Solar PV Assembly Process Flow

SOLAR PV ASSEMBLY PROCESS FLOWManufacturing processes of conventional PV module

Author I Made Wiratha N. (PV Technologist)

SOLAR PANEL ANATOMY Front & Rear

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Solar Cell

Ribbon

Frame

Locking Mechanism

Mounting Hole + Ground Backsheet

Junction Box/Electrical Contact Point

Cable

3

SOLAR PANEL ANATOMY Module Sandwich

Aluminum Frame

String Ribbon

Bus Bars

SOLAR PANEL ANATOMY Structure

Stringing Process

Lay Up Process

• Panel dimension: 1650mm x 992mm• Cell count per panel: 60 cells (6 x 10)• Output: 4.23 watt/cell• Panel overall output: 250 watt

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SOLAR PANEL Technical Spec

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PROCESS FLOW

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PROCESS FLOW Glass Preparation

Tempered Glass Stack

Glass Loading Conveyor

Bidirectional Conveyor

Manual Loading

Upper EVA Lay Up

The cleaning agent is H2O and it has vapor chamber to dry the

clean glass.

If glass washing machine is out of

action, we proceed with plan B, manual

indeed .

Ethylene-Vinyl Acetate (EVA)

Stack)

This is the second layer after glass. We

put EVA on top of clean glass

Glass Washing Machine(55-90 glass/hour)

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X-Cell Stringer MachineCell

MagaineLoading

Glass Queue Conveyor & String Lay Up

Operator load the magazine with cells, the X2P machine integrate the cell into string using soldered ribbon (10

cells per string).

The GL30 lay-up robot then picks the string, measure and lay them up onto the

queued glass + EVA 1.

Ribbons on each string is connected together using bus bar forming solar module

Ethylene-Vinyl Acetate (EVA)

Stack

Robotic Lay-Up

Machine

3 Bussing Station (<2.5 minutes/panel)

Backsheet Stack

Glass queue

Five layers: Glass, EVA, Cells, EVA,

Backsheet

PROCESS FLOW Stringing Cells

Centering Station

Stringer is the most complicated machine and has a lot of parts. Stringer peak throughput is 1400 cells/hour, and it average

1200 cells/hour

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Diffluence Conveyor

Reject Defect Module

Rotating Station


PROCESS FLOW Electroluminescence Test

Computer for EL Test

EL Test for any defect such as chipping, cracks, micro

cracks and bad interconnection.

If some module messed up in the chamber, then the

panel will be kicked out from the race. The defected

module will go to rework station.

Electroluminescence Test Chamber

Then the line is split into two

thread for faster

process

LAMINATOR 1

LAMINATOR 2

If electrical current flowing through the circuit, the cell will go reverse bias mode

and emit near-infrared wave then camera with special

filter will capture the image.

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Loader to Laminator


Unloader to Laminator



LAMINATOR 2

The module will be encapsulated under near-vacuum condition at certain

temperature. All the layers will be fused together and form solid panel which can withstand over 25 years of weathering.

LAMINATOR 1

LINE 1

LINE 2

Three important parameters: Temp, Pressure, Time (T-P-t).

Fine tuned this parameter will maximize the module quality. this The maximum capacity of laminator is 12 panels/hour.

PROCESS FLOW Lamination

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Visual Inspection Bidirectional Conveyor

Reject Defect Module

In this station, visual inspection is conducted by

QA/QC team before the panel encapsulated in metal frame

at the framing station.

Rotate & Trimming

After lamination there are excess of material on the panel’s edges need to be remove by manual

cutting using special knife.

Visual Inspection

If defect or imperfection is spotted, the panel will go to the

reject tray. It is up to the QA engineer to determine whether

the panel will be ditch or still usable with special

circumstances

Visual Inspection means “eyeballing” the panel. QA/QC team will decide if defected panel will be

passed or not

PROCESS FLOW Trimming & Visual Inspection

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Framing Junction Box Assembly

Glue Dispenser for Frame

Silicon glue is added to the frame before it attached to

the panelGlue

Dispenser for J-Box

Pre-FramingFraming Cleaning & Corner

Chamfering

CURING

The duration of curing process is about 6

hours. This is intended to make sure that every

glue is firmly stick

Junction Box Assembly

The module and the frame pressed by hydraulic

cylinder to guarantee the perfect rectangle shape of

the module

PROCESS FLOW Framing & J-Box AssemblyInside J-Box there are several diodes to by-pass dead string

prevent the module from total shut down.

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Cleaning Conveyor

Insulation & Hi-Voltage Test

I-V Characteristics Test/Sun Simulator

Electroluminescence Test 2 Chamber

Computer for I-V Test

Computer for EL Test

Before module get tested, its surface must

be clean out. The cleaning agent for this

process is Isopropyl Alcohol (IPA).

This test is intended to check the

isolation, conductor, build and assembly quality of the panel.

Current & Voltage output

characteristic will be tested on this station using sun

simulator

Sun simulator is calibrated so that the

irradiance of the flash is analogous to the Sun

which is 1000 watt/m2

Sun Simulator

Charge Source

PROCESS FLOW Final Product Test

Hi-Pot Test is technically application of high voltage to stress the

insulation beyond what it will encounter during normal operation.

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Cartesian Robot Sorting

FINISH GOODLabelling

After several test, solar module is given their output parameter based on previous measurement such as I-V characteristic and power rated.

Centering Station

Cartesian robot sorting distributes the finish good to the proper

position and awaits for the packaging and

shipping.

PROCESS FLOW Goods ManagementSorter machine classifies modules into different bins such as grade A,

B, C based on the test data and module grading agreement.

Thank You

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Email: [email protected]: +62 856 9213 7616

Engineering

Solar PV Assembly Process Flow