Solar Simulator LED Cooling Layout for Continuous PV Testing
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Solution Overview
Problem
Existing solar simulator apparatuses suffer from overheating issues due to inadequate thermal management, which compromises the quality of prolonged photovoltaic panel tests, especially when conducted in continuous mode.
Innovation Solution
A solar simulator apparatus with a first liquid cooling unit for the LED lighting unit and a second air cooling unit for the object, featuring a modular heat extraction device and optimized distance between LED boards and control boards, along with a rest plane design to minimize thermal bridges, ensures efficient thermal control and accurate testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If LED boards are operated in continuous mode for prolonged testing, then test duration and productivity are improved, but thermal accumulation causes LED overheating and wavelength distortion compromising test accuracy
Solution Approach 1:
A water-cooling plate is introduced as an intermediary thermal management component between the LED boards and the test environment. The cooling plate with internal channels circulates water to actively remove heat from the LED boards during continuous operation, preventing thermal accumulation and maintaining LED emission wavelength accuracy throughout prolonged testing periods
Solution Approach 2:
A hydraulic cooling system using circulating water is implemented to manage thermal loads. The water flows through channels in the cooling plate, providing continuous heat removal from LED boards, enabling sustained operation without temperature-induced wavelength drift while maintaining measurement precision
2Device complexity
If passive finned dissipation surfaces are used for thermal control, then device complexity is reduced, but cooling efficiency is insufficient for prolonged continuous operation
Solution Approach 1:
The patent transitions from passive air cooling to active hydraulic cooling by implementing water circulation through embedded channels in the cooling plate. This active thermal management system provides reliable and sufficient cooling for prolonged continuous LED operation, ensuring stable test conditions without the inadequate heat dissipation limitations of passive finned surfaces
3Area of stationary object
If LED boards are positioned close to control boards for compact design, then device footprint is reduced, but thermal coupling between components increases causing mutual interference
Solution Approach 1:
The water-cooling plate serves as a thermal intermediary barrier positioned between the LED boards and control boards. It actively manages heat flow, preventing thermal coupling and mutual interference between these sensitive components while maintaining a compact apparatus configuration through its integrated design
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The apparatus maintains the LED lighting efficiency and object temperature within optimal ranges, ensuring reliable and accurate test results over extended periods without deactivating the irradiating surface.
Implementation Method 1
a first liquid cooling unit for the LED lighting unit... heat extraction device associated with the lighting unit
Implementation Method 2
first liquid cooling unit... connected cooling device outside the containing structure
Implementation Method 3
a second air cooling unit for the object
Implementation Method 4
second air cooling unit... air feeding circuit connected to the central collector
Implementation Method 5
LED lighting unit... individual LEDs of each board are capable of emitting beams of light at different wavelengths
Implementation Method 6
LED lighting unit... generate the artificial light
Implementation Method 7
the object of the test, be it a photovoltaic panel, string or cell which, when illuminated by the radiation produced by the LEDs, generates current
Data Source
AI summary
A solar simulator apparatus to perform a test on at least one object including a containing structure having an internal operating space in which there is defined an irradiation chamber equipped with a lighting unit; a rest plane associated with said containing structure and configured to support said object, said rest plane being able to be selectively positioned facing said lighting unit.