The automated production line for solar photovoltaic modules integrates advanced equipment and optimized processes to ensure high efficiency and quality. It includes laser cutting, string welding, laminating, EL testing, framing, and IV testing, among other steps. The line’s capacity varies based on its scale and automation level, ranging from 1,000 to over 20,000 modules per day. By continuously optimizing equipment and processes, the line can significantly enhance production capacity and product quality, meeting the growing market demand for solar energy solutions.

Automated Production Line for Solar Photovoltaic Modules

Solar Photovoltaic Module Automated Production Line Description

I. Production Process

The production process of solar photovoltaic modules mainly includes the following steps:

  1. Cell Sorting: Testing and classifying the output parameters (current, voltage, etc.) of solar cells to group cells with consistent or similar performance together.
  2. Laser Cutting: Cutting solar cells into the required shapes, such as halving cells for half-cut modules to reduce current losses and improve module efficiency.
  3. Welding:
  • Single Welding: Soldering interconnects onto the main busbars of individual solar cells.
  • String Welding: Connecting multiple solar cells in series using interconnects to form strings.
  1. Laminating: Laying out the welded cell strings, tempered glass, EVA, and backsheet in a specific order in preparation for lamination.
  2. Lamination: Placing the laid-out modules into a laminator, where vacuum extraction and heating melt the EVA, bonding the cells, glass, and backsheet together. The laminated modules are then cooled and removed. Lamination is a critical step in module production, with temperature and time settings determined by the properties of the EVA.
  3. Visual Inspection and EL Testing: Conducting visual inspections and electroluminescence (EL) testing on laminated modules to ensure performance and safety.
  4. Framing: Installing aluminum alloy frames to protect the edges of the modules and facilitate subsequent installation.
  5. Junction Box Installation: Attaching junction boxes to connect and protect the modules, allowing the generated electricity to be conducted out for use.
  6. Curing: Solidifying the sealant injected during framing and junction box installation to enhance sealing effects and protect the modules from harsh external environments.
  7. Testing:
    • Insulation and Dielectric Testing: Testing the safety between the frame and internal electrical components.
    • Ground Continuity Testing: Measuring the resistance between the frame and ground to ensure proper grounding.
    • IV Testing: Measuring electrical performance parameters to determine module grading.
  8. Cleaning and Final Inspection: Cleaning the modules and conducting final inspections to ensure product quality.
  9. Packaging: Packaging the qualified modules for shipment.

II. Equipment Configuration

The equipment configuration of a photovoltaic module automated production line corresponds to the production process and mainly includes the following equipment:

  1. Laser Cutting Machine: Used for cutting solar cells.
  2. String Welding Machine: Including tab welding machines and cell string welding machines, used for welding solar cells.
  3. Automatic Laminating Equipment: Used for laying out cell strings, glass, EVA, and backsheet in sequence.
  4. Laminator: Used for laminating modules.
  5. EL Tester: Used for detecting electroluminescence in modules to ensure there are no internal defects.
  6. Automatic Frame Installation Machine: Used for installing aluminum alloy frames.
  7. Junction Box Welding Machine: Used for attaching junction boxes.
  8. Module Flipping Unit: Used for flipping modules during cleaning and inspection processes.
  9. IV Curve Tester: Used for measuring electrical performance parameters.
  10. Flipping Inspection Unit: Used for flipping modules during final inspection to check appearance and quality.
  11. Packaging Line: Used for packaging and warehousing modules.

In addition, equipment manufacturers can also provide integrated automated equipment lines covering all stages to achieve turnkey projects.

III. Production Line Capacity

The capacity of a production line depends on several factors, including the degree of automation of the equipment, the optimization of the production process, and the proficiency of the production personnel. Generally speaking:

  • Small Automated Production Lines: Capacity may range from 1,000 to 5,000 modules per day.
  • Medium Automated Production Lines: Capacity can reach 5,000 to 20,000 modules per day.
  • Large Automated Production Lines: Capacity is typically over 20,000 modules per day.

By optimizing equipment configuration, enhancing automation levels, and strengthening production management, the capacity and efficiency of the production line can be further improved.