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Concentrating Photovoltaic (CPV) modules are getting thinner and using smaller cells now days. Correspondingly, large area intensive lens arrays with smaller unit dimension and shorter focal length are wanted. However, the size and power center of lens array focal spots usually differ from the design value and are hard to measure, especially under large area situation. It is because the machining error and deformation of material of the lens array are hard to simulate in the optical design process. Thus the alignment error between solar cells and focal spots in the module assembly process will be hard to control. Under this kind of situation, the efficiency of CPV module with thinner body and smaller cells is much lower than expected. In this paper, a design of large area lens array focal spots automatic measurement system is presented, as well as its prototype application results. In this system, a four-channel parallel light path and its corresponding image capture and process modules are designed. These modules can simulate focal spots under sunlight and have the spots image captured and processed using charge coupled devices and certain gray level algorithm. Thus the important information of focal spots such as spot size and location will be exported. Motion control module based on grating scale signal and interval measurement method are also employed in this system in order to get test results with high speed and high precision on large area lens array no less than 1m×0.8m. The repeatability of the system prototype measurement is ±10μm with a velocity of 90 spot/min. Compared to the original module assembled using coordinates from optical design, modules assembled using data exported from the prototype is 18% higher in output power, reaching a conversion efficiency of over 31%. This system and its design can be used in the focal spot measurement of planoconvex lens array and Fresnel lens array, as well as other kinds of large area lens array application with small focal spots.
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