Periodic Reporting for period 2 - HIPERION (HYBRID PHOTOVOLTAICS FOR EFFICIENCY RECORD USING INTEGRATED OPTICAL TECHNOLOGY)
Reporting period: 2020-12-01 to 2022-02-28
HIPERION project is to bring to fruition at the industrial scale a tested disruptive technology of solar modules, based on the planar optical micro-tracking technology, which concentrates sunlight on multi-junction solar cells on top of a conventional silicon back plane.
Resulting in unique highly efficient solar modules and providing absolute record of energy generation per m2, with up to 50% gain in Central Europe and even 80% in Southern Europe.
Hence, HIPERION consortium proposes a plan to develop tailored assembly techniques, build a pilot production line and perform qualification tests from relevant norms. The first phase will mainly be dedicated to product industrialisation and assembly equipment construction, leading to the pilot line installation. The second phase will be dedicated to the production of a first series of modules, their extensive testing and monitoring on commercial pilot sites and planning the production scale-up. The target market segment is expected to be 1.25 GWp/yr but the production ramp-up to 1.25 FW should take at least 5 years.
HIPERION will demonstrate at pilot-line level the assembly of these high efficiency modules, while several commercial pilot sites across Europe and qualification tests will further validate the performance and reliability. Also, how the technology can be industrialised for mass production, enabling its integration by manufacturers into their existing production lines.
Resulting in unique highly efficient solar modules and providing absolute record of energy generation per m2, with up to 50% gain in Central Europe and even 80% in Southern Europe.
Hence, HIPERION consortium proposes a plan to develop tailored assembly techniques, build a pilot production line and perform qualification tests from relevant norms. The first phase will mainly be dedicated to product industrialisation and assembly equipment construction, leading to the pilot line installation. The second phase will be dedicated to the production of a first series of modules, their extensive testing and monitoring on commercial pilot sites and planning the production scale-up. The target market segment is expected to be 1.25 GWp/yr but the production ramp-up to 1.25 FW should take at least 5 years.
HIPERION will demonstrate at pilot-line level the assembly of these high efficiency modules, while several commercial pilot sites across Europe and qualification tests will further validate the performance and reliability. Also, how the technology can be industrialised for mass production, enabling its integration by manufacturers into their existing production lines.
WP1 – Management (CSEM): Coordinate, monitor and implement the necessary measures for the achievement of HIPERION objectives on time, within the allocated budget and according to high quality standards, the management team has implemented different actions (meetings, amendments, reporting, payment, etc.) to ensure the smooth running of the project.
WP2 – Hybrid Module design optimization for performance, costs and reliability (INSO): GEN1 and GEN2 module design has been finalised. All GEN1 modules have been built, shipped, installed and tested. The GEN2 design incorporates key improvements in performance, reliability, ease of assembly and BOM. GEN2 modules’ production has started and is ongoing as of the writing of this report. Feedback from WP4, WP5 & WP6 will still be gathered to document any potential improvements for future designs of HIPERION designs.
WP3 – Multi-junctions micro-cell receiver, test and board assembly (X-C): High efficiency solar cells were sourced and integrated into a LED-style packaging process using SMT, wire bonding and injection moulded secondary optics. Additionally, efforts to assess alternative methods and materials for packaging are being explored with the aim of reducing the production cost at scale.
WP4 – Module – assembly method and tests (MASS): Within WP4 it has been possible to define a manufacturing/assembly process for the different steps necessary for the correct assembly of the GEN 2.0 module.
Regarding the necessary elements to obtain an assembly and control line, there are the machines for framing and outline control, which are in the final stages of assembly before shipment, which is scheduled for the end of April, the flasher is already in the stage of fine-tuning at destination and the top lenses assembly machine is in the final design phase.
WP5 – Pilot production line installation, hosting and operations (CSEM): In Task 5.1 the site hosting the pilot line has been equipped according to the specificities required for the planned machines. The UPM flasher has been installed. The Characterization Bench and the Framing Machine will be installed in May 2022 at CSEM and the Lens Assembly in September 2022. The production of the modules has started and the supply chain is defined and secured. In Task 5.2 the production of the hybrid modules has started. About 40 modules have been produced in the first batch and the rest of the modules will be produced with the pilot line equipment.
WP6 – Modules certification, pilot and reliability tests (UPM): 2 most important standard norms of PV technology, design qualification of the product and the power rating of a module have been addressed: a measurement procedure to determine the nominal power of hybrid CPV/PV modules has been defined, and a proposal for the quality assurance tests and the type approval of hybrid modules has been completed. The pre-qualification of the module design has started, results achieved with GEN1 have provided feedback for the design of the GEN2.
WP7 – Blueprint evaluation (3S): In Task 7.1-7.3 potential pilot sites were identified, conceptualized, planned and prepared (BOM purchasing, cabling plan, etc.). Partner MIS made studies about the difficulties to make a rooftop installation and agreed with INSO to change plans to a grounded installation. However, due to other influences, MIS left the project. In Task 7.2 LCOE/IRR results were obtained for Lyon and Madrid. In Task 7.4 LCA calculations to determine environmental impact of GEN2 module have been carried out. First approximation of waste scenario for GEN2 module is planned next.
WP8 – Dissemination, Communication and Exploitation (L-UP): Dissemination and communication plan defined and regular monitoring of all dissemination and exploitation activities: 28 dissemination events, 1 conference and 1 workshop organized, 4 peer-reviewed scientific OA articles, 16 public presentations, 61 mass media articles and press releases published; project corporate identity defined, communication set produced, project public website released online with regular updates and news, project social networks set up and regularly fed with news and videos, including HIPERION video series; 4 public newsletters released; cross-fertilization to other H2020 sister projects; business and exploitation plan produced.
WP9 – Ethics requirements (CSEM): Ensure compliance with the 'ethics requirements' set by the EC. The ethical and gender issues are regular monitored.
WP2 – Hybrid Module design optimization for performance, costs and reliability (INSO): GEN1 and GEN2 module design has been finalised. All GEN1 modules have been built, shipped, installed and tested. The GEN2 design incorporates key improvements in performance, reliability, ease of assembly and BOM. GEN2 modules’ production has started and is ongoing as of the writing of this report. Feedback from WP4, WP5 & WP6 will still be gathered to document any potential improvements for future designs of HIPERION designs.
WP3 – Multi-junctions micro-cell receiver, test and board assembly (X-C): High efficiency solar cells were sourced and integrated into a LED-style packaging process using SMT, wire bonding and injection moulded secondary optics. Additionally, efforts to assess alternative methods and materials for packaging are being explored with the aim of reducing the production cost at scale.
WP4 – Module – assembly method and tests (MASS): Within WP4 it has been possible to define a manufacturing/assembly process for the different steps necessary for the correct assembly of the GEN 2.0 module.
Regarding the necessary elements to obtain an assembly and control line, there are the machines for framing and outline control, which are in the final stages of assembly before shipment, which is scheduled for the end of April, the flasher is already in the stage of fine-tuning at destination and the top lenses assembly machine is in the final design phase.
WP5 – Pilot production line installation, hosting and operations (CSEM): In Task 5.1 the site hosting the pilot line has been equipped according to the specificities required for the planned machines. The UPM flasher has been installed. The Characterization Bench and the Framing Machine will be installed in May 2022 at CSEM and the Lens Assembly in September 2022. The production of the modules has started and the supply chain is defined and secured. In Task 5.2 the production of the hybrid modules has started. About 40 modules have been produced in the first batch and the rest of the modules will be produced with the pilot line equipment.
WP6 – Modules certification, pilot and reliability tests (UPM): 2 most important standard norms of PV technology, design qualification of the product and the power rating of a module have been addressed: a measurement procedure to determine the nominal power of hybrid CPV/PV modules has been defined, and a proposal for the quality assurance tests and the type approval of hybrid modules has been completed. The pre-qualification of the module design has started, results achieved with GEN1 have provided feedback for the design of the GEN2.
WP7 – Blueprint evaluation (3S): In Task 7.1-7.3 potential pilot sites were identified, conceptualized, planned and prepared (BOM purchasing, cabling plan, etc.). Partner MIS made studies about the difficulties to make a rooftop installation and agreed with INSO to change plans to a grounded installation. However, due to other influences, MIS left the project. In Task 7.2 LCOE/IRR results were obtained for Lyon and Madrid. In Task 7.4 LCA calculations to determine environmental impact of GEN2 module have been carried out. First approximation of waste scenario for GEN2 module is planned next.
WP8 – Dissemination, Communication and Exploitation (L-UP): Dissemination and communication plan defined and regular monitoring of all dissemination and exploitation activities: 28 dissemination events, 1 conference and 1 workshop organized, 4 peer-reviewed scientific OA articles, 16 public presentations, 61 mass media articles and press releases published; project corporate identity defined, communication set produced, project public website released online with regular updates and news, project social networks set up and regularly fed with news and videos, including HIPERION video series; 4 public newsletters released; cross-fertilization to other H2020 sister projects; business and exploitation plan produced.
WP9 – Ethics requirements (CSEM): Ensure compliance with the 'ethics requirements' set by the EC. The ethical and gender issues are regular monitored.
WP2: GEN2 module design has been finalised and multiple modules (10+) have been built with the remaining ones to be built in 2022. Modules were installed at various locations and performance and reliability measurements achieved.
WP3: Demonstrated a robust manufacturing process that ensures 1mm2 space-grade solar cells and SOE are assembled on a PV backplane within required alignment tolerance; cost competitive for high volume production.
WP4: As a new process, strong and usable points have been detected and weak points to avoid in future assemblies have also been detected and adhesive application techniques. within this point, it is worth highlighting the use of plasma treatment, which has been seen to significantly improve adhesion results.
WP5: Demonstrate the pilot production and transfer the know-how and product from laboratory to industry. Upscaling the product from GEN0 to GEN2 and optimize the whole product chain at lower cost. Provide a training base and make a study of learning curve, collect product experience for mass production. Demonstrate small scaling production and lock the interest of potential investors, and a novel technology made in Europe and differentiate with recent commercial PV product.
WP6: Develop international standard norms for hybrid CPV/PV modules.
WP7: Select, conceptualize, plan, and implement potential applications of the INSO module using pilot plants under various climatic conditions, and determine early on the expected impact of an INSO module on climate change.
WP3: Demonstrated a robust manufacturing process that ensures 1mm2 space-grade solar cells and SOE are assembled on a PV backplane within required alignment tolerance; cost competitive for high volume production.
WP4: As a new process, strong and usable points have been detected and weak points to avoid in future assemblies have also been detected and adhesive application techniques. within this point, it is worth highlighting the use of plasma treatment, which has been seen to significantly improve adhesion results.
WP5: Demonstrate the pilot production and transfer the know-how and product from laboratory to industry. Upscaling the product from GEN0 to GEN2 and optimize the whole product chain at lower cost. Provide a training base and make a study of learning curve, collect product experience for mass production. Demonstrate small scaling production and lock the interest of potential investors, and a novel technology made in Europe and differentiate with recent commercial PV product.
WP6: Develop international standard norms for hybrid CPV/PV modules.
WP7: Select, conceptualize, plan, and implement potential applications of the INSO module using pilot plants under various climatic conditions, and determine early on the expected impact of an INSO module on climate change.