Solar Technology English Jan 2012 (5)

7/27/2019 Solar Technology English Jan 2012 (5)

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Solar Technology

Thin Film on Glass and Web | ConCenTraTed PhoTovolTaiCsConCenTraTed solar PoWer


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The ast growing solar market has ocused on cost reduc-

tion, increased eciency and throughput. With these targets

in mind, Grenzebach has developed sophisticated auto-

mation and process equipment to provide a maximum o

yield, throughput and quality. Starting with individual layout

concepts with yield and buer simulations, Grenzebach has

established an enviable reputation as a provider o equip-

ment and services rom the start o a project, thru commis-

sioning o the line to aer-sales support.

Grenzebach experience embraces all practical thin lm and

web technologies such as CIGS, a-Si/c-Si and CdTe and has

installed such lines all over the world. Combining all depo-

sition processes with reliable conveying and

buer technology in a clean room atmosphere

is key to Grenzebachs expertise. Complicated

interaces and data communications are coor-

dinated by Grenzebachs material ow cont-roller and MES soware.

Our ocus targets soware solutions which

support the customers needs and expectations.

Grenzebachs surace inspection systems take account o all

necessary process steps in order to receive instant quality

data regarding the product.

CSP is another alternative energy solution with dierent chal-

lenges. Grenzebach expands the product portolio with produc-

tion lines or linear Fresnel and parabolic trough collectors. Full

or semi automatic production lines assemble precisely rame

and these collectors to a high ecient technology.

Concentrated Photovoltaic CPV creates an increasing demand

or high ecient PV modules. Grenzebach integrates complex

dispensing technology and combines it with a sophisticated

mounting system to achieve maximum eciency.

Leading global players count on Grenzebachsexperience in line automation p u ut t ptz pc utzt puct tugput.

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Grenzebach has achieved a leadingposition as an outstanding partneror line automation. at t tt gup uccu c tw g kt.

When deciding how a new production line will be set

up the client can incur a major nancial investment

particularly in respect o deposition processes and

buildings. Investors preer well simulated production

lines to eliminate potential risk or uture investment.

Global industry is constantly searching or experi-

enced partners with a spotless reputation, oering

development capabilities with layout planning and

line simulation to provide an optimized production line.

Grenzebach has proved a highly reliable partner or

top global players in the thin lm business.

More than 40 o our thin lm lines are producing

over 2,2 GWp o thin lm modules every year.

With its roots in the glass business, Grenzebach

calls on 40 years o high level technology experience,

thus ensuring, that our customers achieve ull

satisaction as ar as reliability and lie span o the

line are concerned.

Detroit

Stuttgart

So Paolo

Athens


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Grenzebach always nds a solution or the customers needs.

The entire group is ocused on the clients requirements.

We know that smoothly running plants and machinery orm the

basis or success. Reliability, expertise and rapid action are key

Grenzebach maxims. The production plants we supply are a

vital cornerstone in ensuring our customers success.

We take this responsibility very seriously. Thereore, service

at Grenzebach is concentrated in a separate division. From the

initial machine design right through production, Grenzebach

engineers ensure long-term serviceability and the highest

possible quality and precision. We support our customers

through all operating phases o the plants. Grenzebach

companies located all over the world employ qualied employees

to provide installation, start up and training services in that

region, so that customers can be

supported in their own language, their

own culture and their own time zone. We

never leave anything to chance; we use

the latest technology and media to keepin permanent touch. Grenzebach is able

to access the customers control system remotely, monitor

operations and intervene with corrective action i required.

We always keep a close eye on the plants we have supplied,

and respond immediately when needed anywhere in the

world. Far-ranging vision, expertise, preventative action and

close cooperation with customers make it possible or us to

guarantee that our plants will operate saely and precisely over

decades. It is oen the case that our customers requirements

and their products will change over time. Soware updates

enable our engineers to adapt the unctions o the plants

accordingly. We oer a comprehensive package with integrated

spare parts supply which is very popular with many customers.

This ensures the plants are always maintained in peak condition

both now and or the uture.

Service at Grenzebach: ru t cck.ru t w. T 24/7 pcp pp t 24 u , 7 wk.


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T F Tcg G bck e / ecput

T F Tcg G-s / c-s

The most practical way oapplying Thin Film technology ccp wt puc. Gzc uttqupt p tg pt t.At an early stage Grenzebach recognized that leading process

suppliers need a strong automation partner to share the responsibi-lity o achieving eciency, yield and throughput. Grenzebach equipped

ront- and back ends or production lines all over the world.

A unique seaming application by means o a robot oers our customer

a two-in-one system or de-stacking the glass and

seaming the edges.For the deposition processes

Grenzebach engineered sophisticated loading tools

to ensure load locks are open or as short a time

as possible. Air conditioned stations and buer

systems improve the yield o the line and t he e-

ciency o the substrates. FILO, FIFO, cassettes and

trolley system are part o our product portolio

capable o operating in a clean room atmosphere.

Splitting larger sizes into handy sizes is just onestep in product diversication.

Our Laser Ablation System warrants a module lie

time and security to satisy market needs.

The quality and lie timeo the PV-module w t t uttg t ck .

The handling o back glasses and lamination oils are part o

our glass experience with all global glass producers. There-

ore paper or string removal applications are an option or ourde-stackers. Climate rooms or PVB coils are routinely planned

and installed by Grenzebach.

Bus bars and butyl applications are part o our supply scope

at the back end. Sophisticated oil trimmers prepare the

module or the lamination process.

Grenzebach oers the two step lamination process by inte-

grating a nip roller urnace ollowed by an autoclave system

specically or the use o PVB oils in the BIPV market.

Grenzebach provides ully automatic solutions or module

handling around the autoclave.

JBox applications attach t he JBox semi- or ully auto matically

on the back glass and connect the contacts with the bus bar.

Flasher, HiPot and Labelling satisy the demanding require-ments o the industry and provide quality dierentiation or

Grenzebach sorting and packing systems.

Filo-Buer

Pre-Laminator

Buer System Glass LoadingShuttle System

Non-Contact-GripperInspection CVD-Loader Angle Transer

Conveyor

Laser Edge Deletion

Cleanroom Conveyor Foil Handling

Autoclave

Buer-RackRoller Conveyor

with Housing

Spacerless Rack

Handling


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CIS/CIGS Best in classin terms o perormanceeiciency. Gzc utt twt t c cgtcg.

The cleanliness o the product was Grenzebach top motivation

to move the sensitive substrates careully through the sputter

and deposition processes. Temperature treatments or buer

systems have been excellently accomplished. Integrated carts

and trolleys prepared or a Nitrogen or inert gas connection

became o crucial importance or this sensitive deposition

technology. A perect option or an innite buer scenario with

lots o exibility.

The decision whether central or de-central buer scenarios are

more economical will be established by our simulation system.

Special handling systems using non-contact grippers li the

substrate rom the top side without touching the deposition side.

Grenzebachs LAS deletes the edges o the substrate and elimi-nates all particles by means o a vacuum system. On demand a

side edge deletion LAS-S or selective layer ablation down to

the Molybdenum can be tested upront and integrated.

Back glass deposition hasdierent requirements atthe Back End. Ptg Jx ptt u t u g. Gzcf t c ut.

Keeping in mind that the back glass has been processed

through the ront end, the back end has to drill holes or the

Jbox. Gre nzebach s upplies s tate-o-the -art las er drilling

systems to insure the highest quality o glass. This new

technology oers a micro-crack-ree glass edge.

Integrated solutions or bussing.

Integrated solutions or bussing systems in combination with

sealant tapes and smart Jbox connections are important

modules o Grenzebachs back end concept.

Light soaking tunnels increase the eciency o CIGS modules

beore ashing. A wide variety o asher suppliers oer our

customers a tower or table asher to prove the eciency othe module.

Manual or automatic raming stations can be easily integ-

rated in the Grenzebach back end.

Foil Trimming Turn Conveyor Barcode Reader Carrier HandlingPacking

Seaming Robot Lifer WasherLaser Edge Deletion

Foil Lay Up

InspectionShuttle with Wireless

Energy Transmission

Destacking with

Paper Rejection


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CdTe Technology has thelargest market gww t upuct t. T gu u puc c tt wt u

utt puct wtGzc t wtcg.

Optical and electrical inspections systems are o prime impor-

tance or the eective protection o a consistent quality in

your production. Fully automated inspection systems are

essential or every photovoltaic production line. Grenzebach

oers extensive solutions. Optical systems equipped with CCD

Cameras and intelligent LED-illumination inspect Front- and

Back glass, Coating and layer deposition, P1 P3 structuring,

as well as the result o lamination. Electrical systems like

IV-Curve, resistance measurement aer LAS and HiPot ensure

consistent quality in production as well as a high yield.

BIPV and module stability:dt tt t u pt lg u qucc uppt.

Grenzebach oers multiple solutions or back rail or bracketapplications. Our ully automated systems clean, prime and

adapt dierent materials to the back side o the module.

Complex systems with material magazines, dispensing stations

and handling o 2K material are just a ew o the possibilities

or connecting modules with ins tallation materials.

All material used will be tracked by our Grenzebach-MES system.

The operator is always kept up to date with production by

means o a material management tool.

Roller Conveyor Rotating Conveyor Scribe Line Inspection AGV System Trolley Buer System Lifer

Inspection Filo-Buer Belt Conveyor Robot LoadingStorage System Ultrasonic Welding


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bck e / ecput

The merging o thin ilmwith crystalline moduletechnology ptg t x t ut w tcg. T t pt z

puct ct.

Grenzebachs ocus in this technology is directed to the appli-

cation and marriage o glass with glass, glass/Tedlar or

exible oils in combination with established web technology.

The development o a non-contact gripper system enhances

the machinery around the back end positions.

Grenzebachs experience rom the building material industry

provides a variety o solutions or coil handling at the ront end.

Coil changers load and unload the roll-to-roll process and

warrant sae transport to the next process step via AGV shuttles.

Complete AGV systems, built to the highest industry standard,are provided through the Grenzebach Group.

Whether lexible or on glass W tcg t tw, tt wt z tt .

The lamination process has dierent requirements when it

comes to the dierentiation between exible and glass

modules. Handling multiple coils or dierent oils is the mostimportant aspect.

The parallel bus connection o serially connected modules is a

urther challange and creates yet another challange or

packing automation. Grenzebach provides solutions or inline

and ofine systems.

Storage System Non Contact Gripper Pairing Station Foil Handling

Inspection Cooling Buer Lif Unit Trimming

Stacking Robot Cleanroom Conveying

Technology

Sorting and Packing


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Cctt s PwTcg CsP

A second pillar or GrenzebachMaschinenbau GmbH tCctt Pw ct CPvTcg. T puct tt wt t pt u utt CPv puct

.Experience gathered rom CSP and Thin Film Technology

provided the critical advantage needed or the assembly

process steps and the very high accuracy required.

High accuracy is especially important as it runs parallel with

the high standard o equipment which brought Grenzebach to

their leading position in this market.

As a result, Grenzebach is ideally qualied or urther growth

in the Concentrator Power sector.

Principal benets are

Experie nce in all major technologies (CSP, CPV and

Thin Film) Very high accuracy and requirements in quality

Fully automatable

Modular and exible or dierent model sizes

The development t-zt CsP upuct pt t tt t t Gzc mcuGh puct pt.This new market emerged rom the experience gathered on

thin-lm photovoltaic module production lines and especiallyocuses on the Fresnel and parabolic trough technologies,

that create the prerequisites or automated production.

New process steps were developed as required and known

processes were aligned on t hermal solar technology.

This resulted in a CSP mirror module production plant built to

the latest technical standards.

Principal benets o this plant

Semi-automatable to reduce the investment volume

Fully automatable to achieve a high output and low labor costs

Modular design

Quick disassembly and reassembly or high exibility as to

the production location High accuracy

Customized concepts

Uploading Assembly InspectionRaw Material Loading

Turning Device Raw Material Loading Assembly Process Assembly Process

Inspection

Storage Areas

CuttingLoading Packing


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PlC, mFC, mes, l sut

ERP

MES

MFC,

Global Saety

Drives,Actors,Sensors

PLC,HMI

Manuacturing Execution System

Material Flow Control

ERP

ProductInormation

ProductionSequences

BuisnessIntelligence

ResourceManagement

ERPInteraction

Reporting

InventoryControl

Long termArchive

SchedulingMaintenance

PlanningSkill

ManagementOrder

Dispatching

EquipmentCustom

InteracesShoploorTerminals

ProductTracking

Simulation RoutingRecipe

DeploymentWork in Process

MonitorSEMI E10

Equip. StatesGlobalSaety

InventoryControl

RedundancyGobalHMI

ID GeneratorBatch

ManagementEvent

TrackingCommunication

Monitor

PC-Panel

Drives

MES

MFC

I/O-Signals

I/O-Signals

Drives

Local PLC 1 with Saety integrated

Global Saety PLC

Proinet

Local PLC 2 with Saety integrated

Visualize, determine andrealize your productionlowrom project start to product-ion start. Gzc upptwt ut tj wt t g ptct

PlC, mFC mes t.Grenzebachs simulation team provides to our customers a

simulation o the uture line which is very close to reality.

Based on SEMI E10 standards, all unscheduled and scheduled

downtimes will be considered in order to determine the

optimal buer space and production equipment. Control o

the production process at all times, quick reaction and ull

use o the line capacity the Grenzebach control system

meets all these requirements in ull.. Grenzebach oers a

complete range o machine controls, specically designed or

individual applications - rom PLC control up to complex

controls or robot movement. The graphic operation concept

is clearly structured and all stations are ully linked with eachother. Grenzebach oers a vast range o control technology

or every level o automation.

Maximize and simply yourproduction line czt tpc u pc wt Gzccutz mes t.As an instant decision maker, Grenzebachs MFC handles all

relevant decisions o the entire line automation.ID - generation, production tracking, WIP , recipe deployment

as well as event tracking, all eature our high reliable MFC

system. A later integration o our MES system is also

possible.l. Teleservice and 24hour service support the opera-

ting sta.

Grenzebachs experience with world wide operating host

computers enhance the eciency o the entire process chain.

The modulized architecture o our MES system incorporates

a long term archive o the production sequence with a

exible reporting tool, production scheduling, business intelli-

gence and resource management. Scheduled production

maintenance in combination with inventory control and skill

management are urther highlights designed to ull custo-mers needs and prepare the line or uture optimization..

Integration into an existing ERP concept is a matter o course

or Grenzebach.


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Wherever metal meets glass, the

connection has previously been o

rather short duration. However, inter-

aces o this kind are widely used in

such practical applications, as in acade

elements or brackets or solar modules.

Grenzebach has addressed this topic

and already registered a patent or

ultrasonic welding.

The process makes possible a lasting

bond between glass and metal. At

present, the technology or ultra-sonic welding is still being improved

and rened; a test machine is already

running. There are many interesting

potential applications or this process,

representing new markets which the

Grenzebach Group are keen to exploit,

sutt t

Grenzebachs participation in the

company LJU has urther enhanced its

product portolio.

The pooling o both companies know-how

has given birth to a new shuttle system

with exceptional properties. Grenzebachs

experience with telescopic and liing

systems combined with LJU expertise

with AGVs has produced an all round

winner or the solar industry.

The shuttle system excels by its modu-

larity. It combines the our primarycomponents carriage, liing axis with

telescope and wireless power and data

transer. This makes the shuttle system

completely versatile.

Benets:

Straightorward design

Individually adaptable axes

High payloads up to 1000 kg

Accommodating individual sheets or

complete cassettes

Individual cassette applications are

also available or inert atmospheres

Harmless to persons tted with a

pacemaker

l cuttg

The operation o laser cutting is similar

to the conventional cutting process.

Its absolute advantage, however, is the

total lack o micro cracks on the glass

surace. The Grenzebach laser cutter

uses a CO2 laser with a specic wave

length that is absorbed by the top

glass layers and where it is converted

into heat. A set o special and adjus-

table mirrors deect and ocus the laser

beam over a specic length along the

score line. This is done several hund-reds o times within a second and heats

up the glass surace in a controlled way.

The heat is applied in a way that avoids

negative eects to the glass structure.

l atst las

Thin solar module manuacturers have

been yearning or such an application

in their eorts to cope with undesirable

power transmissions.

Grenzebach have strived to develop a high

exibility system. This has resulted in a

system or any module size. Benets o

our laser-based edge ablating process:

non-contact process to avoid glass

damage

no additional process media such asshot or chemicals needed and thus no

extra recycling costs

Another eature, oering extra benets,

is the vertical process arrangement:

t or processing dierent glass sizes

t or BIPV module centre ablating

ecient extraction system

Our system can ablate all usual ront and

back contacts, semi-conductor coatings

and TCO coatings.

n ctctg gg

Our non-contact handling systems

benet rom the grippers ultrasound

air bearing. 6-axis industrial robots or

multi-axis gantries are tailored to the

needs o the handling application. The

grippers ultrasound air bearing (made

by Zimmermann & Schilp) is t or all

atmospheric applications. It generates

a load bearing gas lm (air or process

gas) between gripper and substrate.

This avoids mechanical contact. The

substrate oats riction-ree eitheron or beneath a gas lm. The equili-

brium between repelling ultrasound

and downward orces on the one hand

and the attracting vacuum orces on

the other hand allow the equipment to

grip the glass rom the top side and

to handle it contact-ree and oating

upside down. The glass is side aligned

against reely congurable adjustable

mobile stoppers.

suc pctt

Grenzebachs new Group member

ALGOSCAN has developed new surace

inspection systems or the thin lm

market.

The state-o-the-art camera inspection

systems detect typical glass deects

especially on the edges o the glass as

well as at the perimeter o the hole.

Another specic system is able to

detect all typical coating deects even

on structured suraces. The system also

checks the scribe line geometry andquality.

The nished modules run on the

conveyor through the nal camera

inspection system which is able to

detect all typical nishing deects such

as bubbles, excessive glue or scratches.

Benets o this inline application:

Automatic inspection is essential or

each solar module line, as a consistently

high quality is needed or maximum

yield o production and or the quality

o the nal product.


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bUildinG maTerials | General indUsTry | serviCe

www.gzc.c

LJU Automatisierungstechnik GmbH

Am Schlahn 1

14476 Potsdam, Germany

Phone: +49 33201 414-0

Fax: +49 33201 414-19

e-mail: [email protected]

GRENZEBACH Machinery Taiwan Ltd.

No. 38, 2F, Keya Rd., Central Taiwan

Science Park, Taichung 428, Taiwan R.O.C.

Phone: +886 4 25667796

Fax: +886 4 25687896


GRENZEBACH Detroit

38855 Hills Tech Drive

Suite 550

Farmington Hills, MI 48331, USA

Phone: +1 248 536-0430


GRENZEBACH Maschinenbau GmbH

Albanusstrae 15, Hamlar

86663 Asbach-Bumenheim, Germany

Phone: +49 906 982-2000

Fax: +49 906 982-2108


GRENZEBACH Algoscan GmbH

Machtlnger Strae 21

81379 Munich, Germany

Phone: +49 89 748558-0

Fax: +49 89 748558-599


GRENZEBACH Machinery (India) Pvt. Ltd.

Devdar 4th Floor, Plot No. 83, S.No. 98

Bhusari Colony, Poona 411038

Maharashtra, India

Phone + Fax: +91 20 252-86012


GRENZEBACH do Brasil

Rua Lagoa Santa, 160, Chacaras Reunidas,

Sao Jose dos Campos, SP

12 238-340 Brasil

Phone: +55 12 3922-9400


GRENZEBACH BSH GmbH

Rudol-Grenzebach-Strae 1

36251 Bad Herseld, Germany

Phone: +49 6621 81-3000

Fax: +49 6621 81-93613


GRENZEBACH Corporation

10 Herring Road

Newnan, Georgia 30265, USA

Phone: +1 770 253-4980

Fax: +1 770 253-5189


GRENZEBACH Mashtech, LLC

Novocheremushkinskaya Street 61

117418 Moscow, Russia

Phone: +7 495 626-5881

Fax: +7 495 626-5882


GRENZEBACH Automation GmbH

Wikingerstrae 11

76189 Karlsruhe, Germany

Phone: +49 721 95240-0

Fax: +49 721 95240-50


GRENZEBACH Machinery (Shanghai) Ltd.

388 Minshen Road, Songjiang Industrial Zone

Shanghai 201612, P.R. China

Phone: +86 21 6126-8000

Fax: +86 21 57685220


GRENZEBACH Machinery S. r. L.

Via Savona 11

12045 Fossano, Cuneo, Italy

Mobile: +39 348 6042740

Fax: +39 0172 630716


Documents

Solar Technology English Jan 2012 (5)