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Digital Prototyping – Application of Numerical Methods in Module Development
M. Pander, U. Zeller, B. Jäckel, M. Ebert
Reliability, Simulation, Standards, PV Module
Photovoltaic Modules and BoS Components
Subtopic: PV Module Design, Manufacture, Performance and Reliability
Event: 36th European Photovoltaic Solar Energy Conference and Exhibition
Session: 4BO.11.2
789 - 794
ISBN: 3-936338-60-4
Paper DOI: 10.4229/EUPVSEC20192019-4BO.11.2
0,00 EUR
Document(s): paper


Photovoltaic Module product development is still very much based on cost pressure, experience, empirical rules, partly on design of experiments and therefore extensive testing compared to e.g. the automotive or wind power industry. Many aspects are evaluated by testing physical prototypes and with classic trial & error further understanding of the products is achieved slowly. This procedure is time-consuming and costly. Utilizing modern sim-ulation methods, the time-consuming production and testing of physical prototypes can be reduced significantly. Mean-while, several simulation models for the evaluation of optical, electrical, thermal and mechanical properties as well as performance simulation software are available. In the specific case of mechanical optimization, the failure modes such as glass breakage, cell breakage and interconnection failure have been addressed in the past by Fraunhofer CSP with the help of simulation methods. In this paper the focus lays on the process of digital prototyping. A concept is presented to do digital prototyping combining finite element simulations, known stress factors from the field and material parameters. It is demonstrated how new technology such as multi-busbar (>3BB), double glass modules or new encapsulant materials influence mod-ule reliability. Based on the results, recommendations for the construction of demonstrator modules in the Fidelitas project were derived to improve reliability and service life.