WO2020219997A1 - System and method for improved solar cell array efficiency in high altitude long endurance aircraft - Google Patents

System and method for improved solar cell array efficiency in high altitude long endurance aircraft Download PDF

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Publication number
WO2020219997A1
WO2020219997A1 PCT/US2020/029976 US2020029976W WO2020219997A1 WO 2020219997 A1 WO2020219997 A1 WO 2020219997A1 US 2020029976 W US2020029976 W US 2020029976W WO 2020219997 A1 WO2020219997 A1 WO 2020219997A1
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WIPO (PCT)
Prior art keywords
solar
string
parallel
strings
high altitude
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PCT/US2020/029976
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French (fr)
Inventor
Nader Lotfy
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Aerovironment
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Publication of WO2020219997A1 publication Critical patent/WO2020219997A1/en

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Classifications

    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05FSYSTEMS FOR REGULATING ELECTRIC OR MAGNETIC VARIABLES
    • G05F1/00Automatic systems in which deviations of an electric quantity from one or more predetermined values are detected at the output of the system and fed back to a device within the system to restore the detected quantity to its predetermined value or values, i.e. retroactive systems
    • G05F1/66Regulating electric power
    • G05F1/67Regulating electric power to the maximum power available from a generator, e.g. from solar cell
    • B64D27/353
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02JCIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/34Parallel operation in networks using both storage and other dc sources, e.g. providing buffering
    • H02J7/35Parallel operation in networks using both storage and other dc sources, e.g. providing buffering with light sensitive cells
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02SGENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S50/00Monitoring or testing of PV systems, e.g. load balancing or fault identification
    • H02S50/10Testing of PV devices, e.g. of PV modules or single PV cells
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02JCIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J2300/00Systems for supplying or distributing electric power characterised by decentralized, dispersed, or local generation
    • H02J2300/20The dispersed energy generation being of renewable origin
    • H02J2300/22The renewable source being solar energy
    • H02J2300/24The renewable source being solar energy of photovoltaic origin
    • H02J2300/26The renewable source being solar energy of photovoltaic origin involving maximum power point tracking control for photovoltaic sources
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/50Photovoltaic [PV] energy
    • Y02E10/56Power conversion systems, e.g. maximum power point trackers
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00Aeronautics or air transport
    • Y02T50/50On board measures aiming to increase energy efficiency

Definitions

  • Unmanned Aerial Vehicles are aircraft with no onboard pilot and may fly autonomously or remotely. UAVs require an energy source to power the motor in order to sustain flight. High altitude long endurance may use battery power to stay aloft, and sometimes for take-off. Continuous flight needs to be sustained and returning to a ground station to recharge is to be avoided as long as possible, or even completely avoided. In such situations, battery powered UAVs are typically charged using onboard solar cells.
  • a solar array circuit for a high altitude long endurance aircraft which includes a solar string having a plurality of solar cells connected in series.
  • the solar string having a MOSFET switch connected in parallel with one or more solar cells in the solar string.
  • an onboard diagnostic method which includes monitoring an output of a solar string, detecting whether a solar string is functioning within an acceptable range of operation, determining whether any of the solar cells in the solar string are functioning within an acceptable range of operation, and bypassing any of the solar cells within the string that are not functioning within the acceptable range of operation so as to improve an efficiency of the solar string.
  • an onboard diagnostic method for a high altitude long endurance solar powered aircraft includes detecting whether a solar cell is functioning within an acceptable range of operation; and bypassing the solar cell if the solar cell is not functioning within and acceptable range of operation by controlling a bypass MOSFET switch connected in parallel with the solar cell .
  • FIG. 1 is a simplified diagram of a circuit having a solar array.
  • FIG. 2 is a simplified diagram of a string circuit.
  • FIG. 3 is a simplified diagram of an improved solar string circuit.
  • FIG. 4 is a simplified diagram of an improved circuit for a solar array is a simplified diagram of a circuit having a solar array.
  • FIG. 5 is a simplified diagram of an improved circuit for a solar array.
  • FIG. 6 is a plot showing an example V-I curve of voltage versus current for a typical solar array system.
  • FIG. 7 is a plot illustrating an example V-I curve of voltage versus current for a solar array system for high performance solar cell utilized in high altitude long endurance aircraft implementations.
  • FIG. 1 is a simplified diagram of a circuit 100 having a solar array.
  • a solar array typically, several independent solar arrays or strings 110a, 110b, and 110c connected in parallel to form a channel 120.
  • a string may have a number of replaceable solar panels, for example.
  • Each of the strings 110a, 110b, and 110c is provided with a serial connected blocking diode 115a, 115b, and 115c.
  • the blocking diode 115a, 115b, and 115c are provided in case one of the strings 110a, 110b, and 110c shorts, to prevent one of the strings 110a, 110b, or 110c from causing shorting, or other failure, in the other non-shorted strings 110a, 110b, or 110c.
  • the blocking diodes add an amount of loss to the system, they are required to reduce failures of associated the solar cells within the array, or other components within the system.
  • the blocking diodes are typically located within a power tracker 180, which also has a boost stage 185 DC/DC converter.
  • the boost stage 185 decouples the supplied voltage and the current from the high voltage power bus 195, i.e. 270V-400V, that is connected to the battery 190, and is configured so that proper voltage is supplied on the high voltage power bus regardless of the voltage and current supplied by the solar array.
  • the power tracker is a maximum power point tracker or MPPT controller configured to boost voltage from the solar array to the output and to adjust a boost ratio to get the maximum power from the solar array.
  • MPPT controllers include Outback® FLEXmax 60/80 MPPT, Xantrex® MPPT Solar Charge Controller, and Blue Sky® Solar Charge Controller.
  • the MPPT controller is configured to maximize the available power going into the battery from the solar array. This is important in various high altitude long endurance aircraft applications where the maximum voltage is a function of the temperature and illumination of the solar array, both of which may vary throughout the day.
  • FIG. 2 shows a simplified diagram of a string circuit 200.
  • the string 200 typically has a bypass diode 245 in parallel with two or more solar cells 205a and 205b.
  • the bypass diode 245 allows the other solar cells 205m to supply current around the solar cells 105a and 205b when one or more of the solar cells becomes non- functional or an open circuit, such as by being cracked, or broken.
  • FIG. 3 shows a simplified diagram of an improved solar string circuit 300 to provide greater solar string 310 efficiency.
  • the bypass diode 245 (FIG. 2) is replaced with a bypass MOSFET switch 360.
  • the MOSFET switch 360 has two back to back, series connected, complimentary MOSFET transistors 360a and 360b.
  • An advantage of the bypass MOSFET switch is that it may be off or inactive until a malfunction is detected.
  • a further advantage is that it has very low power consumption when activated.
  • Such an embodiment allows further efficiency over the diode when a solar cell 205a, 205b, ...or 205m (FIG. 2) fails, due to the lower power loss associated with a MOSFET switch 360 as compared to the bypass diode 245.
  • the switch 360 When one of the individual solar cells 305a or 305b is malfunctioning, or just not performing optimally, or within an acceptable range of operation, the switch 360 is turned on to allow a bypass pathway around the solar cells 305a and 305b.
  • the maximum allowable current for the string 310 is restricted by the restriction of the lowest individual solar cell.
  • a method for improving the efficiency of a solar array includes monitoring and detecting when a solar string is not functioning optimally.
  • a small number of individual solar cells within a solar string may be bypassed to improve the power output of the individual string.
  • the monitoring and detecting may be accomplished by selectively turning on individual bypass MOSFET switches and sensing whether the power output of the string improves. This can be done by sensing the power output of all, or of a small group of solar strings or solar channel, or by sensing power output changes of individual solar strings. In one possible implementation, the output of the individual solar strings may be decoupled from the solar array or from a solar channel to detect the health of the individual solar string.
  • FIG. 4 shown is a simplified diagram of an improved circuit 400 for a solar array.
  • MOSFET switches 415a, 415b, and 415c are utilized having back-to-back MOSFETS devices 415ai and 415a 2 .
  • the MOSFET switch allows each string 410a, 410b, or 410c in the channel 420 to be individually completely disable or open, even though the output of multiple strings go into a single power stage, such as a boost stage 485 DC/DC converter, which supplies current to the power bus 495 for charging the battery 490.
  • the boost converter 485 controls the MOSFET switches 410a, 410b, or 410c and utilizes the detected string voltages to determine the health of the strings 410a, 410b, or 410c along with all the other strings (not show) and channels (not show) over the entire solar array.
  • each string can be tested in flight to determine the optimal power output for each string individually according to its V-I and power output characteristic.
  • the string characteristics can be tested over time to determine the health of the string. This is particularly important during long duration flights, and during high altitude flights, so that the need for maintenance and/or remedial measures, such as solar panel replacement, can be anticipated and made when convenient.
  • each string includes a number of solar panels grouped generally spanwise along the wing of the aircraft, for example four, five, or six smaller solar panels are grouped per string.
  • the solar panels are grouped in this way so that the solar panels in a string experience similar environmental and operational conditions together.
  • the solar panels at the leading edge of the wing may be grouped together in a string, while solar panels near the trailing edge of the wing may be grouped together, possibly with one or more strings also extending spanwise or laterally along the span of the wing, between the leading and trailing edge strings.
  • the grouping of the solar panels into strings is significant. This is because the temperature can vary greatly from the leading to the trailing edge of the wing. Further, the orientation of the aircraft with respect to the sun, in elevation, azimuth, rotation, etc., as well as having a greater curvature from leading to trailing edges of the wing, can further exaggerate the temperature differential. In high altitude long endurance solar powered aircraft, the temperature can range across the wing from -60 degrees Celsius on the leading edge to +60 degrees Celsius on the trailing edge of the wing. As such, grouping solar panels into strings combined with being able to individually switch on or off individual strings based on the performance of a string allows for more efficient solar power generation .
  • FIG. 4 is a simplified diagram of an improved circuit 400 for a solar array.
  • a solar string control MOSFET 415 is used in the channel 410.
  • This configuration is more efficient than the circuit of FIG. 1 because it eliminates the voltage drop loss across a diode 115a, 115b, or 116c when the solar string control MOSFET 415 is turned on.
  • This embodiment when the solar string control MOSFET 415 is turned on, it does not inherently provide isolate between parallel connected solar strings in the event there is a short in a solar string 410.
  • the voltage drop across the solar string control MOSFET 415 is detected and monitored so as to determine the magnitude and direction of the current in the solar string 410 to determine whether another solar string (not shown) has shorted. If it is determined, based on the monitoring of several parallel connected strings, that one of the solar strings has shorted, the solar string control MOSFET in line with the shorted solar string is opened so as not to damage the other parallel connected solar strings. With the solar string control MOSFET 415 open, it performs as a diode as in FIG. 1, to block current through the shorted solar string.
  • the embodiment of FIG. 4 provides a more efficient power transfer, but requires monitoring of the current in the solar string 410 to determine if a short has occurred in the solar string 410, or in any of the associated strings.
  • the monitoring and control of the solar string control MOSFET 415 is conducted by a power tracker, or other associated electronics.
  • the power tracker includes the solar string control MOSFET 415 and the boost stage 485, which supplies power to the power bus 495.
  • FIG. 5 is a simplified diagram of an improved circuit 500 for a solar array.
  • This embodiment allows solar string isolation by allowing a solar string to be individually and selectively decoupled from a solar channel.
  • MOSFET switches 515a, 515b, and 515c are utilized having back-to-back MOSFETS devices 515ai and 515a 2 .
  • the MOSFET switch allows each string 510a, 510b, or 510c in the channel 520 to be individually completely disable or open, even though the output of multiple strings go into a single power stage, such as a boost stage 585 DC/DC converter, which supplies current to the power bus 595 for charging the battery 590.
  • the boost converter 585 controls the MOSFET switches 510a, 510b, or 510c and utilizes the detected string voltages to determine the health of the strings 510a, 510b, or 510c along with all the other strings (not show) and channels (not show) over the entire solar array.
  • An advantage of this is that it allows the system to target each string 510a, 510b, or 510c and perform a lot of diagnostics in flight, such as short circuit current, open circuit voltage, on a per string basis.
  • MOSFET switches can be selected to have lower power loss across the switch as compared to a protection diode. As such, it increases the efficiency of the charging system, and also allows you to predict (through trend analysis) and detect failures much easier. Imminent failures can be predicted and action taken before a failure becomes critical. This is important in high altitude long duration aircraft, so as to enable avoidance of a critical failure that could otherwise lead to a power off, or even a crash landing. Since strings can be individually tested, it provides much more "visibility" into the functionality and health of the solar array in flight .
  • each string can be tested in flight to determine the optimal power output for each string individually according to its V-I and power output characteristic.
  • the string characteristics can be tested over time to determine the health of the string. This is particularly important during long duration flights, and during high altitude flights, so that the need for maintenance and/or remedial measures, such as solar panel replacement, can be anticipated and made when convenient.
  • each string includes a number of solar panels grouped generally spanwise along the wing of the aircraft, for example four, five, or six smaller solar panels are grouped per string.
  • the solar panels are grouped in this way so that the solar panels in a string experience similar environmental and operational conditions together.
  • the solar panels at the leading edge of the wing may be grouped together in a string, while solar panels near the trailing edge of the wing may be grouped together, possibly with one or more strings also extending spanwise or laterally along the span of the wing, between the leading and trailing edge strings.
  • the grouping of the solar panels into strings is significant. This is because the temperature can vary greatly from the leading to the trailing edge of the wing. Further, the orientation of the aircraft with respect to the sun, in elevation, azimuth, rotation, etc., as well as having a greater curvature from leading to trailing edges of the wing, can further exaggerate the temperature differential. In high altitude long endurance solar powered aircraft, the temperature can range across the wing from -60 degrees Celsius on the leading edge to +60 degrees on the trailing edge of the wing. As such, grouping solar panels into strings combined with being able to individually switch on or off individual strings based on the performance of a string allows for more efficient solar power generation .
  • an advantage of various embodiments over solar string circuits 110 (FIG. 1) using blocking diodes 145 is that the blocking diodes 145 can contribute a loss of about 0.7% due to the voltage drop across the diode, whereas the MOSFET switch presents essentially no voltage drop when turned on.
  • other comparable type switch i.e light weight, low loss switch, could be utilized in other embodiments.
  • embodiments may contain two or more strings, and multiple channels.
  • Various embodiments enable, or expand the capability to run in-flight diagnostics.
  • factors such as turbulence, frequent and extreme thermal, motor vibrations can increase the possibility of failure.
  • Various embodiments provide performance tracking over time, with trend analysis, and can enable eminent failure detection, more flexible scheduling of service/periodic maintenance, and avoidance of lack of airborne network capability/coverage or surveillance capability/coverage in the coverage area. This is particularly important if the high altitude long endurance aircraft is being used as a cellular repeater or for other network communications in area that would otherwise be without coverage should the platform be missing from the network.
  • the MOSFET switches may be controlled by a power point tracker, or other monitoring, detection, and evaluation controller, such as a processor.
  • a power point tracker or other monitoring, detection, and evaluation controller, such as a processor.
  • the voltages may be detected by, or passed to the power point tracker, where the voltages, and/or the solar currents are calculated for use in determining the functionality of the solar cells, solar strings, or solar channels.
  • the power point tracker, or other controller controls the MOSFETs, for example.
  • FIG. 6 is a plot 600 showing an example V-I curve 610 of voltage versus current for a typical solar array system.
  • the power curve 620 for the solar array system is superimposed on the plot 600. It is desirable to extract the maximum power from the solar array system. As such, it is desirable to operate along the V-I curve 610 where the power for the system is at its peak.
  • FIG. 7 is a plot 700 showing an example V-I curve 210 of voltage versus current for a solar array system for high performance solar cell utilized in high altitude long endurance aircraft implementations.
  • the V-I curve 710 and the power curve (not shown) have a very steep slope as they approach the maximum current.
  • the optimum operating point of the system lies with a narrow operating range. If the current is too great by even a slight amount, the voltage goes to zero or short circuits very easily.
  • the difference between optimum power output and short circuit can be as low as 100mA of current per channel 120 (FIG. 1) .
  • a voltage loop is utilized to monitor voltage while determining the peak power operating point, as well as monitoring the current and power. This is because the change in voltage is much bigger than either the power or the current near this point.
  • the current is regulated, while monitoring the voltage as well as the power.
  • the commanded current is varied by power point tracker circuitry, while monitoring power.
  • the voltage is also monitored to determine when the power output is maximized because the rate of change of the voltage is greater than the rate of change of the power at near the maximum power output operating point.
  • the voltage is monitored at a faster rate than the current and power.
  • the voltage may be monitored ten time faster than the current or power.
  • the current and/or power may be monitored at 10 times a second, while the voltage is monitored at 100 time a second.
  • Fig. 7 depicts example V-I curves for hotter temperature 710 and colder temperature 711 for bright solar exposure 710, and shadowed solar exposure 712.
  • any reference to "one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment may be included in an embodiment, if desired.
  • the appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
  • each of the various elements of the invention and claims may also be achieved in a variety of manners.
  • This disclosure should be understood to encompass each such variation, be it a variation of any apparatus embodiment, a method embodiment, or even merely a variation of any element of these.
  • the words for each element may be expressed by equivalent apparatus terms even if only the function or result is the same.
  • Such equivalent, broader, or even more generic terms should be considered to be encompassed in the description of each element or action. Such terms can be substituted where desired to make explicit the implicitly broad coverage to which this invention is entitled.
  • all actions may be expressed as a means for taking that action or as an element which causes that action.

Abstract

In one embodiment, a solar array circuit for a high altitude long endurance aircraft, which includes a solar string having a plurality of solar cells connected in series. The solar string having a MOSFET switch connected in parallel with one or more solar cells in the solar string. A method comprising monitoring an output of a solar string, detecting whether a solar string is functioning within an acceptable range of operation, determining whether any of the solar cells in the solar string are functioning within an acceptable range of operation and bypassing any of the solar cells within the string that are not functioning within the acceptable range of operation so as to improve an efficiency of the solar string.

Description

SYSTEM AND METHOD FOR IMPROVED SOLAR CELL ARRAY EFFICIENCY IN HIGH ALTITUDE LONG ENDURANCE AIRCRAFT
BY: Nader Michael Lotfy
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of the following applications, which are all herein incorporated by reference in their entireties:
U.S. Provisional Application No. 62/893,762, filed
08/29/2019, by Nader Lotfy, entitled SYSTEM AND METHOD FOR
IMPROVED SOLAR CELL ARRAY EFFICIENCY IN HIGH ALTITUDE LONG
ENDURANCE AIRCRAFT;
U.S. Provisional Application No. 62/893,726, filed
08/29/2019, by Nader Lotfy, entitled SYSTEM AND METHOD FOR
SOLAR ARRAY DIAGNOSTICS IN HIGH ALTITUDE LONG ENDURANCE AIRCRAFT;
U.S. Provisional Application No. 62/838,937, filed
04/25/2019, by Nader Lotfy, entitled SYSTEM AND METHOD FOR
SOLAR ARRAY DIAGNOSTICS;
U.S. Provisional Application No. 62/893,766, filed
08/29/2019, by Nader Lotfy et al., entitled METHOD FOR TRACKING AND CONTROL OF OPTIMUM OPERATING POINT FOR HIGH ALTITUDE LONG ENDURANCE AIRCRAFT SOLAR CELLS; and
U.S. Provisional Application No. 62/838,783, filed
04/25/2019, by Sechrist et al., entitled HIGH ALTITUDE LONG ENDURANCE (HALO) AIRCRAFT.
BACKGROUND
[0001] Unmanned Aerial Vehicles (UAVs) are aircraft with no onboard pilot and may fly autonomously or remotely. UAVs require an energy source to power the motor in order to sustain flight. High altitude long endurance may use battery power to stay aloft, and sometimes for take-off. Continuous flight needs to be sustained and returning to a ground station to recharge is to be avoided as long as possible, or even completely avoided. In such situations, battery powered UAVs are typically charged using onboard solar cells.
[ 0002 ] As such, what is needed is a way to ensure that that the solar cells deliver the most power possible. This is of particular significance in high altitude long endurance solar powered aircraft, where what is needed is a way to extract the most amount of solar energy from a solar array so that the aircraft may stay aloft for as long as possible.
SUMMARY
[ 0003 ] In one embodiment, a solar array circuit for a high altitude long endurance aircraft, which includes a solar string having a plurality of solar cells connected in series. The solar string having a MOSFET switch connected in parallel with one or more solar cells in the solar string.
[ 0004 ] In one possible implementation, an onboard diagnostic method is provided, which includes monitoring an output of a solar string, detecting whether a solar string is functioning within an acceptable range of operation, determining whether any of the solar cells in the solar string are functioning within an acceptable range of operation, and bypassing any of the solar cells within the string that are not functioning within the acceptable range of operation so as to improve an efficiency of the solar string.
[ 0005 ] In one implementation, an onboard diagnostic method for a high altitude long endurance solar powered aircraft is provided, which includes detecting whether a solar cell is functioning within an acceptable range of operation; and bypassing the solar cell if the solar cell is not functioning within and acceptable range of operation by controlling a bypass MOSFET switch connected in parallel with the solar cell . BRIEF DESCRIPTION OF THE DRAWINGS
[ 0006 ] FIG. 1 is a simplified diagram of a circuit having a solar array.
[ 0007 ] FIG. 2 is a simplified diagram of a string circuit.
[ 0008 ] FIG. 3 is a simplified diagram of an improved solar string circuit.
[ 0009 ] FIG. 4 is a simplified diagram of an improved circuit for a solar array is a simplified diagram of a circuit having a solar array.
[ 00010 ] FIG. 5 is a simplified diagram of an improved circuit for a solar array.
[ 00011 ] FIG. 6 is a plot showing an example V-I curve of voltage versus current for a typical solar array system.
[ 00012 ] FIG. 7 is a plot illustrating an example V-I curve of voltage versus current for a solar array system for high performance solar cell utilized in high altitude long endurance aircraft implementations.
DESCRIPTION
[ 00013 ] FIG. 1 is a simplified diagram of a circuit 100 having a solar array. Typically, several independent solar arrays or strings 110a, 110b, and 110c connected in parallel to form a channel 120. In some embodiments, a string may have a number of replaceable solar panels, for example. Each of the strings 110a, 110b, and 110c is provided with a serial connected blocking diode 115a, 115b, and 115c. The blocking diode 115a, 115b, and 115c are provided in case one of the strings 110a, 110b, and 110c shorts, to prevent one of the strings 110a, 110b, or 110c from causing shorting, or other failure, in the other non-shorted strings 110a, 110b, or 110c.
Although the blocking diodes add an amount of loss to the system, they are required to reduce failures of associated the solar cells within the array, or other components within the system.
[ 00014 ] The blocking diodes are typically located within a power tracker 180, which also has a boost stage 185 DC/DC converter. The boost stage 185 decouples the supplied voltage and the current from the high voltage power bus 195, i.e. 270V-400V, that is connected to the battery 190, and is configured so that proper voltage is supplied on the high voltage power bus regardless of the voltage and current supplied by the solar array. In one embodiment, the power tracker is a maximum power point tracker or MPPT controller configured to boost voltage from the solar array to the output and to adjust a boost ratio to get the maximum power from the solar array. Examples of MPPT controllers include Outback® FLEXmax 60/80 MPPT, Xantrex® MPPT Solar Charge Controller, and Blue Sky® Solar Charge Controller. Generally speaking, the MPPT controller is configured to maximize the available power going into the battery from the solar array. This is important in various high altitude long endurance aircraft applications where the maximum voltage is a function of the temperature and illumination of the solar array, both of which may vary throughout the day.
[ 00015 ] FIG. 2 shows a simplified diagram of a string circuit 200. In FIG. 2, the string 200 typically has a bypass diode 245 in parallel with two or more solar cells 205a and 205b. The bypass diode 245 allows the other solar cells 205m to supply current around the solar cells 105a and 205b when one or more of the solar cells becomes non- functional or an open circuit, such as by being cracked, or broken.
[ 00016 ] FIG. 3 shows a simplified diagram of an improved solar string circuit 300 to provide greater solar string 310 efficiency. In this embodiment, the bypass diode 245 (FIG. 2) is replaced with a bypass MOSFET switch 360. The MOSFET switch 360 has two back to back, series connected, complimentary MOSFET transistors 360a and 360b. An advantage of the bypass MOSFET switch is that it may be off or inactive until a malfunction is detected. A further advantage is that it has very low power consumption when activated. Such an embodiment allows further efficiency over the diode when a solar cell 205a, 205b, ...or 205m (FIG. 2) fails, due to the lower power loss associated with a MOSFET switch 360 as compared to the bypass diode 245.
[ 00017 ] When one of the individual solar cells 305a or 305b is malfunctioning, or just not performing optimally, or within an acceptable range of operation, the switch 360 is turned on to allow a bypass pathway around the solar cells 305a and 305b. The maximum allowable current for the string 310 is restricted by the restriction of the lowest individual solar cell. By providing a bypass MOSFET switch 360, several individual solar cells 305a and 305b, can be bypassed to optimize power output of the string 310.
[ 00018 ] Thus, in some implementations, a method for improving the efficiency of a solar array is provided which includes monitoring and detecting when a solar string is not functioning optimally. When a solar string is not performing optimally, a small number of individual solar cells within a solar string may be bypassed to improve the power output of the individual string.
[ 00019 ] The monitoring and detecting may be accomplished by selectively turning on individual bypass MOSFET switches and sensing whether the power output of the string improves. This can be done by sensing the power output of all, or of a small group of solar strings or solar channel, or by sensing power output changes of individual solar strings. In one possible implementation, the output of the individual solar strings may be decoupled from the solar array or from a solar channel to detect the health of the individual solar string.
[ 00020 ] Turning to FIG. 4, shown is a simplified diagram of an improved circuit 400 for a solar array. In this embodiment, in place of the blocking diodes 115a, 115b, and 115c (FIG. 1), MOSFET switches 415a, 415b, and 415c are utilized having back-to-back MOSFETS devices 415ai and 415a2. The MOSFET switch allows each string 410a, 410b, or 410c in the channel 420 to be individually completely disable or open, even though the output of multiple strings go into a single power stage, such as a boost stage 485 DC/DC converter, which supplies current to the power bus 495 for charging the battery 490. The boost converter 485 controls the MOSFET switches 410a, 410b, or 410c and utilizes the detected string voltages to determine the health of the strings 410a, 410b, or 410c along with all the other strings (not show) and channels (not show) over the entire solar array. An advantage of this it that it allows the system to target each string 410a, 410b, or 410c and perform a lot of diagnostics in flight, such as short circuit current, open circuit voltage, on a per string basis.
[ 00021 ] Replacing the protection diodes with MOSFET switches is undesirable in a terrestrial solar system because it increases the cost of the system. Using the MOSFET switches, however, is very desirable in high altitude long endurance aircraft, where it is significant and important to extract the maximum energy from the solar array. MOSFET switches can be selected to have lower power loss across the switch as compared to a protection diode. As, such it increases the efficiency of the charging system, and also allows you to predict (through trend analysis) and detect failures much easier. Imminent failures can be predicted and action taken before a failure becomes critical. This is important in high altitude long duration aircraft, so as to enable avoidance of a critical failure that could otherwise lead to a power off, or even a crash landing. Since strings can be individually tested, it provides much more "visibility" into the functionality and health of the solar array in flight .
[ 00022 ] Moreover, each string can be tested in flight to determine the optimal power output for each string individually according to its V-I and power output characteristic. As such, the string characteristics can be tested over time to determine the health of the string. This is particularly important during long duration flights, and during high altitude flights, so that the need for maintenance and/or remedial measures, such as solar panel replacement, can be anticipated and made when convenient.
[ 00023 ] In some embodiments, each string includes a number of solar panels grouped generally spanwise along the wing of the aircraft, for example four, five, or six smaller solar panels are grouped per string. The solar panels are grouped in this way so that the solar panels in a string experience similar environmental and operational conditions together. For example, the solar panels at the leading edge of the wing may be grouped together in a string, while solar panels near the trailing edge of the wing may be grouped together, possibly with one or more strings also extending spanwise or laterally along the span of the wing, between the leading and trailing edge strings.
[00024] In high altitude applications, the grouping of the solar panels into strings is significant. This is because the temperature can vary greatly from the leading to the trailing edge of the wing. Further, the orientation of the aircraft with respect to the sun, in elevation, azimuth, rotation, etc., as well as having a greater curvature from leading to trailing edges of the wing, can further exaggerate the temperature differential. In high altitude long endurance solar powered aircraft, the temperature can range across the wing from -60 degrees Celsius on the leading edge to +60 degrees Celsius on the trailing edge of the wing. As such, grouping solar panels into strings combined with being able to individually switch on or off individual strings based on the performance of a string allows for more efficient solar power generation .
[00025] FIG. 4 is a simplified diagram of an improved circuit 400 for a solar array. In this embodiment, in place of the blocking diodes 115a, 115b, or 115c (FIG. 1), a solar string control MOSFET 415 is used in the channel 410. This configuration is more efficient than the circuit of FIG. 1 because it eliminates the voltage drop loss across a diode 115a, 115b, or 116c when the solar string control MOSFET 415 is turned on. This embodiment, however, when the solar string control MOSFET 415 is turned on, it does not inherently provide isolate between parallel connected solar strings in the event there is a short in a solar string 410.
[00026] As such, in this embodiment, the voltage drop across the solar string control MOSFET 415 is detected and monitored so as to determine the magnitude and direction of the current in the solar string 410 to determine whether another solar string (not shown) has shorted. If it is determined, based on the monitoring of several parallel connected strings, that one of the solar strings has shorted, the solar string control MOSFET in line with the shorted solar string is opened so as not to damage the other parallel connected solar strings. With the solar string control MOSFET 415 open, it performs as a diode as in FIG. 1, to block current through the shorted solar string.
[ 00027 ] Thus, the embodiment of FIG. 4 provides a more efficient power transfer, but requires monitoring of the current in the solar string 410 to determine if a short has occurred in the solar string 410, or in any of the associated strings. Typically, the monitoring and control of the solar string control MOSFET 415 is conducted by a power tracker, or other associated electronics. The power tracker includes the solar string control MOSFET 415 and the boost stage 485, which supplies power to the power bus 495.
[ 00028 ] FIG. 5 is a simplified diagram of an improved circuit 500 for a solar array. This embodiment allows solar string isolation by allowing a solar string to be individually and selectively decoupled from a solar channel. In this embodiment, in place of the blocking diodes 115a, 115b, and 115c (FIG. 1), MOSFET switches 515a, 515b, and 515c are utilized having back-to-back MOSFETS devices 515ai and 515a2. The MOSFET switch allows each string 510a, 510b, or 510c in the channel 520 to be individually completely disable or open, even though the output of multiple strings go into a single power stage, such as a boost stage 585 DC/DC converter, which supplies current to the power bus 595 for charging the battery 590. The boost converter 585 controls the MOSFET switches 510a, 510b, or 510c and utilizes the detected string voltages to determine the health of the strings 510a, 510b, or 510c along with all the other strings (not show) and channels (not show) over the entire solar array. An advantage of this is that it allows the system to target each string 510a, 510b, or 510c and perform a lot of diagnostics in flight, such as short circuit current, open circuit voltage, on a per string basis.
[00029] Replacing the protection diodes with MOSFET switches is undesirable in a terrestrial solar system because it increases the cost of the system. Using the MOSFET switches, however, is very desirable in high altitude long endurance aircraft, where it is significant and important to extract the maximum energy from the solar array. MOSFET switches can be selected to have lower power loss across the switch as compared to a protection diode. As such, it increases the efficiency of the charging system, and also allows you to predict (through trend analysis) and detect failures much easier. Imminent failures can be predicted and action taken before a failure becomes critical. This is important in high altitude long duration aircraft, so as to enable avoidance of a critical failure that could otherwise lead to a power off, or even a crash landing. Since strings can be individually tested, it provides much more "visibility" into the functionality and health of the solar array in flight .
[00030] Moreover, each string can be tested in flight to determine the optimal power output for each string individually according to its V-I and power output characteristic. As such, the string characteristics can be tested over time to determine the health of the string. This is particularly important during long duration flights, and during high altitude flights, so that the need for maintenance and/or remedial measures, such as solar panel replacement, can be anticipated and made when convenient.
[00031] In some embodiments, each string includes a number of solar panels grouped generally spanwise along the wing of the aircraft, for example four, five, or six smaller solar panels are grouped per string. The solar panels are grouped in this way so that the solar panels in a string experience similar environmental and operational conditions together. For example, the solar panels at the leading edge of the wing may be grouped together in a string, while solar panels near the trailing edge of the wing may be grouped together, possibly with one or more strings also extending spanwise or laterally along the span of the wing, between the leading and trailing edge strings.
[ 00032 ] In high altitude applications, the grouping of the solar panels into strings is significant. This is because the temperature can vary greatly from the leading to the trailing edge of the wing. Further, the orientation of the aircraft with respect to the sun, in elevation, azimuth, rotation, etc., as well as having a greater curvature from leading to trailing edges of the wing, can further exaggerate the temperature differential. In high altitude long endurance solar powered aircraft, the temperature can range across the wing from -60 degrees Celsius on the leading edge to +60 degrees on the trailing edge of the wing. As such, grouping solar panels into strings combined with being able to individually switch on or off individual strings based on the performance of a string allows for more efficient solar power generation .
[ 00033 ] Various embodiments allow for closer monitoring and predictive analysis of individual, or a small group of solar cells for better predictive analysis of the string.
[ 00034 ] Thus, an advantage of various embodiments over solar string circuits 110 (FIG. 1) using blocking diodes 145 is that the blocking diodes 145 can contribute a loss of about 0.7% due to the voltage drop across the diode, whereas the MOSFET switch presents essentially no voltage drop when turned on. Though discussed above with respect to a MOSFET switch, other comparable type switch, i.e light weight, low loss switch, could be utilized in other embodiments. Furthermore, although shown in FIG. 1 with only three solar strings in a channel for illustration purposes, embodiments may contain two or more strings, and multiple channels.
[ 00035 ] Various embodiments enable, or expand the capability to run in-flight diagnostics. In high altitude long endurance solar power aircraft, factors such as turbulence, frequent and extreme thermal, motor vibrations can increase the possibility of failure. Various embodiments, provide performance tracking over time, with trend analysis, and can enable eminent failure detection, more flexible scheduling of service/periodic maintenance, and avoidance of lack of airborne network capability/coverage or surveillance capability/coverage in the coverage area. This is particularly important if the high altitude long endurance aircraft is being used as a cellular repeater or for other network communications in area that would otherwise be without coverage should the platform be missing from the network.
[ 00036 ] Although not shown in each figure, the MOSFET switches may be controlled by a power point tracker, or other monitoring, detection, and evaluation controller, such as a processor. Thus, for example the voltages may be detected by, or passed to the power point tracker, where the voltages, and/or the solar currents are calculated for use in determining the functionality of the solar cells, solar strings, or solar channels. Further, the power point tracker, or other controller, controls the MOSFETs, for example.
[ 00037 ] FIG. 6 is a plot 600 showing an example V-I curve 610 of voltage versus current for a typical solar array system. The power curve 620 for the solar array system is superimposed on the plot 600. It is desirable to extract the maximum power from the solar array system. As such, it is desirable to operate along the V-I curve 610 where the power for the system is at its peak.
[ 00038 ] FIG. 7 is a plot 700 showing an example V-I curve 210 of voltage versus current for a solar array system for high performance solar cell utilized in high altitude long endurance aircraft implementations. In various high performance solar cell implementations which may be utilized in high altitude long endurance aircraft, the V-I curve 710 and the power curve (not shown) have a very steep slope as they approach the maximum current. Thus, the optimum operating point of the system lies with a narrow operating range. If the current is too great by even a slight amount, the voltage goes to zero or short circuits very easily. For example, the difference between optimum power output and short circuit can be as low as 100mA of current per channel 120 (FIG. 1) . Depending on solar cell and channel configuration, this could be even lower in some embodiments, such as 75 mA, 50 mA, 25mA, or less. To avoid this while achieving the highest power output, a voltage loop is utilized to monitor voltage while determining the peak power operating point, as well as monitoring the current and power. This is because the change in voltage is much bigger than either the power or the current near this point.
[ 00039 ] Thus, to find the optimum operating point of the system, the current is regulated, while monitoring the voltage as well as the power. The commanded current is varied by power point tracker circuitry, while monitoring power. Additionally, the voltage is also monitored to determine when the power output is maximized because the rate of change of the voltage is greater than the rate of change of the power at near the maximum power output operating point.
[ 00040 ] To achieve the most efficiency in some embodiments, the voltage is monitored at a faster rate than the current and power. In some embodiments, the voltage may be monitored ten time faster than the current or power. For example, the current and/or power may be monitored at 10 times a second, while the voltage is monitored at 100 time a second. [00041] This enables various embodiments to extract the most amount of solar power from the solar panels in high altitude long endurance aircraft applications, without drawing too much current and sending the voltage to zero, thereby shorting the solar cell.
[00042] It is important to note that factors such as the solar panel temperature and the amount of solar exposure can shift the maximum power operating point. In high altitude long endurance solar powered aircraft, these factors are more significant because the temperature range across the solar cells is more extreme, as discussed further below, and the shading or shadowing is typically experienced more frequently and to a greater degree. Thus, monitoring and adjusting the operating point is especially important in high altitude long endurance solar powered aircraft. Fig. 7 depicts example V-I curves for hotter temperature 710 and colder temperature 711 for bright solar exposure 710, and shadowed solar exposure 712.
[00043] It is worthy to note that any reference to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment may be included in an embodiment, if desired. The appearances of the phrase "in one embodiment" in various places in the specification are not necessarily all referring to the same embodiment.
[00044] The illustrations and examples provided herein are for explanatory purposes and are not intended to limit the scope of the appended claims. This disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the spirit and scope of the invention and/or claims of the embodiment illustrated.
[00045] Those skilled in the art will make modifications to the invention for particular applications of the invention. [ 00046 ] The discussion included in this patent is intended to serve as a basic description. The reader should be aware that the specific discussion may not explicitly describe all embodiments possible and alternatives are implicit. Also, this discussion may not fully explain the generic nature of the invention and may not explicitly show how each feature or element can actually be representative or equivalent elements. Again, these are implicitly included in this disclosure. Where the invention is described in device-oriented terminology, each element of the device implicitly performs a function. It should also be understood that a variety of changes may be made without departing from the essence of the invention. Such changes are also implicitly included in the description. These changes still fall within the scope of this invention.
[ 00047 ] Further, each of the various elements of the invention and claims may also be achieved in a variety of manners. This disclosure should be understood to encompass each such variation, be it a variation of any apparatus embodiment, a method embodiment, or even merely a variation of any element of these. Particularly, it should be understood that as the disclosure relates to elements of the invention, the words for each element may be expressed by equivalent apparatus terms even if only the function or result is the same. Such equivalent, broader, or even more generic terms should be considered to be encompassed in the description of each element or action. Such terms can be substituted where desired to make explicit the implicitly broad coverage to which this invention is entitled. It should be understood that all actions may be expressed as a means for taking that action or as an element which causes that action. Similarly, each physical element disclosed should be understood to encompass a disclosure of the action which that physical element facilitates. Such changes and alternative terms are to be understood to be explicitly included in the description. [ 00048 ] Having described this invention in connection with a number of embodiments, modification will now certainly suggest itself to those skilled in the art. The example embodiments herein are not intended to be limiting, various configurations and combinations of features are possible. As such, the invention is not limited to the disclosed embodiments, except as required by the appended claims.

Claims

WHAT IS CLAIMED IS:
1. In a high altitude long endurance aircraft, a solar array circuit comprising a solar string having a plurality of solar cells connected in series, the solar string comprising at least one bypass MOSFET switch connected in parallel with at least one of the plurality of solar cells in the solar string .
2. The solar array circuit of Claim 1, wherein the at least one bypass MOSFET switch is connected in parallel with a group of solar cells of the plurality of solar cells in the solar string.
3. The solar array circuit of Claim 2, wherein the at least one bypass MOSFET switch comprises a plurality of bypass MOSFET switches each connected in parallel with at least one of the plurality of solar cells in the solar string.
4. The solar array circuit of Claim 3, wherein the plurality of bypass MOSFET switches are each connected in parallel with a group of solar cells of the plurality of solar cells in the solar string.
5. The solar array circuit of Claim 1, wherein the at least one bypass MOSFET switch comprises a plurality of bypass MOSFET switches each connected in parallel with a group of solar cells of the plurality of solar cells in the solar string.
6. The solar array circuit of Claim 5, wherein the solar string further comprises a series connected blocking MOSFET switch.
7. comprising a plurality of the solar array strings connected in parallel to comprise a solar string channel.
8. The solar array circuit of Claim 9, wherein each of the plurality of solar array strings in the channel comprise a blocking MOSFET switch.
9. The solar array circuit of Claim 1, wherein the solar string further comprises a series connected blocking MOSFET switch
10. The solar array circuit of Claim 9 further
comprising a plurality of the solar array strings connected in parallel to comprise a solar string channel, wherein each of the plurality of solar array strings in the channel comprise a blocking MOSFET switch.
11. In a high altitude long endurance solar powered aircraft, an onboard diagnostic method comprising:
a) monitoring an output of a solar string;
b) detecting whether a solar string is functioning within an acceptable range of operation;
c) determining whether any of the solar cells in the solar string are functioning within an acceptable range of operation; and
d) bypassing any of the solar cells within the string that are not functioning within the acceptable range of operation so as to improve an efficiency of the solar string.
12. The method of Claim 11, wherein bypassing comprises turning on a bypass MOSFET switch connected in parallel with a solar cell that is not functioning within the acceptable range of operation.
13. The method of Claim 12, wherein bypassing comprises turning on the bypass MOSFET switch connected in parallel with a plurality of solar cells within the solar string.
14. The method of Claim 11, wherein detecting comprises selectively turning on individual ones of a plurality of bypass MOSFET switches and sensing whether a power output of the solar string improves.
15. The method of Claim 11, wherein detecting comprises selectively turning off multiple solar strings within a solar channel of parallel connected solar strings so as to isolate an individual solar string within the solar channel.
16. The method of Claim 15, wherein selectively turning off multiple solar strings within the solar channel comprises using blocking MOSFET switches, each solar string comprising at least one of the blocking MOSFET switches connected in series within the solar string.
17. The method of Claim 16, wherein detecting and bypassing comprises detecting and bypassing while the high altitude long endurance solar powered aircraft is in flight.
18. The method of Claim 11, wherein detecting and bypassing comprises detecting and bypassing while the high altitude long endurance solar powered aircraft is in flight.
19. In a high altitude long endurance solar powered aircraft, an onboard diagnostic method comprising:
a) detecting whether a solar cell is functioning within an acceptable range of operation; and
b) bypassing the solar cell if the solar cell is not functioning within and acceptable range of operation by controlling a bypass MOSFET switch connected in parallel with the solar cell .
20. The method of Claim 19, wherein controlling the bypass MOSFET switch comprising controlling series connected complimentary MOSFETs.
PCT/US2020/029976 2019-04-25 2020-04-25 System and method for improved solar cell array efficiency in high altitude long endurance aircraft WO2020219997A1 (en)

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