Solar Array

Cell availability:
C60: SunCat Solar and Gochermann Tech can obtain them from SunPower and
encapsulate them into array modules.

HIT: Although unlikely but businessman Curtis is in talks with Panasonic.

Table 1 Cell comparison
Company Cell EFF Vmp Thermal Coefficient (per

increase)
SunPower C60 22.50% 0.58 -0.32% power, -1.8 mV voltage
Panasonic HIT-N 21.60% 0.6 -0.3% power, -1.8 mV voltage

Simulation:
Using the arraysim Matlab program developed by Ahthavan simulations of power input
for different aero-bodies were run. The program simulates the car in race conditions at
a certain speed. It takes into account race route, charging stops, luminosity, time, sun
path, and angle dependence. 6m^2 of solar was laid on various aero-bodies with cell
efficiency at 22.5% from which the total power input was calculated. Three main aero-
bodies with variations in 2-D, 3-D shape were compared in this exercise.

BUTT = Buttamaran

FAT= Dream III

FF = Five Fairing


*Note: All array results are compared to the FF, 3D


Table 2 - Simulation results with solar car going 75km/hr
BUTT,
curved BUTT, flat FAT FF, 3D FF, 2D
FF, 2D,
back
Total E
(kwh) 44.5 47.2 36.1 44.7 45.8 45.5
% Diff -0.3 5.7 -19.2 2.6 2.0
Drag force
equivalent
(N) -0.1 2.9 -9.8 1.3 1.0
*Note: All aero bodies here are compared to the FF, 3D



Table 3 - Simulation results with solar car going 60km/hr
BUTT,
curved BUTT, flat FAT FF, 3D FF, 2D
FF, 2D,
back
Total E
(kwh) 45.4 47.9 37.7 45.6 46.5 46.3
% Diff -0.4 5.0 -17.4 1.9 1.5
Drag force
equivalent
(N) -0.2 2.6 -9.1 1.0 0.8
*Note: All aero bodies here are compared to the FF, 3D



We can see from the table(s) and graphs (next page) that the DREAM aero-body has
significantly worse array performance. In both cases it produces 18-19% less power
compared to Five Fairing 3D. For the other aero body shapes their array performance
was relatively close to the final Five Fairing 3D design. The simulation was run
assuming cell efficiency of 22.5%.



Video of Five Fairing 3D array input simulation: (control click)
http://www.blueskysolar.utoronto.ca/data/engineering/array/ff2_cells.mp4
Note: At control stops the simulation assumes array perpendicular to sun.










Graph 1 - Power input simulation for Butt 2D, DREAM, and FF,3D. 75 km/hr cell EFF
at 22.5%

Graph 2 Power input simulation of Five Fairing - 3D cell EFF at 22.5%

0
200
400
600
800
1000
1200
1400
1
2
2
4
3
6
4
8
5
1
0
6
1
2
7
1
4
8
1
6
9
1
9
0
2
1
1
2
3
2
2
5
3
2
7
4
2
9
5
3
1
6
3
3
7
3
5
8
3
7
9
4
0
0
4
2
1
4
4
2
4
6
3
4
8
4
5
0
5
5
2
6
Butt, 2D
DREAM
FF, 3D
P
o
w
e
r
(
W
)
time = 1/4 hr
Katerine
317km
Alice Springs
1494km
Adelaide
Dummarr
TennantCK
985km
Cadney 2025km
PtAugusta
2719km
0
200
400
600
800
1000
1200
1400
1
2
2
4
3
6
4
8
5
1
0
6
1
2
7
1
4
8
1
6
9
1
9
0
2
1
1
2
3
2
2
5
3
2
7
4
2
9
5
3
1
6
3
3
7
3
5
8
3
7
9
4
0
0
4
2
1
4
4
2
4
6
3
4
8
4
5
0
5
5
2
6
FF, 3D
P
o
w
e
r
(
W
)
time = 1/4 hr
Encapsulation:
The team has 2 options for encapsulation: Sun Cat Solar or Hans Gocherman
Technology. The team ruled out in house lamination because saving a little bit money
is not worth the loss in array performance. The team feels that the lamination job is best
left to professionals.
Currently the team is leaning towards having the solar cells (Sun-power C60)
encapsulated by Sun-cat Solar. The reason is that SunCat Solar is able to have its dicing
company cut solar cells into any specs given wheras Gochermann only seems to be able
to cut 93mm by 125mm C60 cells. Suncat also provides high quality encapsulation at a
reasonable price. The team spoke with Alain at ASC 2012 about encapsulation and
currently communicates with him on regular basis.
Table 4 Solar Cell encapsulation comparison
SunCat Solar Gochermann Tech.
Power Loss % due to
lamination
- 3 % - 0.9%
Power gain % with
texturing
3 % (?) 3 %
Thickness 1.2 mm (+/- 0.1 mm) 0.7 mm (+/- 0.1 mm)
Laminate Structure Tefzel/EVA/Tedlar fibreglass/clear laminate
Unit weight 0.98kg/m2 1.1 kg/m2
Lamination + Cell price $21-25k CAD $ 41.2 k CAD
AR coating $ 1.5 k CAD
Pro(s) - less expensive
- Alain Chuzel willing to help
with technical details
- no significant problem of dust
accumulation on module

- more flexible module
- micro-textured pyramid
anti-reflective coating
- Nano-second laser cutting
of solar cells
-Offers 0.6mm cell spacing
Con(s) - no micro pyramid AR
technology
-overall less technically
sophisticated as Gochermann

- more expensive
- dust accumulation on
micro texturing
- Can only cut C60s to
93mm by 125mm
*for Gochermann pricing euro:CAD is 1 : 1.27 (Sept 12, 2012 Bank of Canada)

SunCat Solar (Alain Chuzel)
SunCat Solar is capable of purchasing C60 Sun-power cells, providing lamination, and
matte surface for anti-reflection. SunCat solar does not have micro-pyramidal
technology like Gochermann does (see Gochermann section for more details). Instead
the modules do have a matte finish which helps reduce light reflection at oblique angles.
While visiting ASC in July, 2012 the array team spoke with Alain Chuzel of Suncat Solar.
He was enthusiastic and indicated he was willing to provide help with the technical
details of the array design
Hans Gochermann Solar Technology (Hans Gochermann)
Gochermanns technology includes texturing the cell surface with matte 5-micrometer-
wide pyramids that reduces refraction at oblique angles. The micro pyramids work by
deflecting some of the suns rays back onto other pyramids, giving the photons a second
chance to produce useful energy and theoretically increasing the arrays power by 4
percent. The technology is particularly effective during mornings and late afternoons,
when the sun is at an angle of less than 45. Standard lamination sometimes reflects half
or more of the incoming rays. By adding a coating with a microstructure made up of
small pyramids the reflection is reduced to roughly 5%.
Many of the top teams have employed this technology including Nuna and Michigan.
One concern with the micro-pyramid structure is the dust accumulation on the array.
There is no real consensus on how to alleviate this problem. Teams typically use non-
stick tape to apply and peel it off the surface of array in hopes the dust have stuck to the
tape. The micro-pyramid structure costs $1.2k and it is optional for one example is
Azures array.
Besides offering micro pyramidal microstructural anti-reflective coating Gochermann
also offers proprietary technology of closer gapping between solar cells 0.6mm as
opposed to the standard 1mm. However, Gochermann doesnt seem to be able to cut
the C60 solar cells down the middle. From the email correspondence it seems that
Gochermanns nanosecond laser is only able to cut solar cells into 93mm by 125mm
specs. If this is confirmed by Gochermann the team feels its a major detriment as with a
curved body shape the cells need to be cut to provide similar power and high enough
voltage for PPTs
Below is photos comparison of Alains lamination vs. Gochermanns lamination

Pic. 5.1. Suncat Solars lamination with matte finish (Michigan solar car 2012 at ASC)


Pic. 5.2. Gochermanns lamination with microtexturing (Michigan solar car 2011 at WSC)
Module Layout
The array team has explored various options for module layout. Due to the curvature of
the body the team would like to minimize differentials between cells when there is
uneven distribution of irradiance in the morning and late afternoons. The team decided
to go with the cut 50mm by 125mm dimension Sunpower C60 solar cells. The cutting of
the cells will be handled by either Suncat Solar or Gochermann Tech. Below is the
proposed module layout.

Pic 3 - preliminary module layout on aero body

Cell Size: 50mm by 125mm
Number of modules to make 6
2
of array: 960
Number of cells on aero body: 963
module cells # dimen (mm) voltage
A 30 13 640 x 312
17.5
B 29 1 640 x 312
16.9
C 29 1 640 x 312
16.9
D 25 1 640 x 261
14.6
E 20 2 514 x 261
11.6
F 6 1 388 x 159
3.5
G 6 1 388 x 159
3.5
H 4 1 388 x 108
2.3
I 25 2 630 x 261
14.6
J 30 4 766 x 261
17.5
K 36 3 766 x 312
21.0
L 42 2 892 x 312
24.4
M 24 1 514 x 312
14.0
N 48 1 1018 x 312
27.9