Periodic Reporting for period 3 - HIPERION (HYBRID PHOTOVOLTAICS FOR EFFICIENCY RECORD USING INTEGRATED OPTICAL TECHNOLOGY)
Período documentado: 2022-03-01 hasta 2023-08-31
HIPERION project aimed to bring a groundbreaking solar module technology to full-scale industrial implementation. This disruptive technology was based on planar optical micro-tracking, which concentrated sunlight onto multi-junction solar cells positioned on a conventional silicon backplane. The result was the creation of highly efficient solar modules that achieved unparalleled energy generation per square meter, with potential increases of up to 30%-40%, particularly in regions like Southern Europe.
HIPERION's initial phase focused on the industrialisation of the product and the construction of assembly equipment, leading to the installation of a pilot production line. HIPERION produced the first series of modules, subjected them to extensive testing and monitoring at commercial pilot sites, and strategized for the eventual scale-up of production. The target market segment for these advanced modules was anticipated to reach 1.25 GWp/yr. However, it is important to note that the production ramp-up to 1.25 GWp/yr was expected to span at least 5 years.
HIPERION's key objectives included demonstrating, at the pilot-line level, the assembly of these high-efficiency modules, conducting extensive testing and monitoring at various commercial pilot sites across Europe, and qualifying the technology's performance and reliability. Additionally, HIPERION aimed to explore how this innovative technology could be effectively industrialised for mass production, enabling manufacturers to seamlessly integrate it into their existing production lines. HIPERION represented a significant step forward in the quest for efficient and sustainable solar energy solutions, and held the potential to revolutionise the solar module industry.
HIPERION's initial phase focused on the industrialisation of the product and the construction of assembly equipment, leading to the installation of a pilot production line. HIPERION produced the first series of modules, subjected them to extensive testing and monitoring at commercial pilot sites, and strategized for the eventual scale-up of production. The target market segment for these advanced modules was anticipated to reach 1.25 GWp/yr. However, it is important to note that the production ramp-up to 1.25 GWp/yr was expected to span at least 5 years.
HIPERION's key objectives included demonstrating, at the pilot-line level, the assembly of these high-efficiency modules, conducting extensive testing and monitoring at various commercial pilot sites across Europe, and qualifying the technology's performance and reliability. Additionally, HIPERION aimed to explore how this innovative technology could be effectively industrialised for mass production, enabling manufacturers to seamlessly integrate it into their existing production lines. HIPERION represented a significant step forward in the quest for efficient and sustainable solar energy solutions, and held the potential to revolutionise the solar module industry.
WP1: To 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 to ensure the smooth running of the project and brought it to a conclusive end.
WP2: GEN1 and GEN2 module design has been finalised. All GEN1 modules have been built, shipped, installed and tested. GEN2 design and production incorporates key improvements in performance, reliability, ease of assembly and BOM.. Feedback from WP4, WP5 & WP6 were gathered to document any potential improvements for future designs of HIPERION.
WP3: Packaging materials and methods were reviewed with the aim of assessing cost competitive assembly strategies for the integration of the solar cells onto the PCB. Separately, a novel interconnection concept was demonstrated where mechanical die was directly bonded and self-aligned to the PCB. The demonstration was tested at ARGO assembly lab.
WP4: The top-glass necessary to complete the demos has been manufactured. The characterisation bench and framing of the assembly and control line have been validated at MASS, sent and commissioned at CSEM facilities. The design, assembly and validation of the top glass assembly machine has been completed at MASS, sent to CSEM and commissioning has been carried out, completing the pilot line.
WP5: Established and operated a pilot production line at CSEM, showcasing new technology developed in earlier WPs. Setting up the pilot line, managing the supply chain, and delivering assembled modules for testing. Key achievements included securing the pilot line facility, successful installation of equipment like the UPM flasher and the tools of MASS, and finalising facility specifications. Challenges were encountered during batches manufacturing, leading to adjustments, but batch 8 production was initiated on the pilot line after resolving issues. Notably, in May 2023, the Lens Assembly Machine integration marked a significant milestone, enabling full-scale GEN2 module production with collaborative efforts.
WP6: Aimed at understanding performance and reliability of the HIPERION technology. UPM and ISE installed pilot demonstrators, which proved instrumental detecting shortcomings with GEN1 modules and addressing in GEN2 design. More in depth characterisation was performed, a draft procedure for power rating of hybrid modules was written and tested via a round robin between the two partners. Appropriate reliability tests were performed to identify any possible issues in a future certification for the technology.
WP7: Flammability issues arose during a fire test. Blueprint evaluation suggests limited-space rooftops are the best market segment but requires refined cost calculations and production infrastructure. LCA shows significant environmental impact from PV cells, structural elements, and top glass. EPBT varies from 3.04 to 4.04 years based on location and insolation. A monitoring system has been developed and implemented in pilot sites (Portugal, Switzerland, Chile) with data online available. Performance issues include optical layer degradation and sun tracking malfunctions, leading to 50% lower energy production, some modules severely degraded.
WP8: Tailored communication and dissemination plan defined, project graphic identity created, communication set produced, project public website released and regularly updated with news and videos, HIPERION community created and managed on several social media, 7 project public newsletters released, several project videos produced and broadcasted. Monitored and reported all dissemination activities. Several workshops, Open Days and training events organised, including in cooperation with sister H2020 projects. Business and exploitation plan produced.
WP2: GEN1 and GEN2 module design has been finalised. All GEN1 modules have been built, shipped, installed and tested. GEN2 design and production incorporates key improvements in performance, reliability, ease of assembly and BOM.. Feedback from WP4, WP5 & WP6 were gathered to document any potential improvements for future designs of HIPERION.
WP3: Packaging materials and methods were reviewed with the aim of assessing cost competitive assembly strategies for the integration of the solar cells onto the PCB. Separately, a novel interconnection concept was demonstrated where mechanical die was directly bonded and self-aligned to the PCB. The demonstration was tested at ARGO assembly lab.
WP4: The top-glass necessary to complete the demos has been manufactured. The characterisation bench and framing of the assembly and control line have been validated at MASS, sent and commissioned at CSEM facilities. The design, assembly and validation of the top glass assembly machine has been completed at MASS, sent to CSEM and commissioning has been carried out, completing the pilot line.
WP5: Established and operated a pilot production line at CSEM, showcasing new technology developed in earlier WPs. Setting up the pilot line, managing the supply chain, and delivering assembled modules for testing. Key achievements included securing the pilot line facility, successful installation of equipment like the UPM flasher and the tools of MASS, and finalising facility specifications. Challenges were encountered during batches manufacturing, leading to adjustments, but batch 8 production was initiated on the pilot line after resolving issues. Notably, in May 2023, the Lens Assembly Machine integration marked a significant milestone, enabling full-scale GEN2 module production with collaborative efforts.
WP6: Aimed at understanding performance and reliability of the HIPERION technology. UPM and ISE installed pilot demonstrators, which proved instrumental detecting shortcomings with GEN1 modules and addressing in GEN2 design. More in depth characterisation was performed, a draft procedure for power rating of hybrid modules was written and tested via a round robin between the two partners. Appropriate reliability tests were performed to identify any possible issues in a future certification for the technology.
WP7: Flammability issues arose during a fire test. Blueprint evaluation suggests limited-space rooftops are the best market segment but requires refined cost calculations and production infrastructure. LCA shows significant environmental impact from PV cells, structural elements, and top glass. EPBT varies from 3.04 to 4.04 years based on location and insolation. A monitoring system has been developed and implemented in pilot sites (Portugal, Switzerland, Chile) with data online available. Performance issues include optical layer degradation and sun tracking malfunctions, leading to 50% lower energy production, some modules severely degraded.
WP8: Tailored communication and dissemination plan defined, project graphic identity created, communication set produced, project public website released and regularly updated with news and videos, HIPERION community created and managed on several social media, 7 project public newsletters released, several project videos produced and broadcasted. Monitored and reported all dissemination activities. Several workshops, Open Days and training events organised, including in cooperation with sister H2020 projects. Business and exploitation plan produced.
WP2: GEN2 module design has been finalised and multiple modules have been built. Modules were installed at various locations and performance and reliability measurements achieved.
WP3: Explored novel cell packaging methods to reduce the overall module cost. Demonstrated self-alignment process of mechanical die mounted directly to the PCB to remove need for wire-bonding.
WP4: Two high-precision machines have been designed in which granite has been used to avoid deformations and high-precision elements with optical rulers are used, thus have an optimal resolution. These improvements are expected to be incorporated into the company's standard products so that the existing catalogue is increased and improved.
WP5: Developed a new generation of breakthrough technology, including advanced materials, equipment, and processes. This pilot line allows for the demonstration of the new technology in a real-world production environment; goes beyond traditional research and development, enabling the project to bridge the gap between lab-scale innovations and commercial viability.
WP6: Identified the main reliability aspects needed to address for the qualification of hybrid CPV/PV modules and contributed to the standardisation of a normative for the rating of this technology. An open source energy modelling has been developed.
WP7: HIPERION's technological advancements could deliver highly efficient modules for many applications (e.g. building-applied), have a high economic impact and support the energy transition if remaining challenges such as soiling, degradation and reliability can be solved.
WP3: Explored novel cell packaging methods to reduce the overall module cost. Demonstrated self-alignment process of mechanical die mounted directly to the PCB to remove need for wire-bonding.
WP4: Two high-precision machines have been designed in which granite has been used to avoid deformations and high-precision elements with optical rulers are used, thus have an optimal resolution. These improvements are expected to be incorporated into the company's standard products so that the existing catalogue is increased and improved.
WP5: Developed a new generation of breakthrough technology, including advanced materials, equipment, and processes. This pilot line allows for the demonstration of the new technology in a real-world production environment; goes beyond traditional research and development, enabling the project to bridge the gap between lab-scale innovations and commercial viability.
WP6: Identified the main reliability aspects needed to address for the qualification of hybrid CPV/PV modules and contributed to the standardisation of a normative for the rating of this technology. An open source energy modelling has been developed.
WP7: HIPERION's technological advancements could deliver highly efficient modules for many applications (e.g. building-applied), have a high economic impact and support the energy transition if remaining challenges such as soiling, degradation and reliability can be solved.