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The CSIR assumed its role as host of South Africa’s Centre for the Fourth Industrial Revolution (C4IR South Africa) in 2021.
Solar Photovoltaic (PV) Quality and Reliability Testing Facility
The CSIR photovoltaic module quality and reliability lab
The CSIR’s photovoltaic (PV) module quality and reliability testing laboratory – a first of its kind for Africa – includes world-class equipment for localising accelerated reliability stress testing on PV modules. This ensures that only high-quality modules that are suitable to the unique South African climate are developed and installed.
The CSIR’s accelerated stress tests provide quantitative metrics for evaluating the performance and reliability of solar PV modules over time. “The tests accelerate the failures in poorly constructed modules that can otherwise take years to occur naturally in the field, thereby helping to ensure reliable solar PV plant performance. Like a referee on the field, the lab tests ensure that the suppliers play fair and provide only high-quality and reliable modules”, says CSIR solar PV expert, Lawrence Pratt.
The environmental and mechanical stress testing forms the foundation for the pre-qualification of new concepts, certification of new PV modules and reliability testing of existing PV technology. “We have the equipment, experience and expertise to conduct testing on most of the common PV technologies, including crystalline, thin film, high capacitance and bifacial modules,” explains Pratt.
The PV module quality and reliability testing services are designed around specialised equipment for PV module extended reliability. The specialised equipment includes environmental chambers to simulate the real-world environmental conditions listed below:
- Thermal cycling of modules from -40 C to 85 C for 200, 400, and 600 cycles to simulate stress from thermal expansion and contraction.
- Humidity freeze testing: 85 C / 85% RH for 20 hours and a -40 C freeze for 10, 20, and 30 cycles to stress the lamination and adhesion strength of the PV module.
- Damp heat testing: 85 C / 85% RH for 1 000 hours, 2 000 hours, with and without electrical bias to stress the adhesion and insulation of the PV module.
- Mechanical load testing: static and dynamic load for simulating transportation, installation, and wind loads that may lead to broken cells and weakened interconnections.
The lab also operates specialised characterisation equipment to measure the electrical performance and safety aspects of the PV module. Pratt points out that the sun simulator outputs an equivalent dose of energy nearly identical to the sun’s energy and spectrum, but only for a fraction of a second. “This is just enough time to accurately and precisely record the current, voltage and power output of the PV module across various temperatures (15 °C and 75 °C) and light intensities (200 W/m2 to 1100 W/m2)”, he says.
The sun simulator is used to compare the output of the PV module as measured at the factory against an independent standard. The sun simulator is also critical to quantify the impact of the accelerated stress tests described above. Finally, the high potential electrical tester helps to identify failures in the insulation resulting from accelerated stresses. Failures in electrical insulation indicate a potential risk to the safe and reliable performance of PV modules over time.
The PV team at the CSIR also offers outdoor test services for module-level performance testing, soiling studies, degradation studies and small-scale string inverter system testing in a real-world environment.
Related Information
Fact sheet
Infographic
Article
The CSIR photovoltaic module quality and reliability lab
The CSIR’s photovoltaic (PV) module quality and reliability testing laboratory – a first of its kind for Africa – includes world-class equipment for localising accelerated reliability stress testing on PV modules. This ensures that only high-quality modules that are suitable to the unique South African climate are developed and installed.
The CSIR’s accelerated stress tests provide quantitative metrics for evaluating the performance and reliability of solar PV modules over time. “The tests accelerate the failures in poorly constructed modules that can otherwise take years to occur naturally in the field, thereby helping to ensure reliable solar PV plant performance. Like a referee on the field, the lab tests ensure that the suppliers play fair and provide only high-quality and reliable modules”, says CSIR solar PV expert, Lawrence Pratt.
The environmental and mechanical stress testing forms the foundation for the pre-qualification of new concepts, certification of new PV modules and reliability testing of existing PV technology. “We have the equipment, experience and expertise to conduct testing on most of the common PV technologies, including crystalline, thin film, high capacitance and bifacial modules,” explains Pratt.
The PV module quality and reliability testing services are designed around specialised equipment for PV module extended reliability. The specialised equipment includes environmental chambers to simulate the real-world environmental conditions listed below:
- Thermal cycling of modules from -40 C to 85 C for 200, 400, and 600 cycles to simulate stress from thermal expansion and contraction.
- Humidity freeze testing: 85 C / 85% RH for 20 hours and a -40 C freeze for 10, 20, and 30 cycles to stress the lamination and adhesion strength of the PV module.
- Damp heat testing: 85 C / 85% RH for 1 000 hours, 2 000 hours, with and without electrical bias to stress the adhesion and insulation of the PV module.
- Mechanical load testing: static and dynamic load for simulating transportation, installation, and wind loads that may lead to broken cells and weakened interconnections.
The lab also operates specialised characterisation equipment to measure the electrical performance and safety aspects of the PV module. Pratt points out that the sun simulator outputs an equivalent dose of energy nearly identical to the sun’s energy and spectrum, but only for a fraction of a second. “This is just enough time to accurately and precisely record the current, voltage and power output of the PV module across various temperatures (15 °C and 75 °C) and light intensities (200 W/m2 to 1100 W/m2)”, he says.
The sun simulator is used to compare the output of the PV module as measured at the factory against an independent standard. The sun simulator is also critical to quantify the impact of the accelerated stress tests described above. Finally, the high potential electrical tester helps to identify failures in the insulation resulting from accelerated stresses. Failures in electrical insulation indicate a potential risk to the safe and reliable performance of PV modules over time.
The PV team at the CSIR also offers outdoor test services for module-level performance testing, soiling studies, degradation studies and small-scale string inverter system testing in a real-world environment.
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Expert profiling
Lawrence has 15 years of experience related to solar PV, including yield impacts of the raw materials on cell efficiency; research and development of emitter wrap-through solar cells; manufacture and certification of next-generation solar PV modules; and the design and installation of residential PV systems in the United States of America.
Testimonial
FAQ
FAQ: CSIR PV testing facility
What are the quality risks related to solar PV panels?
It is often found that the module power is lower than advertised. Modules also run the risk of degrading faster than expected and may not have adequate insulation for safe operation.
Other quality risks relate to microcracks in the solar cells and delaminated backsheets that may lead to increased power degradation, compromising safety.
What are the common failures that occur in PV panels?
- Micro cracks in solar cells
- Backsheet delamination
- Encapsulant discoloration
- Moisture ingress through the backsheet
- Safety failures due to insufficient insulation and sealing
- Bypass diode failures
Are locally manufactured PV panels of higher quality than imports?
The CSIR has tested a batch of modules from a domestic supplier and the quality and reliability was similar to three other batches of imported modules tested simultaneously.
Which manufacturers have high-quality PV panels?
This is difficult to answer as the module quality and reliability varies from one batch to the next. As consumers, we know that consistent quality can be a problem, even with day-to-day purchases. This is why the CSIR recommends testing modules from a specific production run when developing large-scale PV installation or procuring large shipments of PV modules for retail distribution.
How does the CSIR test the reliability and quality of PV panels?
The CSIR designed and built an indoor quality and reliability lab for PV modules to provide local services based on international best practices. The lab produces quantitative performance and safety test results to score the quality of the PV modules as delivered from the factory across a broad range of metrics. The modules are then subjected to accelerated environmental stress tests that are designed to test the reliability of PV modules over years in the field, based on test sequences ranging from a few weeks to a few months.
Ventilators
CSIR L.I.F.E. - Acting swiftly to touch lives through innovation
The digital design and production of a local ventilator to support the national response to the Covid-19 pandemic took place in under 3 months, and saw the CSIR take the lead in this collaborative effort to swiftly touch lives through innovation.
Under the auspices of the Department of Trade, Industry and Competition (the dtic), the CSIR worked closely with a number of local partners to develop the Continuous Positive Airway Pressure (CPAP) device that uses an innovative design to provide a mild level of oxygenated air pressure to keep the airways open and, thus, assist with breathing. Through this project, a total of 18 000 ventilators were produced supplying oxygen to Covid-19 patients showing respiratory distress.
Under the project name, ‘CSIR L.I.F.E.’ (Lung Inspiratory Flow Enabler), the innovative system uses standard, hospital-grade oxygen supply, and features easy-to-use, on-device flow gages to adjust Fraction of Inspired Oxygen in steps of 10% oxygenation.
The development forms part of government’s National Ventilator Project (NVP), and is supported by the Solidarity Fund. “While ensuring that we achieve this in a short period of time, we had to ensure that we follow a rigorous, documented product lifecycle methodology that would ensure scalable manufacturing, as well as compliance and licensing under the South African Health Products Regulatory Authority (SAHPRA) and guidelines of the World Health Organization,” says Ajith Gopal, Executive Manager of CSIR Future Production: Manufacturing.
Related Information
Fact sheet
Article
CSIR L.I.F.E. - Acting swiftly to touch lives through innovation
The digital design and production of a local ventilator to support the national response to the Covid-19 pandemic took place in under 3 months, and saw the CSIR take the lead in this collaborative effort to swiftly touch lives through innovation.
Under the auspices of the Department of Trade, Industry and Competition (the dtic), the CSIR worked closely with a number of local partners to develop the Continuous Positive Airway Pressure (CPAP) device that uses an innovative design to provide a mild level of oxygenated air pressure to keep the airways open and, thus, assist with breathing. Through this project, a total of 18 000 ventilators were produced supplying oxygen to Covid-19 patients showing respiratory distress.
Under the project name, ‘CSIR L.I.F.E.’ (Lung Inspiratory Flow Enabler), the innovative system uses standard, hospital-grade oxygen supply, and features easy-to-use, on-device flow gages to adjust Fraction of Inspired Oxygen in steps of 10% oxygenation.
The development forms part of government’s National Ventilator Project (NVP), and is supported by the Solidarity Fund. “While ensuring that we achieve this in a short period of time, we had to ensure that we follow a rigorous, documented product lifecycle methodology that would ensure scalable manufacturing, as well as compliance and licensing under the South African Health Products Regulatory Authority (SAHPRA) and guidelines of the World Health Organization,” says Ajith Gopal, Executive Manager of CSIR Future Production: Manufacturing.
The device was wholly designed and produced in South Africa by the CSIR and local manufacturing and industry partners such as Siemens, Simera, Akacia, Gabler, Umoya and the University of Cape Town (UCT), with others soon to join.
Siemens provided the necessary software support for the product lifecycle management, as well as software to facilitate rapid production scaling. “This way, we remain true to the role of the CSIR – which is to perform research, development and innovation that is cutting edge and fosters industrial development,” Gopal explains.
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Expert profiling
Bosscha leads the industrial robotics research group, where the focus is on product development and conducting research in the fields of industrial robotics and industrial automation, developing new algorithms for robot control, perception, application of machine learning techniques, as well as planning and developing robotic systems for industrial purposes.
Coetzee leads the future production systems research group and has a keen interest in digital transformation for various applications. Currently, the group is focusing on investigating how emerging 4IR technologies and digital platforms can advance manufacturing and provide a competitive advantage for industry. The future production systems group is also driving the Learning Factory, Smart Factory, Blockchain and Plant Simulation platforms to support the local industry.
Testimonial
FAQ
Q: Where does one get hold of ventilators and replacement patient circuits?
A: Ventilators and patient circuits have been donated to both public and private hospitals. Hospitals can contact the National Department of Health for distribution of more ventilators and patient circuits.
Q: Does the CSIR offer any help, support and/or training on the use of the ventilators?
A: Manuals are supplied with each CSIR LIFE Ventilator.
The CSIR contracted QualiHealth to provide support to hospitals. For any queries, please call the following numbers:
- Medical Queries: 071 194 4129
- Technical Queries: 071 585 2120
WhatsApp:
We have tried to make information easily accessible.
By sending “Hi” to 071 585 2120 via WhatsApp, you will receive access to:
- Manuals
- Training Videos
- Patient Leaflets
Q: What were the minimum requirements for ventilators?
A: The minimum requirements were:
- Full time supervision by qualified healthcare professional; and
- Oxygen supply up to 400kPa.
Q: How can the CSIR support medical device manufacturers?
A: The CSIR has the capabilities, experience and expertise to support the industry in various ways:
- New product development;
- Regulatory compliance and support;
- Production design and manufacturing support;
- Plant optimisation;
- Advanced materials development; and
- Product design and concept development.
Q: What are the CSIR’s plans for the ventilators?
A: We are in the process of commercialising the ventilator; and interested parties can contact the CSIR for more information.
The CSIR thermal laboratory
The water and health microbiology research facility is key for research on the presence of microorganisms in water and how they impact human health.
The CSIR provides capability development and management decision support for clients in the safety and security cluster.
Secure Identity Framework
CSIR engineers a secure identity framework towards the development of the SMART ID card in South Africa
Responding to its objective to conduct research, development and innovation that supports the development of a capable state, the CSIR collaborated with the Department of Home Affairs to design and develop a secure identity framework that enabled the department to issue South Africans with a new Smart ID card embedded with security features aimed at significantly reducing potential forgery.
“This innovation is characterised by a multiapplication contactless card that securely stores the biographic and biometric data of the applicant during the personalisation and printing of the card,” explains CSIR information security expert, Samuel Lefophane. The secure identity framework enables identification, verification and authentication for e-government and e-commerce services, thus allowing the transition of government services from manual to digital.
The Smart ID card was adopted to reduce fraudulent activities that were prevalent in the era of the green ID book. Its development also presented benefits for both the public and private sectors, as they are now able to conduct identity verification for their customers employing improved and more reliable processes. The functionalities that are embedded in the Smart ID card are aligned with international standards, taking into consideration the unique needs of South Africa.
Some of the institutions that are likely to benefit from this CSIR technology within the private and public sectors are the Department of Health, Department of Community Safety, the South African Social Security Agency, the Traffic Department, Statistics South Africa, the Independent Electoral Commission, banks, insurance companies and many more.
Related Information
Fact sheet
Infographic
Article
CSIR engineers a secure identity framework towards the development of the SMART ID card in South Africa
Responding to its objective to conduct research, development and innovation that supports the development of a capable state, the CSIR collaborated with the Department of Home Affairs to design and develop a secure identity framework that enabled the department to issue South Africans with a new Smart ID card embedded with security features aimed at significantly reducing potential forgery.
“This innovation is characterised by a multiapplication contactless card that securely stores the biographic and biometric data of the applicant during the personalisation and printing of the card,” explains CSIR information security expert, Samuel Lefophane. The secure identity framework enables identification, verification and authentication for e-government and e-commerce services, thus allowing the transition of government services from manual to digital.
The Smart ID card was adopted to reduce fraudulent activities that were prevalent in the era of the green ID book. Its development also presented benefits for both the public and private sectors, as they are now able to conduct identity verification for their customers employing improved and more reliable processes. The functionalities that are embedded in the Smart ID card are aligned with international standards, taking into consideration the unique needs of South Africa.
Some of the institutions that are likely to benefit from this CSIR technology within the private and public sectors are the Department of Health, Department of Community Safety, the South African Social Security Agency, the Traffic Department, Statistics South Africa, the Independent Electoral Commission, banks, insurance companies and many more.
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Expert profiling
Lefophane’s research interest and expertise are in identity authentication, with a special focus on automatic identification and data capture technologies, embedded systems, Internet of Things and sensor node development.
Testimonial
FAQ
Q: What other areas of the public and private sectors can benefit from the CSIR’s secure identity framework to enhance service delivery to South Africans?
A: From a public services delivery perspective, the Department of Transport, specifically the licensing department can benefit from the features offered by the Smart ID. The Independent Electoral Commission, Department of Health and the Retail Sector would also benefit from incorporating this framework into their systems to allow for seamless identification of individuals, linking their various data.
Q: Does the CSIR plan to collaborate with Department of Home Affairs to develop a Smart Passport in order create a more capable boarder control system?
A: The CSIR supports government and industry in responding to digital identity challenges, cyber threats and risks.
Q: Aside from the banking sector, in which ways can other financial institutions leverage off this technology to upgrade digital security in their operations?
A: By employing an improved and secure identity process, various financial institutions (e.g., Insurance companies) can conduct reliable identity verification and authentication for their customers.
Q: Is this framework suitable for the digital communication industry and compatible with mobile cell phones, tablets and other gadgets?
A: Yes, the CSIR supports collaboration where research and innovation of home-grown identity management; cyber and information security solutions and approaches to securely identify, protect people and systems against vulnerabilities, threats and risks is realised. The communication industry can certainly benefit from this capability.
SARS-COV-2 diagnostic PCR test kit
CSIR and CapeBio lead development of local SARS-COV-2 diagnostic PCR test kit
An overburdened demand, coupled with a worldwide shortage of rapid Covid-19 test kits, prompted the CSIR and CapeBio to demonstrate their expertise in biomanufacturing as a solution to provide the country, and the region, with a locally developed PCR test kit for Covid-19.
In early 2020, the CSIR, in collaboration with CapeBio, demonstrated the efficiency of the biomanufacturing process for two enzymes, which were combined to formulate a locally produced one-step Covid-19 diagnostic assay.
The diagnostic assay has been validated in a clinical setting and proven to have the capability to detect coronavirus 2 (SARS CoV-2)-specific genetic biomarkers. Furthermore, the single-step format of the diagnostic assay reduces the turnaround time of tests and assists in managing and monitoring the spread of SARS CoV-2.
Additionally, external evaluation by the National Health Laboratory Service was passed, and the South African Health Products Regulatory Authority subsequently licensed Cape Bio to manufacture the diagnostic kit at their facility in Centurion.
This significant milestone, which took place in under a year, resulted in the kit hitting the local market in August 2021. According to CapeBio CEO, Daniel Ndima, at full operational capacity, the company is able to produce up to 5 000 kits a day, with each kit providing 1 000 tests.
This is a clear demonstration that the CSIR, through its industrialisation strategy and commitment to assisting new and emerging small, medium and micro enterprises, is touching lives through innovative biomanufacturing processes.
The research and development funded by the South African Medical Research Council and the Technology Innovation Agency enables a faster response in terms of active case identification, quarantine and contact tracing. Additionally, the localisation of the production of these reagents continues to increase accessibility to locally produced diagnostic kits – a very significant milestone that will reduce the country’s reliance on international suppliers.
Related Information
Fact sheet
Infographic
Article
CSIR and CapeBio lead development of local SAR-COV-2 diagnostic PCR test kit
An overburdened demand, coupled with a worldwide shortage of rapid Covid-19 test kits, prompted the CSIR and CapeBio to demonstrate their expertise in biomanufacturing as a solution to provide the country, and the region, with a locally developed PCR test kit for Covid-19.
In early 2020, the CSIR, in collaboration with CapeBio, demonstrated the efficiency of the biomanufacturing process for two enzymes, which were combined to formulate a locally produced one-step Covid-19 diagnostic assay.
The diagnostic assay has been validated in a clinical setting and proven to have the capability to detect coronavirus 2 (SARS CoV-2)-specific genetic biomarkers. Furthermore, the single-step format of the diagnostic assay reduces the turnaround time of tests and assists in managing and monitoring the spread of SARS CoV-2.
Additionally, external evaluation by the National Health Laboratory Service was passed, and the South African Health Products Regulatory Authority subsequently licensed Cape Bio to manufacture the diagnostic kit at their facility in Centurion.
This significant milestone, which took place in under a year, resulted in the kit hitting the local market in August 2021. According to CapeBio CEO, Daniel Ndima, at full operational capacity, the company is able to produce up to 5 000 kits a day, with each kit providing 1 000 tests.
This is a clear demonstration that the CSIR, through its industrialisation strategy and commitment to assisting new and emerging small, medium and micro enterprises, is touching lives through innovative biomanufacturing processes.
The research and development funded by the South African Medical Research Council and the Technology Innovation Agency enables a faster response in terms of active case identification, quarantine and contact tracing. Additionally, the localisation of the production of these reagents continues to increase accessibility to locally produced diagnostic kits – a very significant milestone that will reduce the country’s reliance on international suppliers.
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Expert profiling
Kwezi’s main research interests are in the combined fields of applied biochemistry and enzymology, structural biology and in recombinant production of enzymes for industrial applications, including reagent enzymes for use as molecular biology tools. Kwezi’s research interests also include the production of vaccines, antibodies and biosimilars through the use of plant-based expression systems.
Testimonial
FAQ
Q. How does the CSIR protect intellectual property (IP) in a collaborative project or partnership?
A. The CSIR is guided by the Intellectual Property Rights (IPR) from Publicly Financed Research and Development Act, 2008 (Act 51 of 2008).
A private entity or organisation can co-own IP that falls under the IPR Act if there has been a contribution of resources by the private entity or organisation, and:
- It includes background IP;
- There is joint IP creatorship;
- Appropriate arrangements are made for benefit-sharing with IP creators at the institution; and
- An agreement for commercialisation of the IP is concluded.
Note that all four of these requirements must be met.
Q. What support structures are available at the CSIR for entities that or individuals who want to collaborate on projects?
A. The CSIR offers technical incubation through its industry-facing facilities, which provide small, medium and micro enterprises and industry partners with access to specialised facilities and skills as part of the Industry Innovation Partnership Fund, supported by the Department of Science and Innovation. A request for participation call is usually sent out on a periodic basis and successful applicants have access to large-scale prototyping and pre-commercial manufacturing infrastructure, equipment, expertise and access to business and technical networks.
Research, development and innovation activities range from laboratory-scale validation to technology prototyping and pilot manufacture. For more information on various industry-facing programmes at the CSIR, visit the following link: Industry Innovation Support | CSIR
Q. What process does the CSIR follow if an individual or potential industry partner wants to express interest in obtaining a licence for a technology developed by the CSIR?
A. A company that or entrepreneur who is interested in licensing a CSIR technology should contact the CSIR Business Development and Commercialisation Office or the relevant commercialisation manager in the business cluster of interest. Contact details can be found here.
The potential licensee will then be provided with information about the technology, where necessary, under a non-disclosure agreement. The potential licensee will then be required to submit a business plan outlining the commercialisation strategy and the company’s resources to accomplish that plan. Once it has been established that a licensing agreement could be mutually beneficial to the parties, licence negotiations will begin in earnest – the first milestone being a non-binding term sheet.
A further evaluation period may be required by one or both parties. This includes due diligence of the potential licensee by the CSIR and evaluation of the technology by the potential licensee for a set period to determine its viability and value to the company.
The CSIR may charge a fee for granting the company the right to exercise its option to license the technology after expiry of the option period.
Q. What was the biggest hurdle in fast-tracking the Covid-19 diagnostic kits project?
A. Rapidly developing and demonstrating a manufacturing process, including the formulation of reagents in a format that meets the standards of a medical device is a challenging task. The major hurdles were the short timeframe within which the kit had to be delivered; and importing critical raw materials in the middle of a global pandemic, which saw imports and exports negatively impacted. This was further exacerbated by the restrictions that were in place.
Q. What does the South African Health Products Regulatory Authority certification mean for CapeBio?
A. The licence granted to CapeBio gives the company permission to manufacture the kit as a medical device in its facility.
The CSIR’s cybersecurity systems research group provides operational effectiveness on a national and organisational level through the operalisation of cybersecurity centric solutions and capabiliti