SPECTRUM "Solar Power Exploitation by Collection and Transportation by fibre optics to Remote Utilisation Modules"

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1 CONSORZIO CEO CENTRO di ECCELLENZA OPTRONICA SPECTRUM "Solar Power Exploitation by Collection and Transportation by fibre optics to Remote Utilisation Modules" JOR3 CT Giuseppe LONGOBARDI

2 4 MAJOR EVENTS AND ACHIEVEMENTS OPTICAL COLLECTORS SUN TRACKING SYSTEM (STS) First configuration of sun tracking system Final sun tracking system FIBER OPTICS OPTICAL SWITCH

3 Major events and achievements on SPECTRUM system Kick-off, Mid-term, Final meetings and all technical contacts among the partners can be considered the events which have conditioned in a fundamental manner the correct development of the project because they always have involved a very deep analysis of the results obtained by each partner and the possible technical alternatives showed by the market. This has been valid mainly for CEO, Ceram and INOA ; from FOCO two important activities were able to help in defining the requirements of SPECTRUM in terms of functionality and costs and to evaluate the state of the art of the solar energy exploitation. The Kick-off was held in Bruxelles at the European Commission on 11 st December The Partners discussed and agreed about the management of the Project and the technical aspects. This first meeting better defined the role of the single partners of the Consortium and their real contribution to the SPECTRUM achievements During the Mid-term the discussion involved the design of the optical system(first crucial point of the project) to use for concentrate the solar light in the small size diameter of optical fibre(second crucial point). Starting from the fibre features three different classes of optical systems have been discussed : Mangin type and all their surfaces spherical; parabolic collectors and aspherical surfaces. On the other and the reached performances and possible improvements in the near future of the fibre optics were analysed. According to the suggestion of the European scientific officer all partners agree that would be very important to organise immediately some technical meetings among CEO, Ceram and INOA in order to find solution to this fundamental part of the system.. On the other during the same meeting all participants agreed that the work done end the results reached by all partners and represented by: 1) The functional and industrial requirements; 2) The architecture of the overall system; 3) The increase of solar plant efficiency thanks to multipurpose use; 4) The features of a single collecting module; 5) The performances of the optical fibre bundle; 6) The cost of the optical components; 7) The increase competitiveness in new market segment. were very significant at this point of the project. Besides because of the demonstrable results the Project was began to produce and also for what displayed in some exhibition visited, the Partners recommended that the Project should be continued. In the same meeting a very important collegial decision was to redirect the project at the 3

4 first for lighting because all partners found for this application a clear and high chance for a near future of SPECTRUM. Besides the participants decided to follow with interest and to experiment also heating application. CEO proposed, during a technical meeting among Ceram and INOA, the possibility to use a modular system, studied from the mechanical point of view, composed by single unit (14cmx14cm) each containing four collector systems. This solution was agreed by the partners after a very deep technical discussion and the advantages carried out. During the Final meeting (Florence Wednesday ) a demonstrator for collection, concentration and conversion of solar energy was shown and activated during all day. It was also underlined that the key aspect was not the prototype but the investigation and development of a wide range of optoelectronic and mechanical solutions, mainly for what concerned the optical collection and their integration into a demonstrator from which appropriate performances could be obtained according to the requirements of applications. The meeting was divided into three parts. a) First of all the work done by all the Partners was presented. b) The second part was given over to two experimental demos. The first took place on the terrace of the INOA building and concerned the demonstrator. Was shown how it worked, its structure and its performances. The second part took place in the laboratory on the ground floor, where sunlight was transported, by 4 optical fibres, from the collector on the terrace. It was possible to see how the sunlight from the fibres output was distributed among different applications by the optical switch composed by a parabolic rotating mirror programmed in three steps. c) The last part was devoted to the exploitation and dissemination of the results. The demonstrator consisted of an outside unit containing four optical collector subsystems which have the task of collecting the maximum efficiency solar radiation in a wavelength spectrum (from 0.4 to 1.4 µm) suitable for OF transmission and focusing it in an OF input. The next figure depicts how the demonstration was organised during the final meeting 4

5 Collector sun tracking was performed by a sun tracking system improved by a position sensor placed in the centre of each tile. The solar energy transported by the optical fibre can be 5

6 utilised in different applications in this way. In order to reach all results shown during the final meeting, the role of each Partner was underlined : - CONSORZIO CEO Acting as Co-ordinator and involved in the study, design and realisation of the Sun Tracking System, and mechanical design of the tiles. - INOA Design and realisation of all optical parts of SPECTRUM; realisation of mechanics and micromechanics utilised during project development. - CERAMOPTEC Development of fibre optics and their supply for system testing. - FOCO Definition and following the functionality of SPECTRUM in order to propose market opportunities. At the end of the Project, the following results were achieved: a) Several Optical configurations have been developed for solar energy collection. Studies of the most appropriate optical system were carried out in order to obtain *best collection efficiency.( the final value reached was about 70%) b) Several racks to allow an effective support for the optical collectors were designed and realised. The final solution was targeted towards modularity in order to meet the specific needs of the building where Spectrum has to be installed also taking into consideration of installation ease. The minimum requirement is a tile of 2x2 optical collectors of 140x140 mm 2 dimension, which can be distributed in a field, hidden on a roof and thus also applied to a historical building. c) Several plastic and metal materials were investigated in order to build a not expensive, light and rigid tile support. d) Electronic design, appropriate position sensors and algorithms development has been carried out for sun tracking system realisation. The system is completely autonomous because the electronics was designed in order to have the lowest energy consumption (drain); an array of photovoltaic cells on the tile edge will supply energy sufficient to move the tiles. During the visit to the demonstrator it will be possible to see experimentally the drain of the Spectrum compared to what the photovoltaic cells can accumulate. e) Optical fibres have been studied and developed with low losses, higher NA and proper diameter. CERAMOPTIC * also studied different types of connectors because the fibre connection to the optical system is a crucial point for the efficiency of the whole system. 6

7 At the moment the diameter of the fibre is 600 µm but in the future it could be 800 µm. f) The possibility of distributing the solar light collected and transported by the fibre in several modules of utilisation by means of an optical switch. The switch s role is to distribute *solar radiation from the fibre output to the user modules. This allows to obtain one hundred per cent utilisation of the collected radiation g) The final cost of the tile was analysed with great care. We searched for components with high performances and low cost. At the present moment, for a production of 200 tiles, the cost of one tile (without the fibres) is *about 200 EUROS. h) Dealing with the first set-up the whole functionality was verified in a full and realistic way by using the mechanical solutions being developed and six distinct optical configurations. i) Unfortunately the weather was not always good in the last period of tests. The field tests have been conditioned by this meteorological changeability. j) A software programme was realised to record and display in real time the quantity of energy collected by the system. The computational system shown the content of *collected energy integration during the length of the registration. 5. Scientific and technical description of the project SPECTRUM is a modular system composed of an optical concentrator coupled to a fibre, which transfers the collected power to several utilisation modules. Different applications can be selected by means of an optical switch for the immediate use of light and energy or its storage for a successive employment. In order to test and demonstrate the capabilities of the different subsystems of SPECTRUM several different demonstration toolkits level were identified and agreed. 7

8 The following figure shows the general architecture of SPECTRUM Figure 1- Spectrum System 8

9 5.1Optical collectors The optical collector subsystems have the task of collecting the maximum efficiency solar radiation in a wavelength spectrum (from 0.4 to 1.4 µm) suitable for Optical Fibre (OF) transmission and focusing it in an OF input. Several optical projects of collectors have been designed, and some of them realised, with the final purpose of obtaining the maximum collected power within the fibre aperture and core diameter, while usually the main requirement for a lens is to give a good image. At the beginning aspheric surfaces were used to achieve a more satisfactory design. The use of aspheric surfaces overcomes optical problems as well as aberrations. These aspheric surfaces cannot be easily generated by the polishing techniques. In order to apply larger amounts of asphericity a turning process is used. This employs single point diamond turning on a modified lathe. The method is expensive together with the surface asphericity control. An original configuration defined Catadioptric Concentrator Monoblock (CCM) has been developed with the aim of optimising the optical characteristics of the collector but also its compactness. It consists on two optical elements in a coaxial configuration, similar to the Cassegrain set-up (see fig. 2). Figure 2 - Layout of CCM The characteristics seem to be particularly useful for our application and the realisation 9

10 procedure appears to be innovative. The CCM was realised in a unique piece of quartz, allowing obtaining an objective characterised by extremely reduced dimensions and great mechanical stability. Five other optical configurations have been examined considering three collectors of Mangin type (see Fig. 3) and two of parabolic type especially adapted for the Spectrum application. Optical Fibre Optical Fibre Secondary mirror Secondary mirror Primary mirror Input window Primary mirror Input window Optical Fibre Lens Secondary mirror Primary mirror Input window Fig.3 - Layout of the three Mangin configurations The Mangin system is composed of a glass meniscus, aluminised on the rear surface, and a secondary mirror, which can be flat or spherical. The optical path between the two surfaces of the meniscus allows the control of the spherical aberration, which can be minimised adjusting their curvature radius. 10

11 The parabolic type collectors are composed of two mirrors, the primary is parabolic and the secondary is flat, with or without correction lens. A photo of a Mangin collector is shown in fig. 4. Fig. 4 Mangin collector Some aspherical plastic lenses have also been selected among the commercially available products. The collection efficiency of the six concentrators have been theoretically simulated both for the single lens and for the collector coupled to the fibre. On the base of this comparative study we have selected CCM and Mangin for the realisation of the prototypes, whose collection 11

12 efficiency has been measured in laboratory, using a solar simulator, and then directly exposing the lens to the sunlight. Several racks(see fig 5) to allow an effective support for the optical collectors were designed and realised. The final solution was targeted towards *modularity in order to meet the specific needs of the building where Spectrum has to be installed also taking into consideration of installation ease. The minimum requirement is a tile of 2x2 optical collectors of 140x140 mm 2 dimension, which can be distributed in a field, hidden on a roof and thus also applied to a historical building. Fig. 5 Examples of racks utilised for SPECTRUM Finally the collector prototypes have been mounted on the frame realising the demonstrator presented during the final meeting. Two frames holding 4 CCM (see fig.5a) and 32 Mangins (see fig.5b) have been placed on the terrace of the INOA building (were CEO organised the 12

13 final meeting) and have been tested in working conditions following the sun. Fig. 5a CCM tile with a minimum number of optical collectors 13

14 Fig. 5b Mangin tile with 32 optical collectors The four CCM have also been coupled to 25m fibres to transfer the light to an internal 14

15 room, where it has been redirected towards three utilisation systems to show the working principle of the optical switch. Field tests on the tile mounted in the demonstrator frame have confirmed that the CCM is easy to be aligned and it performs good power collection. The Mangin collectors, representing the best trade-off between efficiency and cost, provide a slightly lower power than CCM. Alignment difficulties are a crucial point of the Spectrum installation since it is supposed include a large amount of modular units assembled into arrays thus increasing alignment problems. It is useful to remind that the mechanical alignment between concentrators and optical fibre for Mangins and Paraboloids is complicated by the fact that the secondary mirror is physically separated from the primary mirror. This longer thickness of these optical systems with respect to CCM also requires a larger frame. CCM, being the more compact, could be mounted on a smaller frame than Mangin, requiring a minor space for the rotation of the sun tracking. The further improvement will be the realisation of plastic optical components, which will allow a massive production at low cost. 15

16 5.2 Sun Tracking System (STS) First configuration of sun tracking system System moves the solar radiation acquisition panel to sun B0 direction by PC System gives control of tracking to the 4 quadrant transducer A1 0 Solar radiation A2 System tracks the sun by looking at its image on the Electronic controller device + azimuth and If the transudecer loses the sun images (i.e. a cloude) the system tracks the sun B3 4 quadra B A B A PC for sun Azimuth and The first configuration of STS consisted of : - A Personal Computer (PC). It must calculate the position of the Sun in the sky: it gives the calculated data, in millesimals, of the Sun position in the sky and makes them available via a serial RS232. The PC also gives the reference Altazimuth system of the instrument. - An Electronic board.. It has to receive the data of the Sun position from the PC via serial transmission, compare them with the previous ones, calculate the number of steps that the 16

17 engines must make and drive them appropriately. This board also controls a 4 quadrant sensor which provides it with the Sun precise position. - A 4 Quadrant Sensor. It informs the electronic board on how precise the remote control is, directing it to the centre of the Sun with the requested precision. This system allows inevitable errors made during the system positioning phase. The Sun Tracking System successively developed consists on : - An Equatorial Structure. It allows Sun tracking controlling (theoretically) only one engine. With this system, declination shift become very small during the day and consequently there is a lower absorption of energy. 17

18 5.2.2Final sun tracking system. 18

19 After the realisation of the first prototype, of the Sun tracking system, we would like to present the Project concepts which represent the natural evolution of the system. Before describing these concepts, it is better to give a brief description of the first prototype realised. At the basis of the first prototype, the possibility of linking tracking control engines to two separate and distinct controls was considered. Practically a master board controls the altazimuth movements of the system in accordance with the Sun position co-ordinates received, in real time, from a PC. Soon afterwards, a system of automatic correction provides alignment of the tile with the Sun with great precision. This remote control system has the advantage of controlling engine movements given directly by the PC calculations digitally and thus with absolute precision. This system allowed us to carry out measurements with remarkable precision, but it limited us because of its complexity, since too many variables were introduced. Besides there are some practical drawbacks such as slacks introduced by the mechanics (we should recall that the motor reducers used are commercial components and they are not free from the slacks), which can make the precision of the PC calculation useless. Another problem was the high dynamics of sky luminosity. For example it was very difficult to distinguish between the Sun at Sunset and the Sun at the zenith when dim: in both conditions the luminance value is the same. Several ambiguous situations like those just mentioned can take place. The problem was resolved by distinguishing between incident and scattered light. The new system was able to overcome the limits of the previous one. Firstly we removed the PC from the system. This will make the tracking system simpler. In order to obtain this result two points have to taken into consideration : 1) Astronomy tells us that the Real Solar Day does not have same duration during the year but can also change in a remarkable way (+ or 15 minutes) according to the different periods. The consequence is the change of the angular shift of the Sun in time. In the first system this problem was solved by PC utilisation during the calculation of altazimuth values. 2) In the previous system another task that the PC carried out was to release automatically the definitive setting up of the instrument was enough, that is leveling of the instrument 19

20 because all the system was hooked to the current Sun position and consequently centred. In the second Project this task will be carried out with the use of an automatic tracking system. Some considerations must be made about the system used in the new Project. With reference to this, it is useful to mention equatorial remote control. This system allows tracking every object on the sky simply orientating the Azimuth axis parallel to the earth rotation axis (called time axis ). In the case of star tracking it will be sufficient to transmit to the time axis a suitable angular shift depending on astral time; in the case of Sun tracking, it will depend on the duration of true day sunlight. Any adjustment of the Elevation axis, called Declination axis, is not necessary, (in theory, at least). We can deduce that this is the best system for tracking every object in the sky. The new Sun tracking configuration was based on this idea. On this subject some clarifications must be made. Firstly, only theoretically does the Declination axis not need any correction: in order not to need this correction, the absolute parallelism between the Time axis and the Earth axis must be respected. Following Astronomy, we know that the inclination of the Hearth axis depends on the place and that it can be expressed as the angular height of the pole in the sky. Otherwise, to determine the parallelism between the instrument axis and this completely theoretical axis is a crucial point, also considering that the discrimination of the NORTH position is neither simpler no automatic as could be believed. So the Spectrum will not be set in a perfectly correct position. Let us consider again the angular shift that the Altazimuth instrument of the first system had to complete each day: since the Sun rises, culminates and sets, each day the instrument should cover an elevation arch from 0 to a max 90 latitude on the Equinox day and (90 lat.) + or 23.5 on the Solstice days. It is clear that in this remote control system the elevation engine works hard. We have noticed that in the Equatorial system, at least theoretically, the Declination axis stands still during the day and that it must anyway correct itself (only in case of Sun tracking) by 43 x(23.5x2) during the whole year (these are the values valid for the latitude of Florence). It is natural to deduce that also in case of a non precise, equatorial setting, the declination engine will not have to shift very much during the day, even if possible correction introduced by the feed-back does not draw advantage from this aspect. 20

21 We can suppose driving the engine of the time axis with a constant movement of 15 seconds of arc per second (deriving from seconds of arc contained in 360 divided by seconds of time contained in 24 hours) obtaining the angular shifting suitable for Sun tracking, This very small correction will be made automatically by the feed-back. The Declination axis will be driven exclusively by the feed-back. This feed-back is the same 4 quadrant sensor, used in the first system, with an acceptance angle of about 3 degrees from the centre. It can bring the Sun to the centre also in case of long periods of cloudy sky. A system clock with the date informs the system when it must set again. The current drains of the whole system can be estimated in avarage currents of 18 milliampere, that is an engaged power of little more than 200 milliwatts. During the project we will study solutions for reducing the absorption more; preliminary tests have given information on the possibility of lowering the feed voltage. The system will be fed by a small battery loaded by a small solar panel. We can estimate that the battery (1.2 Ah) will leave the instrument independent for some days in absence of the Sun, while it can be reloaded with 3 hours of exposition. I the case of no Sun the battery will be partially reloaded by the diffuse light always present during daylight. 21

22 5.3Fiber Optics Fibre optics acts as guide for transporting the concentrated solar radiation to the user s ends. The principal objectives for this part were the execution and optimisation of the fibre optics cable on the basis of the results obtained in task 4 Optical Fiber Optimisation. After two years we can maintain that fibre optics appears an interesting solution for light transportation from optical concentrators to optical interface with minimum loss. Fiber Optics utilization is the second crucial point of the Project after the optical concentrators. Properties of the fibre to be utilised depend on the association between fibres and sun light concentrator. The fibre has a numerical aperture (NA) and this is an important parameter in the design of concentrator optical system to-fibre couplers, for example. If the fibre is completely filled with modes, at the radiating end of the fibre the light will spread out into a cone of half-angle α. The NA is defined as sen(α). The broadband long range transmission is limited by the ability of silica fibres to transmit well from the UV through the IR. Besides, cost and performance analysis is also an important parameter because the field of application must be different such as lighting and heating. CeramOptec has focused on the generation of a low attenuation teflon cladded fibre with an inner core diameter of 600 µm, the NA of 0.57 but still the attenuation which ought to be in range of 3dB/100mt showed to be twice as large. The drawing a teflon cladded silica/silica core fibre in order to improve the attenuation was decided. In the next figure (fig.6) is shown the attenuation vs the wavelength for the improved fibre from CeramOptec. This attenuation is down to 30dB/km for a wide range of wavelengths such as in the visible spectrum. Last point concerns the attenuation of fibre connector. CERAM produced a deliverable document Technical Analysis of Optoelectronic Components (SPECT02PT005DL170599PG10) which shows clear relationships among structural and functional characteristics, field of application and costs. CeramOptec has shown the use of single connectors as well as multi-link connectors for this kind of application. Attenuation of 10% to 13% in average per link are acceptable for these kinds of connection. 22

23 JOR3 CT Fig.6 Attenuation graph for the improved FO 23

24 5.4 Optical switch Once the wide spectrum solar energy has reached the end of the transmission line, the applicators will be designed as function of the required utilisation. Solar energy can be widely available for a lot of different utilisation modules such as lighting, thermal applications, direct production of electricity, green house and so on. In order to distribute the energy at the output of the glass fibre ribbon so exploiting the 100% of the collected energy, an optical switch has been designed and developed. The switch realised is simple, reliable and highly efficient and can be programmed, at present, in three steps (see Fig. 7) Fig. 7: Optical switch: basic concept 24

25 The switch consists of a mirror mounted on one rotation axis for redirect the light from the output of the glass fibre ribbon to the different end users. The mirror has an elliptical shape in the direction orthogonal to the line along the glass fibres and was chosen in order to redirect the collected sun light. The size diameter of the optical switch used in the demonstrator is of 50 mm. The driver of the switch is an electronic board which allow, at the moment, three possible positions. 25

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