Getting every watt off the array
The team was budgeting array power from cell datasheets, which ignores everything that happens between a bare cell and an encapsulated module on a moving vehicle.
- Characterise Maxeon Gen III cells by outdoor four-wire IV sweep on a Keithley 2461, and analyse 3×6 modules for mismatch loss to inform cell binning and array layout.
- Lead infrared and electroluminescence inspection to find hotspots, cracks and interconnect faults; piloted a new encapsulation method for durability and water-ingress resistance.
- Build Python tools modelling bypass-diode configurations and temperature-driven efficiency loss, to inform thermal and cooling design for the next-generation array.