【 Collection Learning 】 Brief Introduction to the Production Process of Photovoltaic Modules

The production process of photovoltaic modules mainly includes:

Cell sorting - laser scribing - single welding - string welding - stacking - appearance and EL inspection - lamination - trimming - appearance inspection - framing - junction box installation - curing - cleaning - IV testing - insulation withstand voltage testing - final EL testing - packaging.

   The component equipment corresponds to the various process flows of component preparation, and the main equipment includes laser cutting machines, string welding machines, automatic stacking equipment, laminating machines, and automatic assembly lines. In terms of specific steps, the equipment required for the welding process includes laser cutting machines, busbar welding machines, and battery cell string welding machines; The equipment required for the stacking process is a template machine; The laminating process requires a laminating machine; The EL testing process requires an EL tester; The equipment required for the framing process is an automatic framing machine; The installation of junction boxes requires a junction box welding machine; The equipment required for the cleaning process is a component flipping unit; The equipment used in the IV testing phase is the IV curve tester; The equipment required for the finished product inspection process is a flip inspection unit; The packaging process requires a packaging production line. In addition to the above-mentioned single equipment, equipment manufacturers can also provide component automation equipment production lines, covering various links and achieving turnkey projects.

    Cell sorting:

    The price adjustment for producing battery cells is random, so it is necessary to select and combine battery cells with consistent or similar

performance before producing components; Workers will test the output parameters (current, voltage) of battery cells and classify them;

    Laser scribing:

    This step is only required for battery cells that need to be sliced, not for the entire battery panel. After the emergence of "Half cut Technology"

and its own advantages, major manufacturers have adopted this technology for the production of photovoltaic modules, using ultraviolet lasers

to cut the entire solar cell in half. Our Zhongbu Qingtian adopts high-speed non-destructive cutting technology, which can reduce damage to

the surface coating of battery cells.

    Series welding of battery cells:

    Using high-speed string welding machine to string weld battery cells

    Layer up:

    Arrange the component strings in order, and then lay other auxiliary materials such as glass, cut EVA, and backboard in a certain layer to

prepare for the next lamination. (Laying hierarchy: from bottom to top: glass, EVA, battery, EVA, backplate). When laying, ensure the relative

position between the battery string and materials such as glass, adjust the distance between the batteries, and lay a foundation for lamination.

    Appearance and EL inspection:

    EL=Electroluminescent， That is to say, electroluminescence is used to detect internal defects in solar cells (silicon wafers) and components.

The EL detection after lamination and before lamination is to detect all semi-finished solar panels. If any problems are found, we can simply

replace the damaged solar cells before laminating. In addition, appearance inspection is also very important, as it determines our customers' first

impression after receiving the panel.

    Laminated:

    Place the pre laid component strings, glass, EVA, and backplate into a laminating machine, evacuate the air inside the components by

vacuuming, and then heat to melt the EVA, bonding the battery, glass, and backplate together; Finally, cool down and remove the components.

This is a crucial step in component production, and the lamination temperature and time are determined by the properties of EVA.

    Trimming Deburring:

    During the lamination process, EVA will have fluidity when heated, and will extend outward under pressure to form burrs. After coming out of

the laminating machine, it needs to be trimmed.

    Appearance inspection:

    Workers will carefully inspect the details of each string of solar cells to ensure a perfect appearance after lamination.

    Framing:

    The commonly used frame is aluminum alloy. The main purpose of framing is to increase the strength of components. In addition, framing

can also seal electrical components and extend their lifespan. The gap between the frame and the glass is filled with silicone resin.

    Installing junction box:

    Stick a box at the back lead of the component to facilitate the connection between the battery and other devices or batteries. And glue the

junction box to ensure it is waterproof and dustproof.

    Solidification:

    There will be a dedicated curing room for this step of curing. After staying in this room for 4 hours, our solar panel specific silicone has

basically solidified.

    Cleaning:

    Workers will clean the surface of the solar panel of EVA residue and remove the protective film on the aluminum frame.

    IV Test IV Test:

    The purpose of testing is to calibrate the output power of the battery, test its output characteristics, and determine the quality level of the

component.

    Voltage resistance and insulation test:

    This test refers to applying a certain voltage between the component frame and the electrode leads, with the aim of testing the withstand

voltage and insulation strength to ensure that the component is not damaged under harsh natural conditions (such as lightning strikes).

    Final EL Test:

    This is the same as the previous EL test.

    Affix the nameplate/label:

    The nameplate indicates product parameters and so on. Now we have launched a photovoltaic module frame marking machine, which has no

loss, anti-counterfeiting traceability, and can further reduce costs and increase efficiency for enterprises.

    Packaging:

    Basically, the component thickness is 35mm, with 30 pieces packed on a tray. When loading a container, usually two high and low pallets are

placed inside.

    Zhongbu Qingtian New Energy provides a 10-500MW photovoltaic module automation production line solution, providing project planning,

whole line equipment, process technology and other support. We can customize various levels of automation and semi automation production

lines for customers based on their different needs, including factory layout, equipment configuration, and production line planning.