The method proposed for the characterization of ADG Fresnel lenses includes two different procedures: the first one uses solar cells as light sensors, while the second is based on a CCD camera.
Applying the solar cell based procedure, the photocurrent generated by a MJ solar cell has been measured using different Fresnel lenses as concentrators. As described in the protocol, the CPV solar simulator makes use of a xenon flash lamp emitting light that is reflected on a parabolic mirror. Such a mirror generates a collimated light beam on the measuring plane (coincident with the lens aperture). Due to the mirror manufacturing tolerances and surface roughness, the collimated light is not uniform on the measuring plane. The non-uniformity of the irradiance created by the solar simulator is the main source of error in our experimental measurements10. Since large lenses integrate the irradiance at the measuring plane over a large area, the error due to non-uniformity depends on the size of the lens. The solar simulator for CPV systems used at the Solar Energy Institute attains a uniformity better than ± 5% for 3x3 cm optics9. For the ADG Fresnel lens tested here, whose optical aperture is 40x40 mm, the effect of non-uniformity over the measurement can be critical. In order to reduce this uncertainty, a reference lens is re-measured prior to conducting any experiment. Moreover, when carrying out these measurements, it is paramount to be especially careful during the alignment of the cell and the lens. In fact, the solar cell has to be placed exactly centered with the light spot cast by the lens in order to avoid misalignment, because if a bad initial positioning is used, the photocurrent reduction due to defocusing is altered. Another error that may occur is that caused by different shading factors of the front metallization grid (the MJ solar cell used as a sensor is calibrated using uniform irradiance but the lenses cast a Gaussian shape profile on it during the measurements). To ensure that the metallization is not affecting experimental results, it is useful to carry out several measurements displacing the lens and, as a consequence, the light spot on the receiver plane. If the measured photocurrent varies significantly when slightly moving the light spot, it means that the metallization grid is affecting the measurements.
There are other methods suitable to measure the optical efficiency of a primary lens, e.g., using thermal irradiance sensors such as thermopiles10. The main drawback of this approach is that the response of a thermal sensor is too slow for any flash-light source. Therefore, it can only be applied to outdoor measurements (which are very sensitive to the spectral distribution of irradiance and other weather conditions). With the proposed method, this limitation is avoided.
Additionally, using the solar cell based procedure, it would also be possible to obtain the size of the light spot cast by a lens. To do so, the photocurrents generated by several MJ solar cells of the same type and different but similar sizes need to be measured. For the cells whose size is smaller than the light spot cast by the lens, the measured photocurrent diminishes as the cell surface decreases due to the light spilling out of the cell. Conversely, the photocurrent remains constant for MJ solar cells whose size is larger than the light spot, since regardless of the cell surface, all the light transmitted by the lens reaches the solar cell. Therefore, the size of the light spot is equal to the size of the smallest cell that attains the maximum efficiency. For this method, the higher the number of solar cells used, the higher the resolution.
Since a set of solar cells suitable to carry out the described measurements is not always available, the CCD camera procedure has been proposed to measure the light spot size. Thanks to the wide dynamic range of the CCD sensor, using photographs of the light spot taken with the camera, an accurate comparison between peak and valley values is possible. In order to calculate the absolute value of the irradiance, a calibration of the whole set-up, including the filters and CCD camera, would be necessary. Nevertheless, from the photographs, it is possible to separate the illuminated area from the dark area over an image and, thus, estimate the light spot size. The main drawbacks of this technique are the spectral mismatch between the CCD sensor and a MJ solar cell and the noise produced by sources of light different from the collimated beam generated by the solar simulator. Regarding the first problem, by adding a hot or cold mirror to the CCD camera, it is possible to obtain a spectral response very similar to that of the top and middle sub-cells (see Figure 6). Additionally, in order to limit the background noise, it is necessary to completely darken the chamber of the CPV simulator. Since it is almost impossible to completely avoid external light sources, the image processing is very important and has to be well programmed. The most critical step is the elimination of background noise. Noise filtering can be partially automated but, due to the strong dependence with external factors that are scarcely predictable, every processed image undergoes a visual examination.
The CCD procedure can be used to obtain the evolution of the light spot size as a function of the lens temperature by adding to the system a thermal chamber where lenses are placed. In this case, besides the error sources previously described, uncertainty arises from the lens temperature measurements. The control thermocouple (the one directly connected to the computer) does not represent the real lens temperature because the sensor is placed in a point of the thermal chamber close but not directly connected to the lenses to be measured. Therefore, the temperature measured using such a thermocouple is an average temperature of the environment surrounding the lenses and it does not necessarily correspond to the real lens temperature. That is why connecting each lens to an independent thermocouple is recommended. Nevertheless, there is probably a temperature gradient between different points of the lens. In order to quantify this uncertainty, once the thermal chamber achieves the desired temperature, and before performing any measurement, it is better to wait 15-20 minutes to let the system temperature become as uniform as possible.