Photovoltaic Module Processing - Seven Process Steps

Products Description

The technology behind photovoltaic module fabrication is a critical component of the solar photovoltaic industry's workflow. This process, which involves encapsulating individual thin-film solar cells, ensures the modules can operate dependably even in the most challenging outdoor conditions. The prevailing photovoltaic module fabrication technology uses EVA film encapsulation and encompasses a series of intricate steps such as cell inspection, single-cell welding, cell series welding, module stacking, lamination, frame installation, junction box attachment, final product testing, packaging, and warehousing. Each step is interdependent, meaning the quality of each process directly impacts the final product's quality and classification.

PV Fuse for photovoltaic solar energy

Photovoltaic module processing technology

Cell Inspection: As the core raw material in photovoltaic module production, the cell's performance is pivotal to the module's quality. Beyond aesthetic checks for appearance and color consistency, resistivity tests are conducted. The cell's output current, voltage stability, and durability under specific lighting and temperature conditions are also evaluated using specialized instrumentation.

Single-Cell Welding: This process involves holding the welding tab with approximately one-third of its length pinched by the left hand, placing it flat on the cell's main grid line, while the right hand operates the soldering iron. The iron is gently pressed from left to right, ensuring a smooth, blemish-free weld without solder bumps or bridges, and the surface should be even and aesthetically pleasing.

Multi-process Welding Workshop

Series Welding: The cells are placed back-to-back on a template, and the soldering iron is used to connect them with a solder strip at the specified spacing. The weld must be flat, straight, and free of defects like solder bumps or incomplete joints.

Stacking: Tempered glass is positioned on the workbench, covered with EVA film, ensuring a 5mm border on all sides. The battery strings are aligned on the EVA according to the template's polarity markings, with the anti-reflection side facing down. The busbar is welded, and the barcode is affixed before the EVA, TPT, and EL tests are performed to check for defects.

Lamination: The laminator is prepped according to the EVA's characteristics, with temperature and evacuation time adjusted and recorded. The component is placed in the laminator, and the machine handles the rest of the process. The final product must be free of debris, fractures, and other imperfections.

Framing: Silicone is applied to the aluminum frame's groove before embedding the component. The frame machine secures the frame, and additional silicone is applied to the TPT-aluminum junction and around the junction box. The frame must be straight, with minimal gaps at the corners and diagonal alignment within 4mm.

Cleaning: The protective film on the aluminum profile is removed, and alcohol is used to clean any contaminants from the component's surface, ensuring a pristine appearance.

Finished Component Testing: The solar module tester is calibrated with a standard component, and the photovoltaic module is tested for electrical performance parameters, which are then recorded for quality assurance.