The module line is also called the packaging line. Packaging is a key step
in the production of solar cells. Without a good packaging process, no matter
how good the battery is, it will not be able to produce good module boards. The
packaging of the battery not only ensures the life of the battery, but also
enhances the battery's resistance strength. The high quality and long life of
the product are the keys to winning customer satisfaction, so the packaging
quality of the component board is very important.
Solar cell assembly process:
Solar cell production process:
1. Battery inspection 2. Front welding inspection 3. Back series connection
inspection 4. Laying (glass cleaning, material cutting, glass pretreatment,
laying) 5. Lamination 6. Deburring (edging, cleaning) 7. Frame installation (
Gluing, installing corner keys, punching, framing, scrubbing remaining glue) 8.
Welding junction box 9. High voltage test 10. Component testing and appearance
inspection 11. Packaging and storage
How to ensure high efficiency and long service life of components:
1. High conversion efficiency, high quality battery cells;
2. High-quality raw materials, such as: EVA with high cross-linking degree,
encapsulant with high bonding strength (neutral silicone resin glue), tempered
glass with high light transmittance and high strength, etc.;
3. Reasonable packaging technology
4. Rigorous work style of employees;
Since solar cells are high-tech products, some details in the production
process, some inconspicuous problems such as wearing gloves but not wearing
them, applying reagents evenly and scribbling, etc., are the enemies of product
quality. Therefore, in addition to formulating reasonable In addition to the
excellent production technology, the seriousness and rigor of the employees are
very important.
Introduction to solar cell assembly process:
Introduction to craftsmanship: Here I will briefly introduce the role of
craftsmanship to give you a perceptual understanding.
1. Battery test: Due to the randomness of the production conditions of
battery cells, the performance of the batteries produced is not the same.
Therefore, in order to effectively combine batteries with consistent or similar
performance, they should be classified according to their performance
parameters; battery testing is Classify batteries by testing the magnitude of
their output parameters (current and voltage). In order to improve the
utilization rate of batteries and make battery components with qualified
quality.
2. Frontal welding: The bus strip is welded to the main grid line on the
front side of the battery (negative electrode). The bus strip is a tinned copper
strip. The welding machine we use can spot weld the solder strip to the main
grid in a multi-point manner. on-line. The heat source used for welding is an
infrared lamp (using the thermal effect of infrared rays). The length of the
welding ribbon is approximately twice the side length of the battery. The extra
soldering ribbon is connected to the back electrode of the subsequent battery
piece during back welding.
3. Backside series connection: Backside welding is to connect 36 cells in
series to form a component string. The process we currently use is manual. The
positioning of the battery mainly relies on a membrane plate with 36 recesses
for placing the battery cells. The size of the slot corresponds to the size of
the battery. The position of the slot has been designed. Different templates are
used for components of different specifications. The operator uses a soldering
iron and solder wire to solder the front electrode (negative electrode) of the
"front battery" to the " On the back electrode (positive electrode) of the "back
battery", connect 36 pieces together in series and weld leads to the positive
and negative electrodes of the component string.
4. Laminated laying: After the back side is connected in series and passed
the inspection, the component strings, glass, cut EVA, fiberglass, and backboard
are laid according to certain levels and prepared for lamination. The glass is
coated with a layer of primer in advance to increase the bonding strength
between glass and EVA. When laying, ensure the relative position of the battery
string and glass and other materials, and adjust the distance between batteries
to lay a solid foundation for lamination. (Laying level: from bottom to top:
glass, EVA, battery, EVA, fiberglass, backplane).
5. Component lamination: Put the laid battery into the laminator, vacuum
out the air in the component, then heat to melt the EVA and bond the battery,
glass and backplate together; finally cool and remove the component. The
lamination process is a key step in component production. The lamination
temperature and lamination time are determined by the properties of EVA. When we
use fast-cure EVA, the lamination cycle time is about 25 minutes. The curing
temperature is 150°C.
6. Trimming: During lamination, the EVA melts and solidifies outward due to
pressure to form burrs, so it should be removed after lamination.
7. Framing: Similar to installing a frame on glass; installing aluminum
frames on glass components increases the strength of the components, further
seals the battery components, and extends the service life of the battery. The
gaps between the frame and the glass components are filled with silicone resin.
Each frame is connected with angle keys.
8. Welding junction box: Weld a box at the lead on the back of the
component to facilitate the connection between the battery and other equipment
or batteries.
9. High-voltage test: High-voltage test refers to applying a certain
voltage between the component frame and the electrode lead to test the voltage
resistance and insulation strength of the component to ensure that the component
is not damaged under harsh natural conditions (lightning strikes, etc.).
10. Component testing: The purpose of testing is to calibrate the output
power of the battery, test its output characteristics, and determine the quality
level of the component.
Solar array design steps:
1. Calculate the capacity p consumed by the load in 24 hours.
p=H/V
V load rated power
2. Select the daily sunshine hours T (H).
3. Calculate the solar array operating current.
Ip=p(1+Q)/T
Q is based on the surplus coefficient during the rainy period,
Q=0.21~1.00
4. Determine the battery float voltage VF.
The single float charge voltages of cadmium-nickel (GN) and lead-acid (CS)
batteries are 1.4~1.6V and 2.2V respectively.
5. Solar cell temperature compensation voltage VT.
VT=2.1/430(T-25)VF
6. Calculate the solar array operating voltage Vp.
Vp=VF+VD+VT
Among them VD=0.5～0.7
Approximately equal to VF
7. What is the output power of the solar cell array WP? Flat-panel solar
panels.
Wp=Ip&TImes;Up
8. According to the Vp and Wp in the silicon battery flat panel combination
series table, determine the number of series blocks and the number of parallel
groups in standard specifications.
Selection of solar cells:
Solar cells are devices that directly convert light energy into electrical
energy through the photoelectric effect or photochemical effect. Thin-film solar
cells that work with the photoelectric effect are the mainstream. How to choose
solar cells troubles some people. Solar cells currently on the market are
divided into amorphous silicon and crystalline silicon. Crystalline silicon can
be divided into polycrystalline silicon and monocrystalline silicon. Judging
from the photoelectric conversion efficiency of the three materials:
monocrystalline silicon (up to 17%) > polycrystalline silicon (12-15%) >
amorphous silicon (about 5%). However, crystalline silicon (monocrystalline
silicon and polycrystalline silicon) basically does not generate current under
low light, and amorphous silicon has a good low-light type (it has very little
energy under low light). Therefore, from a comprehensive perspective, it is
appropriate to use monocrystalline silicon or polycrystalline silicon solar cell
materials.
How to choose solar cells
1. When we purchase solar cells, we focus on the power of the solar cells.
Generally speaking, the power of the solar panels is directly proportional to
the area of the solar wafer. The area of the solar cell wafer is not completely
equal to the area of the solar package panel, because although some solar panels
are large, the gaps between single solar wafers are very wide, and the power of
such solar panels is not necessarily high.
2. Generally speaking, the bigger the power of the solar panel, the better,
so that the current generated in the sunlight is large and the built-in battery
can be fully charged quickly. But in reality, it is necessary to find a balance
between the power of the solar panel and the portability of the solar charger.
It is generally believed that the minimum power of a solar charger cannot be
less than 0.75w, and a sub-power solar panel can generate a current of 140mA
under standard strong light. The current generated under general sunlight is
about 100mA. If the charging current is too small below the sub-power, there
will basically be no obvious effect.
Solar cell selection tips
With the widespread use of various solar products, solar cells are
increasingly used in our lives. But faced with various types of solar cells on
the market, how should we choose? Now let’s learn how to choose solar cells.
1. Selection of solar battery capacity
Since the input energy of the solar photovoltaic power generation system is
extremely unstable, it generally requires a battery system to work. Solar lamps
are no exception and must be equipped with a battery to work. There are
generally lead-acid batteries, Ni-Cd batteries, and Ni-H batteries. Their
capacity selection directly affects the reliability of the system and the system
price. The selection of battery capacity generally follows the following
principles: first, on the premise that it can meet the needs of night lighting,
try to store the energy of solar cell components during the day, and at the same
time, it must be able to store the electrical energy needed to meet the needs of
night lighting on continuous rainy days. The battery capacity is too small and
cannot meet the needs of night lighting. The battery capacity is too large. On
the one hand, the battery is always in a state of power loss, which affects the
battery life and causes waste.
2. Selection of solar cell packaging form
At present, there are two main packaging forms of solar cells, lamination
and glue. The lamination process can ensure the working life of solar cells for
more than 25 years. Although glue was beautiful at the time, the working life of
solar cells was only 1 to 2 years. Therefore, low-power solar lawn lights below
1W can use epoxy packaging if there are no excessive life requirements. For
solar lights with specified service life, it is recommended to use laminated
packaging. In addition, there is a kind of silicone gel used to encapsulate
solar cells. It is said that the working life can reach 10 years.
3. Selection of solar cell power
What we call the output power Wp of solar cells is the output power of
solar cells under standard sunlight conditions, that is: the 101 standard
defined by the European Commission, radiation intensity 1000W/m2, air quality
AM1.5, and battery temperature 25°C. This condition is about the same as the
normal sunlight conditions around noon on a sunny day (it can only be close to
this value in the lower reaches of the Yangtze River). This is not as some
people imagine. As long as there is sunlight, there will be a rated output
power. They even think that solar cells will have a rated output power. It can
also be used normally under fluorescent lights at night. That is to say, the
output power of solar cells is random. At different times and in different
places, the output power of the same solar cell is different. Regarding solar
lamp data, between aesthetics and energy saving, most choose energy saving. The
ideal tilt angle for solar cells in the lower reaches of the Yangtze River is
about 40 degrees, with the direction due south.
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