As a staff in the photovoltaic industry, Have you ever visit a solar factory before? Do you know the whole process for solar module production? Do you know the Key Point For Quality control? Today I Will take "you" into a Full-Auto factory to see the all processes, a total of 15 steps.
Solar modules are made up from this material (Backsheet, EVA, Cells, Glass, Junction Box, Interconnector, Silicon Gel, Aluminum frame), Before production should inspect all these materials, avoiding the bad materials used in the production.
Cells are the most important material for the solar modules, We should check Facade/size/color discrepancy...Must Use A Grade, Many factories mixed A and B Grade Cells to Down the costs.
Connecting individual cells into strings, normally it should be 10/12 cells for a string,6 strings together make up a 60/72 cells module.
(1) put the welded cell strings on top of EVA;
(2) The strings are connected in series by interconnector.
Electroluminescence(EL)imaging is used to detect a multitude of defects in crystalline silicon cells. Micro cracks, Poor welding, Bad finger contacts, Fragments in broken cells... Click See Video.Must strict control. Many factories quality control standard is quite low, Treated The Problem One As Good One.
This process mainly replaces the problem cells(Micro cracks issue)or welding again(Poor welding issue)from the feedback of Firstly EL Testing. Many factories ignore such problems, Refuse to change the bad cells to save costs. Because We Can't See Any Difference By Our Eyes.
The sandwich structure is then laminated under vacuum so as to suck out any air bubbles and a suitable proper laminator temperature allows the thermoplastic EVA to fully embrace the cells. Furthermore, electrical and environmental insulation is assured.
Checking the visual look after laminating, to inspect whether have break cells or any dirty stuff during the laminating process.
Inserting the laminated module in the frame mounting cavities, properly filled with silicone gel sealant, and punched aluminum profiles with an assembly machine.
The Junction Box is placed on the back side of the module fixing it by a proper amount of silicone gel.The four ribbons coming out from the laminated module are inserted and fixed in the dedicated tight connection clamps.
Need machines to check this module safety from three respects, Grounding resistance test, Insulation&withstand test, Insulation resistance test.
After the framing and mounting of the Junction Box, The silicon gel needs a proper solidification time for drying and acquire its standard strength and weather resistance, normally it should be around 4-8 hours. After curing, the excess silicone gel is removed with ethyl alcohol.
After the solidification of the silicone gel, the module can be taken under the electrical IV test. During this test, all the main electrical parameters of the module are measured. The test is performed using the best quality AAA-Class Sun Simulator, ensuring to the customer true electrical parameters measured on the module and furthermore reported on the flash-list. Many factories Put Fake Lable On the module, Like The Real power is 320W, But They label 330W And Sell With 330W. So They Can offer a Better Price Compare with Factories that supply Real 330W Power. Solarborn Solar Panels Output Will always be Positive(+0-5W).
This process mainly checks the potential defect problem under the laminating pressure. Have Micro cracks, Poor welding, Short Circuit, etc Problems, This Panel Should Downgrade as B Because there is no way to repair, it's finished product, But Many factories Mixed B Grade and A-Grade, Selling Customers With "A" Grade to offering Good Price.
Checking whether still have some dirty stuff and the position of labeling,In the end, wrap the protector on the four corners and packed into a cartoon box.