Harnessing the sun’s energy can be challenging, especially when some of the sunniest regions have environmental conditions that preclude traditional solar modules. Standard solar arrays are often installed no less than 25 miles inland from the coast because of wind, humidity, and salt exposure. Deep mountain snows and searing desert temperatures also limit solar module placement.
Solar Infra, Inc., a manufacturer of solar modules, sought to overcome these limitations and extend the reach of solar power, which is projected to become a $70 billion market by 2013. Working with Sandia National Laboratories and a dc-to-ac inverter manufacturer, the California-based company developed the Solar Infra AC-Enabled (ACE) solar module, a rugged module system with internal dc-to-ac inversion.
“Fulfilling the promise of solar energy requires modules that last longer and can be used anywhere,” said Larry Holmberg, CEO and company cofounder. “We asked our engineers to use whatever tools were necessary to overcome lifecycle and durability challenges quickly and efficiently.”
The first step was choosing a design environment, according to mechanical engineer Elise Moss. “This project required iterations through which my chief scientist and I would create design concepts and work with specialists at Sandia to analyze performance within extreme environments. Solar Infra and Sandia had experience using the integrated SolidWorks design simulation platform. Because of the collaborative nature of the work, integration between CAD and FEA was critically important.”
Jason Strauch, Sandia engineering analyst said, “That integration was vital for working with Solar Infra to incorporate the findings of our structural and thermal analyses into the design. It was faster and easier to make the necessary adjustments to the model from within the CAD system.”
Solar Infra chose SolidWorks 3D CAD and Simulation packages because the full integration of design and analysis tools would save time, reduce costs, and carry the greatest potential for making a breakthrough in solar module design.
With SolidWorks, Solar Infra was able to overcome two historic design challenges in solar module design. The first problem was sustaining environmental loads that range from hurricane-force winds to several feet of snow to the highest possible temperatures on earth, without increasing weight. The second challenge involved extending the lifecycle for dc-to-ac inverters from 10 to 25 years.
Solar Infra solved the dc-to-ac inverter dilemma by working with partners to incorporate a micro-inverter as part of the actual module, rather than as a separate component. As the company was developing an entirely new frame profile that doubled a solar module’s strength, but increased its weight by only 4%, it validated its design ideas in models with Sandia National Laboratories.
“We were able to save time and money during development because we could do itall in software using simulation to test our concepts instead of building prototypes,” Moss points out. “Using this approach, I would estimate that we easily saved $100,000 on the development of our new ACE product.”
Using the simulation software, Sandia National Laboratories replicated the structural and thermal loads associated with extreme environments to ensure that the new design could withstand rugged conditions. Straunch added, “We analyzed 150 mph winds to simulate a hurricane; the weight of 35 ft of dry snow; and the worst-case temperature scenario on earth: 130° F at high altitude. The ability to analyze stresses and thermal behavior allowed us to ensure that the module would perform under even the most extreme conditions.”
In addition to helping reduce development costs, SolidWorks tools help Solar Infra realize manufacturing savings and other business efficiencies. “Overall, SolidWorks saves about 25% of operating expenses when it is implemented properly,” Moss noted. Using photorealistic renderings created in SolidWorks allowed Solar Infra to begin marketing prior to production. “We saved time and money getting our collateral together,” said Director of Marketing Christy Hurlburt. “We were able to use renderings to create data sheets pre-prototype, which allowed us to seed the market and get the word out on this exciting extension of solar potential.” SPE
SolidWorks www.solidworks.com
Solar Infra www.solarinfra.com
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