Measurement technologies & operation systems in solar test facilities (relevant hardware/software)

Dr. Jan-Peter Säck

2

Content

- SCADA system

- Sensors & actors

- In- and outputs

- Software

- DLR inhouse systems

SCADA (Supervisory Control & Data Akquisisiton)

- Central control system- Managing of different hardware- Interface for database- Connection between hardware via

bus systems- Hard- and software server as

interfaces- Visualisation of process data- Storage of process data- Control of the process- Industrial standards

3

Source: National Instruments

Source: Eaton

Supervisory control

- Programmable Logic Controller (plc)- Realtime system- Main processor unit- Program code internal- Mostly modular systems- Digital in- and output (cards)- Analogue in- and output (cards)- Different bus systems & cards- Motion control cards- Safety functions can be included

4

Source: Allen Bradley

Source: Mitsubishi

Source: Beckhoff

Source: Siemens

Data Akquisition

- Mainly for data collect & storage- Storage internally or externally on

a personal computer- Incidentily for control- Sometimes modular systems- Digital in- and output (cards)- Analogue in- and output (cards)- Use for Research & Development- Easily to program and to visualize

data- Use for meterological stations

5

Source: Advantech

Source: Gantner Instruments

Source: Gantner Instruments

Source: Campbell Scientific

Sensors

- Latin: sentire = to feel- Determination of properties like:

- Heat radiation- Temperature- Humidity- Pressure- Radiance- Acceleration- And many more…

- Passive & active - Digital & continuous analogue

6

Source: Eaton

Actors

- Latin: Actor = converter- Conversion of signals to physical

quantity like:- Mechanical motion

- Rotation- Linear

- Temperature- Pressure

- Electrical (e.g. motor)- Hydraulical (e.g. cilinders)- Pneumatical (e.g. cilinders)- Electrochemical (e.g. battery)- Magnetical (e.g. transformator)

7

Source: Petersdorff

Digital in- and outputs (Bool)Signal:„low“ = 0 (0V) & „high“ = 1 (24V)

Inputs:- Status input signals (limit switch)- Counter- Frequency- Encoder (Rot/Incl.)

- Incremental- Absolute

Outputs:- Status output signals (Relay)- Pulse-Width-Modulation (Motor)

8

Source: Parkermotion

Analogue in- and outputs (Voltage & Current)Voltage:Typical measuring ranges:

- 0….10V- 0….5V- 0….1V- 0….XXmV

Current:- Typical measuring ranges:

- 0….20 mA- 4….20mA

- 4…20 mA wire break security- Low losses over long distances

9

UIn/Out

IIn/Out

Analogue inputs (Resistance)

- Potentiometer- Voltage divider- Different measuring ranges- Linear & rotational- Longitude & angle measuring- Control element e.g.:

- Frequency converter- Temperature controller- Flow controller

10Source: Conrad

R=U/I

+5V 0V

Ana

log

In

0…5V

Analogue inputs (Temperature Resistance)

- Temperature dependency ofresistance value

- Use of linear part of curve(Measuring range)

- NTC-Resistance (Negative Temperature Coefficient

- PTC-Resistance (Positive Temperature Coefficient)

- Cheap but not very exact- Not industrial standard

11Source: TC Direct

T

Analogue inputs (PT100)

- Resistance thermometer- Industrial common- Normed in EN 60751- Used Metal: Platinum- R0=100Ω- 2-, 3-, 4-wire-circuit- Measuring range:- 0…850 °C: R = R0 · (1 + a · t + b · t2)- -250…0 °C: R = R0 ·(1 + a ·t + b · t2 + c ·

(t − 100 °C) · t3)- Also used:

- PT500: R0=500Ω- PT1000: R0=1000Ω

12

Source: TC Direct

Analogue inputs (Thermocouples)

- Seebeck effect = thermoelectric effect- Two different metals welded together- Voltage difference prop. to temperature

difference

Different Metal Pairs:- Type B: Rh/Rh 600 to 1820°C- Type C: Re/Re 0 to 2316°C- Type E: Ni-Cr/Cu-Ni -250 to 1000°C- Type J: Fe/Cu-Ni -201 to 1200°C- Type K: Ni-Cr/Ni-Al -200 to 1372°C- and many more…

13

Source: TC Direct

Ni-Cr/Ni

Source: Kipp & Zonen

Source: Kipp & Zonen

Meteorological sensors (Pyrheliometer)

Measurement of direct solar radiation (DNI)For use on two axis trackerInternal temperature compensation

Specifikations:

14

Spectral range 200 to 4000 nmSensitivity 7 to 14 µV/W/m²Operational temperature range -40 to +80 °C

Maximum solar irradiance 4000 W/m²

International standards (ISO) First Class

Meteorological sensors (Pyranometer)

- Measurement of global radiation(GHI) or diffuse radiation (DHI)

- Shadow band or ball- Excellent linearity- Fast response time- Low tilt error

Specifications:

15

Source: Kipp & Zonen

Source: Kipp & Zonen

Spectral range 285 to 2800 nmSensitivity 7 to 14 µV/W/m²Operational temperature range -40 °C to +80 °CMaximum solar irradiance 4000 W/m²Field of view 180 °

Meteorological sensors (Wind)

- Wind speed:

- Wind direction:

16

Source: ThiesKlima

Source: ThiesKlima

Measuring range 0 ... 360 °Ambient conditions -50 ... +80°CElectrical output Potentiometer 10 k,

Voltage, Current

Measuring range 0,3...75 m/sAmbient conditions -50…+80 °CElectrical output Frequency, Voltage,

CurrentFrequency 1082 Hz @ 50 m/s

Meteorological sensors (Humidity, pressure & temperature)

- Capacitive humidity element - barometric ambient pressure - Pt 100 resistance thermometer- Integration in weather- and thermal

radiation shield

- Specifications:Temperature: - 30 ... + 70°CHumidity: 0 ... 100%Analogue outputs: RS485

ResistanceVoltageCurrent

17

Source: ThiesKlima

Source: Endress & Hauser

Meteorological sensors (Rain)

- Measuring the height, quantity and the intensity of the precipitation (rain)

- collecting surface - tipping-bucket- induces an output pulse

Specification:

18

Source: ThiesKlima

Collector surface 200 cm² Resolution 0,1 mmMeasuring range max. 11 mm/min. Measuring principle tipping-bucketElectrical output pulsesAmbient temperature -35... +60°C with additional

heatingHeating 24 V AC/DC

Mass flow control

- Sensor types:- Ultrasonic- Differential pressure- Magnetic- Inductive- Turbine- Thermal- Venturi- Sinker method- And many more…

- Actor types:- Valve with controller (Prop.)

19

Source: Bronkhorst & Mättig

Source: Analyt MTC

Source: MKS Instruments

- Depending on function, force or exactness

- Motor types:- Asynchronus / Synchronus- 3-phase / 1-phase- Stepping- DC- Servo- Linear / Rotary

- Control possibilities:- On/Off => Relay- Speed control =>Controller- Torque control => Controller

Motors & Control

20

Source: Sito

Source: Direct industry

Source: Festo

Source: Lenze

Source: Conrad

Network

- Connecting hardware on different places without losses

- Reducing cable installation- Different networks

- Star- Bus- Ring- Tree- Mesh

- Different protocols

21

SourceWikipedia

Software (PLC programming-Code)

- Software special from every hardware company

- Industrial standard- WinCC

- Possibilities for visualization- SimaticManager

- Hardware configuration- Program code- Binary functions- Counter functions- Time functions- Analogue functions- Simple mathematical functions

22

Source: Siemens

Software (Dasylab)

- Easy connection to hardware- Frontpanel for visualization- Blockdiagram for program code- Simple mathematic functions- Simple data storage- Simple visualization=> Usable for:

students,non software-experiencescientists

23

Source: Dasylab

Software (Labview)

- Easy connection to hardware & software

- Frontpanel for visualization- Blockdiagram for program code- Complex mathematical functions- Control & Design (PID & Fuzzy)- Camera programming (Vision)- Touchpanel & PDA visualization (HMI)- Matlab integration & Simulation- Server communication- Complex data storage & analysis

=> Best solution für R&D

24

Source: National Instruments

Software (OPC Server)

- Open Process Control- Based on Microsoft Windows

technology- Acts as easy protocol converter- Hardware manufacturer specific- Read and write function- Connection to

- Device e.g. PLC, DAQ- Database e.g. Excel, Access- HMI (Human Machine

Interface, e.g. Touchpanel)- Spreadsheet- Trending application

25

Source: Servicelab

26

Thermocamera-system

- Measuring surface temperature- Temperature distribution easy possible- Installation outside the concentrated

solar radiation- Reactors with quartz window problem- Error caused by the reflected solar

radiation & window- DLR-development: measuring with

spectral filters- Usage of water-absorption-band to

reduce the influences (λ=2,6 μm)Source: DLR, Hydrosol 2 project

27

Flux measurement- Indirect measuring- Camera target method- White Lambert‘ian target- Rotation through the focus- Shot of 15 single pictures- Construction of one complete

picture- Building of greyscale matrix- Calibration with radiometer- Calculation of flux density

distribution- Error ≤ ±5 %- Other systems: Fatmes, Barmes,

Scanmes, SunCatch, etc.

ProHeRMeS

0 500 1000 1500 2000 2500 30000

50

100

150

200

250

300

350

Flussdichte Linearer Fit Flussdichte

Sol

are

Flus

sdic

hte

in k

W/m

2

Grauwerte

y=0,11819x

Source: Montereal et al

28

Deflektometry

- Measure the shape of mirrors- Pattern reflexion method- Projektor in heliostat field- Camera on top of the tower- Sinus stripes with phase shift- Measurement

- Horizontal- Vertical

- Deformation of the lines- Algorithm for the calculation of

geometry & error of shape- Error <1 mrad- Parabolic trough, dish concentrator or

Fresnel collector

Projektor

KameraKamera

Heliostat

Target

Turm

i

n

r

i

n

r

i

n

r

i

n

r

Source: Ulmer et al

29

Thanks for your attention!Jan.saeck@dlr.de