Solar panel manufacturing steps (Final Product)

Solar panel manufacturing steps

·         Solar Cell Testing

The equipment is developed to an automated work unit which characterizes PV cell efficiency using a current-voltage (I-V) test. I-V test subjects a PV cell to a calibrated light source to generate electrical current at different voltages. Using this data, the cell’s efficiency can be characterized. The system then sorts the PV cells according to eight different efficiency ratings for subsequent use in solar panels where cells with similar efficiencies are grouped to maximize the overall panel efficiency.

·         Solar Cell Cutting

Solar cell standard size is 156mm × 156 mm size, sometime cell having 125 mm × 125 mm size. For making different size panels the cell must be needed to cut in custom size. After cell testing, the cell is cutting in solar cell laser cutting machine. This machine is fully automated machine in which size we want to cut cell that size is logged in automated software system.

·         Solar Cell Tabbing and Stringing

Tabbing and bussing are two applications that link individual solar cells together to form a solar module (or solar panel). These applications also provide a method to transfer power from the solar cells to a power output, the junction box. Solar cell interconnect occurs when individual solar cells are joined together with tabbing ribbon (also called stringing ribbon), forming a cluster of solar cells. This is frequently referred to as cell tabbing (or stringing). The tabbing ribbon carries the solar cell’s current to a larger ribbon, the bus ribbon, which then carries power from the cell clusters to the module’s junction box for final output.

Tabbing ribbons are commonly applied as parallel strips that weave from the top of one cell to the bottom of the next to connect the positive and negative sides of the cells in series. The ribbon is soldered onto the paste that was applied to the TCO. The tabbing application creates a cluster of solar cells. Once all of the cells have been strung together with tabbing ribbons, they are then placed onto a substrate, typically glass. Then the thicker bus ribbon is soldered so that it connects to the tabbing ribbon of each solar cell cluster. The tabbing ribbon collects electric current within its cluster of solar cells and delivers it to the bus ribbon. The bus ribbon then conducts the cumulative electric power from all of the solar cell clusters to a junction box for final output. Imagine tabbing ribbon as a road that travels across the solar cell. The bus ribbons serve as the highways to connect and tie them together. Bus ribbon is larger in cross-section because it has more electrical power to carry.

·         Solar Panel Lamination

Lamination is the major process in solar module manufacturing. In this process, all materials are pressed into laminate as a whole. In the first stage, air in the chamber of the machine is pumped out and turned to vacuumed. Then, heating at 150 ° C and pressing will laminate all the materials together. Normally whole lamination cycle (including loading and unloading time) is approximately 6 minute.

·         Trimming & Framing

Debris and uneven edge surface of panel caused in lamination are trimmed to smooth and even in this process by using knife. Silicon glue is spread on aluminum frames manually, then operators collect the glued frames and fix them onto the panels manually, after that, operators load the panels on the framing machine, and frames are fastened and locked by framing machine.

·         Junction Box Fixing

In this proposal, silicon glue is spread on back side of junction boxes manually, and then the junction box is fixed manually on the back side of the panel.

·         Cable Connection

          Cables are connected from the junction box for output power of the panel. This cable called MC4

          connector.