Solar Panel Manufacturing Process

Solar panel manufacturing process first starts at the glass loading station. There are 2 robots in the glass loading machine, one of these robots takes the protective paper between the glass and the other one works to give the glass to the production. When the glass loading machine robot gives the glass to production, an air spray system is used in case there is dust and foreign objects on the glass.

The next stop of the glass given to production is the bottom eva laying machine. At this station, eva is laid on the glass and sent to the stringer machine.

Stringer Machine (Ribbon Soldering)

Stringer machine is known as the most important place in the solar panel production process. The Stringer machine creates strings by soldering ribbons on the cells, which are the most important raw materials of the Solar Panel. String is the soldering of a certain number of cells in a single row. After soldering the strings, the ribbon adhesion control is performed by the operator. If there is a problem in adhesion, parameter setting is made on the machine.

Lay-up robot makes the process of arranging the incoming strings on the glass. After laying a certain number of strings, the glass is sent to the autobussing machine.

Busbar Soldering Process (AutoBussing)

Autobussing machine is the process of soldering the ribbons soldered on the strings to the busbars. There are busbars on both sides of the solar panel and they are called main busbar and daughter busbar.

Eva Spreading Machine

Upper Eva Laying machine, like the Lower Eva laying machine, performs the task of laying the upper eva, which we call the upper eva, on the strings. Then the backsheet is laid and the panel is sent to the next station, the EL-TEST machine.

EL-TEST Solar Panel X-Ray

EL-TEST machine is the checking machine of the solar panel before it is sent to lamination. You can think of this machine as a kind of x-ray machine. Our aim is to check if there are any foreign objects in the solar panel or most importantly, are there any broken cells etc.? If there is, it needs to be intervened and replaced at the repair station. Otherwise, the panel with broken cells will be S Class or the panels next to it will also be S Class due to the vacuum problem in the lamination machine.

Solar Panel Lamination Process

Lamination Machine is the process of melting and bonding the lower eva and upper eva in the solar panel. The purpose of this process is to bond all the raw materials in the Solar Panel and ensure that it is robust. The Solar Panel Lamination Process is a very careful matter. Because the panels will be scrapped due to the formation of air bubbles in all panels, especially in the error made parametrically. There are 2 regions in laminations or we can say 2 covers. The following operations are performed on these covers.

Lamination Vacuuming

– 1st cover : In this region, high vacuum and a certain level of heating, melting process is performed. The reason for vacuuming is to expel the gases coming out of Eva and to ensure that the raw materials stick together more.

Lamination Heating

– 2nd cover : The same process is done in this area but in reverse. The heat is raised and the vacuum is lowered. Because the laminating process is done better on the 1st lid.

Visual Control

The purpose of Visual Inspection is to inspect the solar panel going through the Production and Lamination process. It will be necessary to inform the Production line in case of a continuous problem in the Solar Panel, and to intervene in Lamination when air bubbles are seen in the Solar Panel (such as parameter control.)

Framing

The framing machine is used to attach the frame to the Solar Panel that comes from the visual inspection without any problems. The frames are used for mounting and fixing the Solar Panel on the Field.

Junction Box Soldering

Juction Box : It is the soldering of the electricity obtained from the cells to the Junction Boxes, which is a kind of terminal box, through the busbars.

Potting – Mixing Silicone and Hardener

The potting machine is responsible for mixing the silicone and hardener poured into the Juction Box. This mixture, which varies according to each brand, is generally made in the form of 5 / 1

5  (silicone), 1 (hardener) is added and mixed and poured into the Junction Box, 4 hours curing time is waited.

Curing Room

Curing Room is the room where the silicone and hardener mixture poured into the Junction Box is kept for 4 hours. In this room, it is expected to be kept at a certain humidity and temperature in accordance with the quality conditions, in short, the silicone is expected to dry.

IV (Current-Voltage) Artificial Light

The IV machine performs the task of testing the solar panel by giving it artificial light to measure the power it will deliver. In these measurements, the Current and Voltage Characteristic Curve is followed and calibration is done in case of Power decrease or Power increase.

Final EL-TEST Control

Final EL-TEST machine does the final check of the panel that has gone through all the processes, in fact, as I mentioned before, it is the x-raying process.