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The Solar Concentrating Photovoltaic (CPV) system developed by Energy Innovations Inc. relies on the patented Fresnel lens technology to focus the amplified sunlight energy on a small area (focal spot). Triple-junction silicon cell. The solar system greatly increases the conversion rate of solar energy and has great potential for development. However, the new energy company that had just started from the solar industry a few years ago when manufacturing the first solar system in China was in crisis because of the problem of accurate alignment of the lens and the photovoltaic cell in the actual production process.
According to Bud Sherman, vice president of marketing for new energy company headquartered in Pasadena, Calif., “At that time, we used manual calibration in production, and the business benefits were not very good. Although we developed excellent products, we failed to make it successful. commercialize."
The solar system typically consists of a 3-inch square solar module, and each solar module consists of 30 solar cells and a focusing lens that is approximately 1 inch away from the solar cell. The truly valuable solar system is a complete system of solar cells that ensures that the lens is focused. Sherman said: "The coincidence accuracy is very important and is the core of the whole system, but manual calibration is difficult to achieve high-precision coincidence."
Accurate calibration
Because manual calibration is not only difficult to ensure 0.005-0.01 inch calibration error, but also it is difficult to ensure the consistency of product quality, resulting in serious constraints on business development. In order to change the status quo, corporate managers are constantly trying new calibration methods, such as using precision optical instruments such as cameras and rear projections, and using robots instead of manual operations. In short, the company is gradually shifting its solar system production line to an automated model.
After many investigations, the company finally chose the FANUC robot. During the transformation of the production line, senior FANUC robot suppliers also provided complete production guidance and assistance for enterprises. Sherman said: "With the help of suppliers, we use robots instead of manual operations to easily achieve accurate positioning and calibration in various process flows."
At the end of last year, the company ordered FANUC's integrated services, including DFM (manufacturability design) research, and a design update program specifically for solar system products under fully automated manufacturing systems. Sherman said: "So far, the integration program we have designed for us has been very successful. It has provided many good suggestions for the improvement and improvement of the company's process flow."
The use of robots has brought tremendous changes to the company. The new Sun Flower 3.0 system production line will start construction in a few weeks. The production line is set up at the California partner's production base, and it is expected that mass production can be achieved in the fourth quarter of this year. Sherman said: "Once this solar cell production line is completed, the production capacity will reach 10MW/year. With this production line, we can produce more products to meet the global demand for increasing solar energy."
The task of the robot
A 10MW capacity solar cell production line requires about 7,000 square feet of factory buildings and about 12 6-axis FANUC robots. In the entire production line, the robots undertake various tasks including precise positioning of large and small parts, ultrasonic welding, sealing, sticking, automatic tightening, and loading and unloading.
The complete automation of the production line has completely solved the problem of poor manual calibration accuracy. Sherman said: "In the new production line, robots are used to complete the precise calibration of the lens and the battery. The calibration error of the robot is always maintained in a negligible 0.015 inch range. The metering device is also provided to ensure the consistency of precision. ."
Robot automation technology is a great savior for the development of new energy companies. Sherman said: "I have been in the manufacturing industry for a long time. In my experience, I do not think that there is any kind of manual operation to complete the current calibration accuracy. Only the robot can achieve, only the robot can always maintain The consistency and accuracy of the product. Moreover, the benefits of using robots for business are far more than the accuracy of manual operations."
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