Solar Panel Manufacturing Machines: A Basic Overview

In this article, you will get a basic overview about the solar panel manufacturing machines and processes used to produce solar panels.

Overview Of Solar Panel Manufacturing Machines And Processes

The following graphic is showing the complete process for solar panel manufacturing and the solar machines needed for each step. The round bubbles are the materials that come into the process.

Here is a list of the main solar panel manufacturing machines:

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

Each of these solar panel manufacturing machines plays an important role. In the following sections, we will briefly summarize how each piece of equipment or parts fits in the production of PV modules.

Stringer

The solar stringer is for connecting individual solar cells together in a series to a string (a 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 infrared soldering process 
7. Presenting the ready made string

Layup station

The strings that come from the stringer are now placed on the glass — including the lamination foil (normally EVA or DESERT PROCESS FOIL for long life panels in hot areas).

Input and output of Layup machine:

Input:

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

Output:

• Glass covered with foil and strings on top

Process of Layup machine:

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 solar glass, covered with embedding foil and the solar strings.

Bussing Station

The bussing station is where the solar strings on the solar glass are connected to a complete module.

All ribbons are connected in a row so that the power can flow through the complete module and (later) be connected to the plus and minus of the junction box connectors.

Input and Output of Bussing Station

Input:

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

Output:

• Connected strings on glass with foil

Process of Bussing Machine

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 bussing station, the glass with strings are covered by another embedding foil and back sheet foil. This "Glass-Foil-Cell" package then has to be converted to a protected solar laminate. This process is done in the laminator.

Input and Output of Solar Laminator

Input:

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

Output:

• Solar laminate

Process of Solar Laminator

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

Foil Cutter And Foil Placing Station

The foil cutter and foil placing station are responsible for cutting the backsheet and embedding foil placing the foil. The backsheet is a thin sheet of plastic that is placed on the back of the solar module to protect it from the elements. The embedding foil is a flexible foil that can be melted and connects the glass, cells and backsheet together to a solid laminate.

The foil cutter is responsible for cutting the sheets to the correct size and shape. The foil placing station is responsible for placing the foil on the cells, ensuring that it is correctly aligned and connected.

Trimming And Taping Station

J-Box Station And Framer

The J-Box station and framers are responsible for connecting the solar module to the J-Box and installing the frame. The J-Box is a junction box that contains the electrical components that connect the module to other modules or to other components of the solar machine.

The framers are responsible for installing the frame, which is necessary for mounting the solar module.

The High Potential Test And Sun Simulator

Testing is an important step in solar module production. Solar modules have to meet certain standards and be able to perform as expected in real-world conditions.

The high potential test and sun simulator are responsible for testing the quality of the solar module. The high potential test measures the voltage of the module, while the sun simulator simulates the effects of sunlight on the module.

Sorting And Packing

The final step in producing solar modules is sorting and packing. This involves sorting the modules into different categories, such as wattage, voltage, and size. It also involves packing the modules into boxes for storage or shipping.

Recent Developments In Machine Design

Developments in solar panel production machines have been driven by the need for higher efficiency and lower costs. One of the most significant developments is the use of automated production lines. These lines consist of several machines working together to produce solar panels from start to finish.

The use of robots and artificial intelligence in solar panel production is also on the rise and will play a big role in further reducing costs and improving efficiency for manufacturers.

The use of advanced machinery and automation in solar panel production has not only led to an increase in efficiency but also a reduction in costs.

In subsequent articles, we will go deeper into each of the main processes as well as the role of automation in solar manufacturing. Make sure to check our blog so you do not miss those articles!