Solar Module Manufacturing Process PDF

SOLAR MODULE MANUFACTURING PROCESS Mar 2023 CSIQ NASDAQ Listed Content Solar Module Introduction Solar Module Materials Solar Module Production Canadian Solar Inc. 2 Solar Cell Introduction...

SOLAR MODULE MANUFACTURING PROCESS Mar 2023 CSIQ NASDAQ Listed Content Solar Module Introduction Solar Module Materials Solar Module Production Canadian Solar Inc. 2 Solar Cell Introduction Solar Module Introduction Module type Module size Canadian Solar Inc. 3 Solar Cell Introduction Cell types Mono MBB(10BB) Mono MBB(12BB) Topcon (18BB) Bifacial 182mm Bifacial 210mm Bifacial 210mm Front Side Back Side Front Side Back Side Front Side Back Side Canadian Solar Inc. 4 Solar Cell Introduction Half cut cells Mono MBB(10BB) Mono MBB(12BB) Topcon (18BB) Bifacial 182mm Bifacial 210mm Bifacial 210mm Canadian Solar Inc. 5 Solar Module Introduction Solar module base on Thailand plant Series 6 Series 7 HiKu6/BiHiKu6 10BB BiHiKu7 MBB TopBiHiKu7 MBB CS6R-MS CS7N-MB-AG CS7N-TB-AG CS6W-MB-AG Canadian Solar Inc. 6  Solar Module Introduction Module size / model Depend on... Cell size 12 half-cells 11 half-cells Mono MBB(1xBB) Mono MBB(1xBB) Bifacial 1xxmm Bifacial 2xxmm Number of cell Canadian Solar Inc. 7 Solar Module Introduction Module type Single glass Double glass Front side Back side Canadian Solar Inc. 8 Solar Module Introduction Solar Module Materials Before lamination material After lamination material Packing material Solar Module Materials Frame Front Glass Frame Glass / POE Cell / POE Polymer Back sheet or Glass Junction box Cell Junction box Back sheet Back Glass Canadian Solar Inc. 10 Solar Module Materials Before lamination  After lamination Cell Frame Junction box Potting Sealant silicone  Packing Tabbing EVA,ECPCE Bus ribbon ribbons and Back sheet strip Temper glass Back Polymer (EVA Used to support the load Protect the cell plate sheet etc.) Clear and white and protect components from the environment. from environmental conditions such as water screen type Canadian Solar Inc. and UV rays. 11 Solar Module Manufacturing Process SOLAR MODULE MANUFACTURING PROCESS Before lamination Lamination After lamination Packing Solar Module Manufacturing Process Solar Module Process Full cells Half cells String cells Material laying Solar Module Canadian Solar Inc. 13 Solar Module Manufacturing Process SOLDERING MATERIAL ALIGNMENT INSPECTION & EL TEST LAMINATION CLEANING PROCESS CURING PROCESS ASSEMBLY TRIMMING & VISUAL INSPECTION IV TEST HI-POT & GROUND CONTINUITY EL TEST AFTER PACKAGING PROCESS Canadian Solar Inc. TEST LAMINATION 14 SOLDERING PROCESS Glass preparation Lift up glass from pallet and send POE auto laying machine Automatic cutting and laying on into soldering machine. glass EL &Inspection Trimming & Soldering Materials Alignment Lamination Visual inspection Assembly (+repair) EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 15 SOLDERING PROCESS  Soldering tabbing ribbons on bus-bar of solar  Two-side soldering machines lead to high productivity cells. That connected into cell strings. levels. EL &Inspection Trimming & Soldering Materials Alignment Lamination Visual inspection Assembly (+repair) EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 16 SOLDERING PROCESS To align cell strings to match with module designed on the glass by using string cell laying robot EL &Inspection Trimming & Soldering Materials Alignment Lamination Visual inspection Assembly (+repair) EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 17 ALIGNMENT MATERIALS PROCESS Soldering tabbing ribbons with bus ribbons(Bus bar) into series circuit by using bus bar automatic welding. EL &Inspection Trimming & Soldering Materials Alignment Lamination Visual inspection Assembly (+repair) EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 18 ALIGNMENT MATERIALS PROCESS Then fix position of string cell by using tape sticking automatic machine. EL &Inspection Trimming & Soldering Materials Alignment Lamination Visual inspection Assembly (+repair) EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 19 ALIGNMENT MATERIALS PROCESS To laying encapsulation and insulation layer (EVA, POE, EPE Back sheet/Glass) EL &Inspection Trimming & Soldering Materials Alignment Lamination Visual inspection Assembly (+repair) EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 20 EL & VISUAL INSPECTION PROCESS To visual inspection 100% of modules in production-line. EL (Electroluminescent) testing for inspecting defects, through captured images via special camera. EL &Inspection Trimming & Soldering Materials Alignment Lamination Visual inspection Assembly (+repair) EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 21 REPAIR MODULE PROCESS Repair and replace NG cells by good cells. EL &Inspection Trimming & Soldering Materials Alignment Lamination Visual inspection Assembly (+repair) EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 22 LAMINATION PROCESS Back sheet/Glass(screen) POE/EVA/EPE Solar cell POE/EVA/EPE Glass(Clear)  To apply heat and pressure to all component for encapsulated and adhered together.  Double layer Lamination machine is high capacity that lead to high productivity. EL &Inspection Trimming & Soldering Materials Alignment Lamination Visual inspection Assembly (+repair) EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 23 TRIMMING PROCESS Trimming the exceed parts of modules after laminated (POE EVA EPE and Back sheet). Then visual inspection 100% of modules. EL &Inspection Trimming & Soldering Materials Alignment Lamination Assembly (+repair) Visual inspection EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 24 VISUAL INSPECTION PROCESS Visual inspection 100% of modules. EL &Inspection Trimming & Soldering Materials Alignment Lamination Assembly (+repair) Visual inspection EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 25 ASSEMBLY PROCESS Injecting silicone sealant into the aluminum frame. Then assembly into the edge of modules. Advantage of automatic assembly machine is stable quantity of silicone and cycle time. EL &Inspection Trimming & Soldering Materials Alignment Lamination Visual inspection Assembly (+repair) EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 26 ASSEMBLY PROCESS Injecting silicone sealant into the junction box and installing J-box. Then soldering out-going bus bar with J-Box by using J-Box automatic welding machine. EL &Inspection Trimming & Soldering Materials Alignment Lamination Visual inspection Assembly (+repair) EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 27 ASSEMBLY PROCESS Injecting potting silicone inside the J-Box. Advantage of automatic potting silicone feeding is stable quantity of silicone and cycle time. And mixing by mixing tube. EL &Inspection Trimming & Soldering Materials Alignment Lamination Visual inspection Assembly (+repair) EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 28 CURING PROCESS Frame Glass POE/EVA Solar cell POE/EVA Glass/ Back sheet J-Box Placing module in temperature and humidity controlled room for accelerating curing silicone. EL &Inspection Trimming & Soldering Materials Alignment Lamination Visual inspection Assembly (+repair) EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 29 CLEANING PROCESS Automatic install cover of J-Box, checking glue status, inspection on back side of solar module and installing testing box. EL &Inspection Trimming & Soldering Materials Alignment Lamination Visual inspection Assembly (+repair) EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 30 CLEANING PROCESS Cleaning, removing stain, rubbing frame corners and inspecting front and back side of solar module. EL &Inspection Trimming & Soldering Materials Alignment Lamination Visual inspection Assembly (+repair) EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 31 IV TEST PROCESS To measure electrical power of solar module in dark room by sun simulator according “Standard test condition”. The solar classifications of I-V tester is class AAA. That long-term instability of irradiance < 1%. It means high stable irradiance. EL &Inspection Trimming & Soldering Materials Alignment Lamination Visual inspection Assembly (+repair) EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 32 HI-POT TEST PROCESS  Hi-pot test is verifies the electric insulation of module by apply high voltage and then check current leak out not over standard.  Ground continuity test for checks surety of current flows easily from one point to another point. EL &Inspection Trimming & Soldering Materials Alignment Lamination Visual inspection Assembly (+repair) EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 33 EL TEST PROCESS  Check 100% of the modules in production- line.  Inspecting defects of the module through EL picture. To confirm no any defects before packaging. EL &Inspection Trimming & Soldering Materials Alignment Lamination Visual inspection Assembly (+repair) EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 34 LABELING PROCESS Automatic label machine and check by operator Labeling manual Labeling of the module base on type of module (take out of testing box). EL &Inspection Trimming & Soldering Materials Alignment Lamination Visual inspection Assembly (+repair) EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 35 SORTING PROCESS Automatic Sorting the classified modules according to electrical power. EL &Inspection Trimming & Soldering Materials Alignment Lamination Visual inspection Assembly (+repair) EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 36 PACKAGING PROCESS CS6W CS7N-TB Packaging modules by using packaging materials. EL &Inspection Trimming & Soldering Materials Alignment Lamination Visual inspection Assembly (+repair) EL Test Sorting & Packaging Hi-pot Test IV Test Cleaning Curing (+labeling ) Canadian Solar Inc. 37 MODULE TYPE CODING Example model : CS7N-680TB-AG CS 3/6/7 N – 680 MS/MB/TB-AG Canadian solar 3 = 1/2 cell 167.3mm MS= Mono PERC MB-AG = Mono Bifacial–Aluminum glass 6 = 1/2 cell 182mm Electrical power TB-AG = Topcon Bifacial–Aluminum glass 7 = 1/2 cell 210mm Drawing No. A-Z Canadian Solar Inc. 38  THANK YOU Mar 2023 Canadian Solar Inc. 39