Solar Panel Making Machines: Key Features and Benefits

This guide offers a fundamental overview of the solar panel making machines and production processes essential for understanding how solar panels are created.

Overview Of Solar Panel Making Machines And Processes

The graphic below illustrates the complete solar panel manufacturing process and the machinery needed for each step. The round bubbles represent the materials entering the process.

Key Solar Panel Making Machines

• Glass Washer
• Foil Cutter
• Stringer
• Layup stations
• Bussing stations
• Laminators
• Foil placing stations
• Trimming and taping stations
• J-box stations
• Framers
• High potential tests
• Sun simulators
• Sorting and packing

Each of these machines plays a vital role in the production of PV modules. In the following sections, we’ll briefly summarize the function of each piece of equipment.

Stringer

The solar stringer connects individual solar cells in a series to form a “string”—a single row of soldered solar cells.

Stringer: Input and Output

Input:

1. Solar cells
2. Ribbon for connecting the cells
3. Flux to activate the soldering paste

Output:

• String

Stringer: Process

1. Checking and alignment of the cell
2. Placing cell on soldering belt
3. Applying the flux on the ribbon
4. Cutting the ribbons
5. Placing the ribbons on the cells
6. Soldering the solar cells together with an infrared soldering process 
7. Presenting the finished string

Solar Stringer Machine

Solar cell on soldering belt without ribbon

Soldering of Solar Cell

Ribbon Placement on Solar Cell

String with Cells and Ribbon

Layup station

The strings from the stringer are placed on the glass along with the lamination foil (typically EVA or DESERT PROCESS FOIL for long-life panels in hot climates).

Layup Station: Input and Output

Input:

1. Solar glass with foil
2. Solar strings (from stringer)

Output:

• Glass covered with foil and strings on top

Layup Station: Process

1. Feed in the solar glass with EVA or DESERT Foil on top
2. Alignment and placement of the solar strings on the glass

The result is a sheet of solar glass covered with embedding foil and the solar strings.

Layup Station for Placing the Strings on the Glass

Glass with solar Strings on Top

Bussing Station

At the bussing station, the individual solar strings on the glass are interconnected. All ribbons are soldered in a row, allowing power to flow through the entire module before being connected to the junction box.

Bussing Station: Input and Output

Input:

1. Bussing ribbon
2. Glass with foil and strings (from layup)

Output:

• Connected strings on glass with foil

Bussing Station: Process

1. Feed in the glass with strings on top
2. Placing the bussing ribbon for interconnection
3. Soldering the ribbons of the strings with the bussing ribbon

Laminator

After the bussing station, the assembly is covered with another layer of embedding foil and a backsheet. This “glass-foil-cell” package is then bonded into a protected solar laminate inside the laminator.

Solar Laminator: Input and Output

Input:

• Solar glass, covered with foils and connected solar strings (from bussing)

Output:

• Solar laminate

Solar Laminator: Process

1. Feed in the glass-foil-string package into the lamination chamber
2. Creating a vacuum by pumping all air from the laminator chamber
3. Pressing and heating the glass and foils to bond the complete package into a solid laminate

Foil Cutter And Foil Placing Station

The foil cutter and placing station prepare the backsheet and embedding foil. The backsheet, a thin plastic sheet, protects the back of the solar module from the elements. The embedding foil is a flexible material that melts during lamination to bond the glass, cells, and backsheet into a solid unit.

The foil cutter cuts these materials to the correct size and shape, while the placing station ensures they are precisely aligned on the module.

Trimming And Taping Station

At the trimming station, any excess foil from the laminate is removed, a process that can be done manually with a knife or with automated equipment.

After trimming, the laminate’s edges are sealed with tape. This tape reinforces the connection between the laminate and the frame, making it stronger and waterproof.

Trimming and Taping: Input and Output

Input: 

1. Untrimmed laminate
2. Tape for laminate

Output:

• Trimmed and taped laminate 

Trim Station with Untrimmed Laminate

Manual Trim of Solar Laminate

Taped laminate

J-Box Station And Framer

The J-Box station connects the solar module’s electrical components to the junction box (J-Box), which allows the module to be connected to other modules or system components. The framer then installs the frame, which is necessary for mounting the panel.

The High Potential Test And Sun Simulator

Testing is a critical step in solar module production, ensuring panels meet performance standards for real-world conditions.

Two key quality tests are the high potential test, which measures the module’s voltage insulation, and the sun simulator, which measures its performance under simulated sunlight.

Sorting And Packing

The final step is sorting and packing. Modules are sorted into categories based on wattage, voltage, and size, then packed into boxes for storage or shipping.

Recent Developments In Machine Design

Recent developments in solar panel production machinery have been driven by the need for higher efficiency and lower costs. One of the most significant advances is the use of automated production lines, where multiple machines work together seamlessly to produce solar panels from start to finish.

The use of robotics and artificial intelligence is also on the rise, playing a key role in further improving manufacturing efficiency and reducing costs.

In future articles, we will go deeper into each of these processes and explore the role of automation in solar manufacturing.

Be sure to check our blog so you don’t miss these updates!

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