2+ ions doped MgS nanoparticles were synthesized by chemical route without the aid of any capping agent. The role of Cu2+ and Sn2+ ions on the structural, optical, photoluminescence properties of MgS nanoparticles have been investigated through various analyses like XRD, TEM, EDX UV- vis absorption, transmittance studies, PL spectra and FT-IR. The average particle size was calculated as ∼ 10 nm and it was varied based on the ionic radius of the dopant. From this comparative study, it was observed that Cu2+ (2%) doped MgS showed a blue shift in Absorbance spectra, wide optical band gap and also exhibited better photoluminescence property. A strong PL emission was received in UV region and in the Red region. This combination of materials can be utilized in solar panel manufacturing as buffer material, optoelectronic devices and in red-emitting luminescent displays.

Cost-benefit analysis of adopting the solar photovoltaic water pumping system: A case of Rajasthan

Rajasthan, the largest state in India, occupies 10.5 per cent of the total geographical area of the country, although about two-thirds of its area is arid. The state has a predominantly agrarian economy, and agriculture is the mainstay of about two-thirds of the workforce. Interestingly, only 28 per cent of the net cultivable area in the state is irrigated, compared to the national average of 49.8 per cent. With the aim to improve irrigation facilities and increase agricultural productivity, the state government implemented the solar photovoltaic water pumping system (SPVWPS) in 2008-09 as an appropriate alternative to grid-connected water pumping. The aim of this paper is to assess the costs and benefits of adopting the SPVWPS using data from a field survey of 126 households. The findings show that use of the SPVWPS offers substantial benefits to adopters in the long run. In addition, government subsidy plays a major role in determining the payback period of adopters' investment in the scheme. The paper suggests that, alongside timely implementation of the scheme, the government should facilitate domestic manufacturing of solar cells and panels to fully harness social benefits of the SPVWPS.

Numerical Analysis of Liquid Immersion of Panels as a Cooling Technique

The materials used in the manufacturing of solar panels is a semiconductor which is sensitive to the irradiation falling on it. The semiconductor materials begin to heat and becomes inefficient after certain point of temperature and the power output becomes too low to utilize. To overcome this problem of high temperature certain cooling techniques are implemented. The aim of this paper is to analyse the reduction in the temperature of the panels which can be obtained for different ambient conditions by implementing liquid immersion of panels as a cooling technique by simulating the equations involved in the dissipation and absorption of heat from the panels. The immersion of panels reduces the direct contact of panels with the heat absorbed from the irradiation by changing the refractive index of the medium from air to water.

Green innovation downturn: the role of imperfect competition

We use strategic interactions to analyze the role of China's state-subsidized production expansion in the recent downturn in solar photovoltaics innovation. To that end, we develop a dynamic game model in which N solar panel manufacturers compete in price and invest in cost-reducing research. The resulting Nash equilibrium reveals an inverted U relationship between a manufacturer's market share and her research effort. In the duopoly case, with a local firm competing against a foreign state-subsidized one, we obtain analytical and numerical results that are consistent with a set of stylized facts, namely (i) the foreign manufacturer progressively expands to become the dominant player (ii) competition and innovation bring marginal costs down to zero (iii) each manufacturer's research effort follows an increasing-then-decreasing curve. At a policy level, these theoretical results suggest that national technology-push policies can affect foreign innovation, by changing the structure of global competition.

Economic feasibility assessment of manufacturing solar panels in South Africa – A case study of Steve Tshwete Local Municipality

South Africa has developed one of the most successful renewable energy development programs in the world. However, the establishment of a South African solar Photovoltaic (PV) manufacturing localisation agenda has fallen behind. This study assesses the financial feasibility for local manufacturing of solar panels in South Africa using the Generally Accepted Accounting Principles (GAAP) method to determine a Minimum Sustainable Price (MSP) for a local production plant. Our findings show that local manufacturing of solar panels can play a role in supporting a “just energy transition”, particularly, in regions that are phasing-out the coal economy. We observed the financial feasibility of solar panel local manufacturing and found that the Internal Rate of Return (IRR) was 1.75%. When sensitivity analysis of +15% was applied, the IRR increased to 3.51%. The study also determined that without any subsidies local manufacturing of solar panel is not economically feasible when the MSP is used. Lastly, the probable negative impacts of coal phase-out can be prudently mitigated by the creation of alternative economic opportunities which promotes a just energy transition in coal phase-out regions like Steve Tshwete Local Municipality (STLM).

The alternative energy Technosphere safety problems

The work shows that the dangerous vulnerability of renewable energy sources is the imperfection of materials and design of energy storage devices. A study of the charge-discharge cycles’ effect on the batteries’ stability in a specially developed installation showed that if even the most promising lithium-ion devices are used, due to the microdamage accumulation, all electric energy storage devices will not be durable and will necessarily fail. In addition, it is shown that the materials used in the manufacture of solar panels and wind turbine blades can harm the environment. It is concluded that the Technosphere safety problems of alternative energy can be solved only if the technology for the efficient utilization of used solar batteries and blades of wind-powered generators is created.

Problems Faced by Automobile Industries: Case Study on Tesla

The study is being done on the problems faced by Automobile Industries while launching Electric Cars. The problems are common for all the automobile industries which had launched the EV, are launching or will launch them. But here the research is done specifically in respect to Tesla. Tesla Motors Inc. is an American automotive and energy company that was founded in 2003 is based in Palo Alto, California. The company specializes in electric car manufacturing, SolarCity subsidiary and solar panel manufacturing. The company is well known for its exclusive models like Model S, Model 3, Model X and the newest one Model Y. Tesla Motors released its first electric car in 2008 that was called The Roadster. Roadster achieved 245 miles (394 km) on a single charge. Since 2008, Tesla sold approximately 2,450 Roadster in over 30 countries through December 2012. Tesla faced many problems while launching the very first EV not only with the model but with its marketing too. So, this Project Report is being prepared by researching the problems faced by the Tesla regarding its first EV and its marketing. There are some particular solutions that are recognized by our team for the respective problems which will be useful for the automobile industries to overcome certain problems. These solutions will open the doors for the industries that are going to launch EV by referring the past data analysis of Tesla which is studied and prepared by our team in this Research Project.

Modeling and Efficiency Improvement of a Pulse Generator for Wire Electric Discharge Machining

Pulse generators for wire electric discharge machining (WEDM) are derived from standard dc–dc converters. However, their design and analysis need to be done carefully by considering the pulsed nature of the load. In this article, these issues are discussed for a dual-converter-based topology considering the application of WEDM for slicing silicon ingots in the solar photovoltaic industry. It is shown that appropriate sizing can reduce the overall size of the pulse generator significantly. The efficiency computation procedure is outlined in detail as it is an important parameter, particularly when WEDM becomes a part of solar panel manufacturing chain. The present control scheme for the pulse generator yields around 31% efficiency. A new pulsed current reference scheme is proposed, which can improve the efficiency to 62%. Frequency-domain modeling is presented by considering distinct stages of operation of the pulsed load. The models are compared with the standard converters from which the topology is derived. This modeling method can be applied to other pulse generators as well. Hardware of the pulse generator is built with a maximum open-circuit voltage of 100 V, a maximum spark current of 10 A, and a pulse repetition frequency of 1 kHz. The novel control scheme is verified with experimental results.

Multi‐attribute analysis of micro‐defect detection techniques suitable for automated production line of solar wafers and cells

Renewable energy is going to play an immensely important role in the coming decades. Hence, the bulk manufacturing of solar panels has seen a renewed interest. For this purpose, it is imperatively important to assess the techniques that can be employed on automated production lines for evaluating the quality of solar wafers and cells. To-date many non-destructive testing methods to access the micro-defects in solar wafers and cells have been developed around the globe; however, not all of them can be applied on a fast-paced production line. In this regard, this study details all the non-destructive evaluating techniques that can be employed on an automated production line. Using a multi-attribute decision-making method, a strategic evaluation procedure is developed that can be adopted for the optimum selection of evaluation tools currently available in the market. This study is aimed at young researchers, graduate students and practitioners who want to come up-to-speed regarding the various defects that occur in solar wafers and cells along with the techniques that are currently being adopted to evaluate those defects. Also, future trends in research are highlighted regarding the development of assessment techniques.

Toward Scalable Perovskite Solar Modules Using Blade Coating and Rapid Thermal Processing

Towards scalable manufacturing of perovskite solar panels, high-performance planar p-i-n perovskite solar cells (PVSCs) and modules have been demonstrated with blade-coating and rapid thermal proce...

Improving the efficiency of the Lay-Up process in the manufacture of Solar Panels through time-study

Lay-Up is a manual process conducted during the manufacture of solar panels where the multiple layers are set together by hand. Since this process is done manually, there is no standard time period for it. Additionally, errors in process can increase production time needlessly. This research paper employs time-study to establish a standard operation time for Lay-Up aimed at singling out steps that cause loss of valuable time, efforts and resources. The time study is carried out by making a note of all the operations involved in Lay-Up and breaking them down into individual steps. The measurements are made using a digital stop watch and time sheet.

Recent advances in non-fullerene organic solar cells: from lab to fab.

Recently, the laboratory-scale power conversion efficiency (PCE) of organic solar cells (OSCs) has reached 18% in single-junction devices due to a combination of the rapid development of novel light-harvesting/interfacial materials and device engineering. Thus, such materials show considerable application prospects in the near future. It is of great importance to develop economically achievable, highly efficient, thickness-tolerant photovoltaic materials and processing methods for the manufacture of large flexible solar panels. Research in this area has been conducted from the very early stages of the development of organic photovoltaic materials and has never stopped. Herein, we focus on the fundamental requirements of photoactive materials and the processing methods used for commercialization based on the recent advances of the booming PCEs, to provide guidelines for future material design and mass production. In this review, the progress toward high-performance materials is briefly summarized, and the essential requirements for large-area printing modules, such as thickness tolerance and cost issues, and the latest findings on non-fullerene OSCs are introduced. In particular, important advances in the material design and device optimization of thick-film OSCs have been discussed. Significant advances in the processing methods used to prepare efficient non-fullerene OSCs and the challenges for the industrialization of OSCs are presented. Furthermore, the prospects and opportunities in this emerging field of research are also discussed.

CO2 emissions from renewables: solar pv, hydrothermal and EGS sources

Geothermal and solar pv are future energy sources, as both these renewables draw energy from natural heat sources i.e. the Earth and the Sun. While geothermal energy utilizes Earth’s heat for power generation and for direct applications, like space cooling and dehydration, solar energy captures the Sun’s energy and converts the energy to electricity through solar pv cells. The quartz required to manufacture solar cells that can generate 1 MWe weighs about 10 tons, and the manufacture of pv cells involves two important stages: metallurgical grade silicon (MGS) and electronic grade silicon (EGS). In the first stage an amount of 1756 × 106 kg of CO2 is released, and a similar amount of CO2 is released during the conversion of EGS to ingots. The total CO2 emissions during the lifecycle of a solar pv cell are about 3312 × 106 kg. This is far higher than a geothermal energy source, which emits about 450 g/kWh. According to the International Energy Agency (IEA), under the sustainable development policy proposed for adoption to mitigate CO2 emissions, nearly 54 × 109 cells are required to meet the generation target of 14,139 TWh. Of solar pv and geothermal energy sources, geothermal energy is the best option under this policy scenario to mitigate CO2 emissions and to control global temperatures. In addition to the emissions related to the manufacture of solar pv cells, solar panels and solar cell waste management are of great concern. Globally the generation of solar panel waste will be of the order of 78 million tons (Weckend et al. 2016). Countries involved in the manufacture of solar pv cells will emit considerable amounts of CO2 from this source in addition to coal-based thermal power plants. Solar pv cells may not emit CO2 during the generation of electricity, but during their life time emissions are considerable. Therefore, solar pv cannot be considered a zero-emission source.

The politics of late late development in renewable energy sectors: Dependency and contradictory tensions in India’s National Solar Mission

Renewable energy investments are expanding across the world at an astonishing rate. The United States and Europe obtained early advantages in renewable energy technologies. However, East Asian late industrializers have now extended substantial support to domestic renewable energy manufacturing firms alongside encouraging increased deployment of renewable energy projects. In the solar energy sector, Chinese companies now dominate global production of solar cells and panels. Other developing countries, in South Asia and Sub-Saharan Africa, have lagged in their support to manufacturing segments of renewable energy sectors. Yet many countries still aim to promote domestic production of solar panels and cells though such priorities are often secondary to increasing deployment of solar power projects. This paper argues that India’s position as a late, late industrializer in the sector, combined with prevailing domestic political economy pressures, have made it extremely difficult to promote the manufacturing of solar panels and cells. The strategy of prioritising increasing installed capacity of solar energy while also attracting lower energy tariffs appears incompatible with the goal of increasing domestic manufacturing capacity. Initially established in 2010 and ramped up after Narendra Modi became Prime Minister in 2014, India’s National Solar Mission (NSM) has received widespread praise for increasing the country’s installed solar energy capacity and for attracting tariffs of Rs. 2.44 per unit (a reduction of 80% within the last six years). However, domestic manufacturing has received limited support, especially after the United States launched a complaint against the NSM’s domestic content requirements, requiring energy developers to procure domestically-produced panels on specific projects. In 2018, the Indian government chose to refocus its attention on supporting manufacturers. However, the government chose a strategy that prioritised retaining a low minimum tariff on projects while increasing protection against imported panels, thereby forcing developers to buy panels at a higher cost. Since then, bidding processes have slowed down, highlighting the incompatibility of these goals. India’s case shows that countries that fail to integrate a strategic focus on manufacturing in their renewable energy expansion strategies from the onset may remain dependent on foreign imports of renewable energy technologies in the long-term. Late late development without adequate attention to industrial policy in renewable energy sectors will inevitably cement a green division of labour, with most of the Global South locked in dependency on American, European and East Asian technologies.

Management of Solar Photovoltaic Panels under the Extended Producer Responsibility Legislation

The Korean government announced the Renewable Energy 3020 Implementation Plan to increase the share of renewable energy in the power sector to 20% by 2030. Accordingly, considerable renewable energy wastes, including those from solar photovoltaic (PV) and wind turbines, are expected to increase in the coming years. To recycle the end-of-life solar PV panel waste in an environmentally safe manner and to establish a waste recycling system in the future, the Korean government has proposed to amend the Enforcement Decree to the Act on the Resource Circulation of Electrical and Electronic Equipment and Vehicles by classifying solar PV panels as an extended producer responsibility (EPR) item, thus making solar panel manufacturers and importers responsible for their recycling. However, implementation of the proposed amendment has been postponed to 2021. This study addresses the important issues regarding the proposed amendment, and explores associated problems and improvements through a comparative analysis of the EPR in Korea and the EU.

Fabrication of Efficient Perovskite Solar Cells in Ambient Air Using a Humidity-Insensitive Method

Fabrication of perovskite solar cells (PSCs) in ambient air is of challenge due to its sensitivity to humidity. In this presentation, we report the fabrication of efficient CH3NH3PbI3 (MAPbI3) PSCs using an antisolvent method which yields decent device performance in a wide range of humidity levels (~ 0% RH, 20% RH, 40% RH, 50% RH and 60% RH). The MAPbI3 films obtained in those conditions are studied by characterizations including scanning electron microscope (SEM), X-ray diffraction (XRD), UV-vis absorption and steady-state photoluminescence (PL). Results exhibit that the quality of the MAPbI3 films shows no obvious difference as a whole. The greatly suppressed influence of humidity is ascribed to the rapid crystallization process due to the antisolvent method. The photovoltaic performances for the devices prepared at these relative humidity (RH) levels are found similar with average power conversion efficiencies (PCE) are around 15%. The storage stability is found similar as well. What’s more, the effect of water absorbed in the hydrophilic precursor to MAPbI3 films and associated solar cells is investigated and found ignorable. As a result, it is concluded that antisolvent method is an ideal humidity-insensitive route to fabricate efficient PSCs in ambient air and may pave the way for massive and low-cost manufacturing of solar panels. Keywords: (perovskite solar cells, CH3NH3PbI3, anti-solvent method, crystallization process)

Access to Alternatives: Increasing Rooftop Solar Adoption With Online Platforms

Residential solar installation prices, which are set on a case-by-case basis, remain both relatively high and variable despite significant declines in solar panel manufacturing costs. In this paper, I estimate a structural model of the solar installation market to quantify market power and to evaluate the welfare effects of connecting buyers and sellers through an online platform. I find that the platform yields a $1,451 increase in consumer surplus by increasing the number of installation bids each household receives. Households with higher energy consumption attract relatively more bids and reap the largest benefits from the platform. Counterfactual simulations yield two main results: 1) an increase from one to five bids per project causes a 15.5% ($4,000) reduction in gross installation prices and a 33% increase in the number of solar installations, and 2) the solar Investment Tax Credit—which is scheduled to be eliminated in 2022—improves total welfare by mitigating market power in addition to reducing pollution externalities from electricity generation.

Public perception toward residential solar panels in Bahrain

In 2017, Bahrain’s Cabinet endorsed the country’s first national renewable energy action plan. The plan included the installation of residential solar photovoltaic cells as a means of using renewable energy in government-built housing units. This was followed by the establishment of the country’s first photovoltaic solar panel manufacturing company and the introduction of a net metering policy. However, public acceptance of residential solar panels has not been researched. This study aimed to address this gap through the distribution of an online survey. A total of 764 complete responses were received. The results showed a considerable number of respondents were interested in installing solar panels. However, the respondents recognized several challenges in both buying and installing them, including capital cost, lack of information, and maintenance requirements. This study’s findings offer insights on how the public perceives solar panels, along with issues the government needs to address to ensure successful public participation in the use of solar energy in the residential sector in Bahrain.