System for manufacturing solar PV modules

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The system consists of 5  independent workstations placed in line. Each workstation performs specific tasks:

WORK AREA A: Automatic assembly of the photovoltaic modules
In this station the photovoltaic module is assembled. It consists in 6 workstations ( o-ringing of the lower plate glass; cell lacing and the automatic placement through robot, welding of strings , siliconizing,top plate glass assembly, automatic unloading).

WORK AREA B: Epoxy resin drying oven
In this area the solar PV modules that had been previously assembled are automatically placed, through a 6-axis controlled robot,on storage racks. Once completed, the storage racks are automatically inserted into the oven where the epoxy resin is dried.

WORK AREA C: cell encapsulation
In this area the solar PV modules outgoing from the oven are “in high vacuum” filled with a special ultra-transparent silicone oil, in order to encapsulate the photovoltaic cells contained within. Prior to filling, all the modules are tested to check the perfect sealing.

WORK AREA D: Photovoltaic module test
In this area all PV modules are tested through a solar simulator.A controlled 6-axis robot, picks up the module from the line, bring the flasher and places the module on two different belts depending on the test result.

WORK AREA E: Photovoltaic module packaging
In this area all photovoltaic modules, successfully tested, are automatically palletized through a  robot with 4 controlled axes.

The system can perform manually and automatically in order to achieve the maximum efficiency and flexibility of the machinery. The operator has a touch-screen operator panel to load the recipe program as well as the operating parameters and for displaying the machinery state. The automation of the machinery is managed and supervised by a PLC logic controller which controls the whole automatic cycle and stores all production data. The management of start-up, stop, anomalies, calibration, etc.. is performed and controlled through the PLC. The change of machinery parameters and the view of the line state of is run directly on the operator panel via intuitive and easy controls. These can be viewed in real time on a monitor placed on the machinery.

Main features:

– The maximum flexibility
– 10/25/50MW/year with 3 work shifts (7 hours) and 6/8 operators per shift
– High quality of the finished product
– Low maintenance