TurnKey Production Lines for Manufacture of PV Modules

Teknisolar offers turnkey lines which integrate the Robostak™ Gen. V lamination line.

Established solar panel manufacturers may need a new line for production expansion, or a startup company may need to invest in first line with the intent of increasing production in future.

Teknisolar manages the design, manufacture, supply of equipment, installation and commissioning of fully automatic or semi automatic production lines. Additional equipment suppliers and line integration services are chosen in accordance with the customer.

A standard line can produce 30 solar panels per hour (approximately 65 MW). The level of automation can be increased or decreased according to customer’s requirements.

A medium line can produce 60 solar panels per hour (approximately 130 MW). The level of automation can be increased or decreased according to customer’s requirements. With this line, there are two stringers installed and one laminator.

A maxi line can produce 90 solar panels per hour (approximately 195 MW). The level of automation can be increased or decreased according to customer’s requirements, although some processes must absolutely be automatic in order to ensure the speed of the line. With this line, there are three stringers, one laminator and some other equipment is boosted to ensure speed of the line.

For more information and to request a personalized MW calculation, please fill out the contact form, including specific information about your company's solar panel type and size, and we will get back to you within a few days time.

Understanding what goes into the production line

1. Pre stringing

The first process step is the preparation and cleaning of the glass plate. This can be done automatically with pick and place systems, robots and glass washing machine or dry brush cleaner. The first sheet of encapsulant is also applied in this step.

2. Stringing

A high quality stringer is fundamental for any line, and is one of the key factors in production capacity calculations. We use stringers made by the market leaders and made in Europe. This is a fully automated process. The operator fills trays with solar cells which are fed automatically into the machine and the stringer applies the busbars. One stringer can process 2100 cells per hour so if only one stringer is installed on a production line, the maximum number of solar panels that can be created is 31 per hour (when producing 60-cell modules). For a higher production rate, two stringers can be installed on one line. Next, the strings are placed accurately on the prepared glass sheet by a robot. Advanced vision and sensor systems ensure proper creation of the cell matrix.

Manual stringing is also possible for small production volumes or research laboratories.

3. Interconnection, inspection & repair

This part of the process is also called “busbar soldering”, where the strings are connected electrically to form a series. This is typically a semi-automatic step, but fully-automatic busbar soldering is also available if required.

Inspection with an electroluminescence test should be done at this step, to make sure that all of the cells generate electricity. Repairs can be carried out in the next station if necessary.

4. Foil and backsheet placement

Fully automatic cutting and placement of encapsulant foil (EVA or POE or other) and backsheet material (or alternatively, placement of second glass sheet) is fully automatic.

5. Lamination

Read more about our laminator here.
The Robostak TM Gen. V laminator ensures even heating throughout the module, deep vacuum removal of air from between the layers, even pressure across the module with no edge pinch, and incredibly high speed, due to the process parameters and machine functions, and also to the patented curing process. This means that just one small laminator can process as much as one stringer can support, or one large laminator can process as much as two stringers can support. This laminator is designed to work perfectly in short cycle times with both glass-glass and glass-backsheet panels at high speeds. In addition, the required space for this lamination equipment is less than competitor laminators.

6. Back end

The back end contains the finishing steps in the solar panel production. All of these steps can be manual, semi-automatic, or fully-automatic, according to the customer’s requirements and budget:

  • Visual inspection
  • Trimming operation to remove excess backsheet (not required on glass-glass modules processed in the Robostak TM Gen. V laminator)
  • Application of silicone or tape to fix the aluminium frame to the module
  • Pressing the frame around the module
  • Gluing and soldering the electrical junction box
  • Sun simulation/flashing: A light source simulates sun light allowing the power of the panel to be measured
  • PE/grounding test: this test verifies if the 4 frame parts are electrically connected to ensure proper grounding at installation.
  • HV/High Voltage test: verifies that there is no electricity flowing from the network of cells to the frame of the panel, minimising the risk to the installer or user.
  • 2nd Electroluminescence (EL) test: At this stage, the test checks the quality of the panel and this data is stored for technical/commercial purposes.
  • Labelling, sorting and packing

Calculations are based on using high quality fast-cure EVA and standard backsheet. With special encapsulant materials such as various types of POE, TPO or special backsheet material, or other types of cells like heterojunction, CIGS, etc., the calculations will vary slightly. Lamination cycle time will be the key factor in variation of these calculations; therefore these materials will require a trial session on the Teknisolar laminator in order to accurately size the line according to the customer’s production requirements.