GUTTEN MORGEN

A Presentation on 3S module line machines and there

working in brief….By Krishnashis Banerjee

LETS START WITH THE BASIC WORKING OF A SOLAR CELL

Photons in sunlight hit the solar panel and are absorbed by semiconducting materials, such as silicon.Electrons (negatively charged) are knocked loose from their atoms, allowing them to flow through the material to produce electricity. Due to the special composition of solar cells, the electrons are only allowed to move in a single direction.An array of solar cells converts solar energy into a usable amount of direct current (DC) electricity.

Working….

So this was the basic principal and working …. And the arrayOf solar cells is constructed by several modulesObtained from the module line.

SO WHAT DOES A MODULE LINE CONSISTS OF????

STRINGER LAY UPLAMINATOR MODULE TESTER THIS IS THE LINE WE TERM AS MODULE

LINE SINCE WE OBTAIN A COMPLETE MODULE FROM SILICON CELLS AS BASIC RAW MATERIAL.

STRINGER

Name says it all…

ELECTRICAL SPECIFICATIONS:

Rapid two: Voltage 3 x 400V Frequency 50 Hz Power 45 Kilo

watt Rated Current 80

Amperes Air pressure 6 bar

Layup unit:•Voltage 3x 400V•Frequency 50Hz•Power 11 Kilowatt•Rated current 20 Ampere •Air pressure 6 bar

TO BE MORE SPECIFIC ABOUT STRINGER…..

Stringer line consists of Cell loading suction cups Pre-work Conveyor where cells are loaded. Cell alignment camera for checking the cells. Stretching unit, scrimping unit, tab cutting unit

used for tab to be aligned over the cells. Main conveyor with tab gripper for tab

transferring. soldering head/cylinders for soldering the tab

to the cells.

TEMPERATURE DETAILS FOR SOLDERING:

Pre-heating zones

Zone1

Zone 2

Zone 3

Zone 4

Zone 5

Zone 6

Zone 7

Zone 8

Zone 9

Zone 10

70° 80° 110° 118° 225° 225° 118° 110° 80° 70°

These are the approximate values and distributed over 7 blocks , which the main conveyor is divided into.

Soldering head temperatures

1.1 1.2 2.1 2.2 3.1 3.2

241° 241° 241° 241° 241° 241°

Cooling plates are attached to the solder heads which presses after the soldering is done for a minimal time of 750ms to 900ms for a better output.

LAY UP

Also known as gantry unit consists of….• Off load arm transfer the string from

main conveyor to lay up arm.• Lay up arm this carries the strings to

place on the glass(covered with EVA sheet).this arm moves in X-axis, Z-axis and C-axis to place the strings in order.

• VNC camera for checking the positivity and negativity of the strings mainly.

After layup it is sent for busing or interconnection of the strings in series….

Consider :10 cells per string x 6 strings= 60 cells.Each cell generates a power of 3.98W(approx)We know,P=P1+P2+…….+P60 Or, P1 x60 => 60 x 3.98W = 238.8W

LAMINATOR

Once the panel comes out from stringer, layup line and inter-connection of the strings are

done, it’s sent for lamination.

Which is making a compact module toughened to last longer and hence increases life.

ELECTRICAL SPECIFICATIONS:

Voltage 3 x 400VFrequency 50 HzPower 175 Kilo wattRated Current 180 AmperesMax- pre fuse current 200 Amperes

WHAT DOES IT BASICALLY INCLUDES????

Heating chambe

r

Oil pump chamber

Heating chambe

r

Oil pump chamber

Cooling chambe

r

Laminator line

And What makes it unique is----- the medium of heating the chambers is oil….which gives a uniform heating and less chances of problems .

RECIPE:So for running modules with different glass type

we need to prepare recipe, where the following parameters are required to be set accordingly

Temperature Pin up and pin down time Pressing time Pressure Venting rate After feeding the recipe the process is started once the set temperature is reached the

modules are released from the transport conveyor.

LAMINATOR CHAMBER’S WORKING….

Heating chamber 1: The modules settles on the heating

plate --- at this point upper chamber pressure is 0 bar and lower chamber pressure is 1 bar.

The glass sits on pins (pin up)--- at the same time the lower chamber starts evacuating.

Suction starts from both upper as well as lower chamber.

This continues for 360 seconds(on the basis of raw material) as per recipe.

CONTINUES…. FOR HEATING CHAMBER 1: Next pins are down but suction is

on for lower chamber, for upper chamber pressure starts increasing to 1bar and pressing takes place.

This continues for 120seconds(on the basis of raw mat.)

LAMINATOR CHAMBER’S WORKING…. CONTINUED…

Heating chamber 2: Once the above process is over module moves on

from 1st heating chamber to 2nd. Here the only difference is that, no pin-up position is

there. In this chamber, the complete 480 seconds(pin up+

pressing time + sync. time) the upper chamber presses and the suction takes place in lower chamber.

After this the module moves into the cooling chamber.[note: the pressure is applied by the membrane fixed to

the upper chamber]

LAMINATOR CHAMBER’S WORKING…. CONTINUED…

Cooling chamber: In this chamber the modules in hot state are

passed in. Water acts as coolant and atmospheric air

and ventilator fans enhance in keeping the water cooler.

Hence the coolant is circulated through grids in both upper and lower section which presses the module thereby absorbs the temperature by the process of convection.

Complete procedure of lamination depicted through graph

Key points: The glass modules are transported with the help of transport sheets. Upper transport sheets are 1 more then the lower sheets, since the chain is lengthier then the lower chain on which the sheets are fixed. Temperature is controlled by 10 sensors fixed on the heating plates.Specification of the modules:

Module type

Length(mm)

Width(mm)

Area(m²)

72 cell 1998 993 1.984

60 cell 1682 982 1.651

48 cell 1331 993 1.321

Before the modules are sent for testing, junction box is attached which contains Connectors interconnected by diodes …

WHAT IS MODULE TESTER??The testing unit for the solar modules…It collects the feedback about the module and help us analyze the state of it…

ELECTRICAL SPECIFICATIONS:

Voltage 1Ф 230VFrequency 50HzPower 3.68 kilo wattRated Current 16 Amperes

WHAT DOES THE PASAN MODULE TESTER CONSISTS OF!!!

A Tunnel. Two xenon bulbs of 50LM/ watt . A monitor cell. Computer system. Electronic load. Flash generator . Printer. Label printer .

SO HOW DO THEY GET CONNECTED…& WHY ARE THEY REQUIRED!!!

FUNCTIONS FOR EACH CAN BE STATED AS BELOW

A monitor cell fixed for collecting the data and transferring the same to the electronic load.(defined below)

Computer system for storing the data and providing the visual output.

Electronic load collects the measurement data from the module or rather from the monitor cell and does the calculation for various parameters to further feed it to the system.

Printer for obtaining printout of the performance measurement values for each solar module tested.

Label printer for providing a brief quotation about the measurements obtained (especially for the customers purchasing the modules.)

Flash generator this supplies power for the xenon bulb and signal to the electronic load.

SO WE CAN OBTAIN BASICALLY THE FOLLOWING INFORMATION'S:

AND HENCE THIS IS OUR MAIN AIM….GUIDING OUR COUNTRY TOWARDS A BRIGHT FUTURE..

FREQUENTLY ASKED QUESTIONS:

Q. Area required for the module line?A: basically 2000m² for 25MW line and 3500m² for

65MW line.Q. What is the average cell breakage rate per day?A: for 180micron cells the breakage rate is 0.2 to

0.3/day. When using cells of less thickness breakage rate is around 0.5/per day.

Q. What is the Laminator heating plate area?A: 2200 x 3600 mm².Q. Calculation procedure for 25MW line?A: 22.5Hrs/day x 16 modules/hr (960 cells) x

4watts/cell average x 293 days(excluding Sundays and 20 national holidays) = 25.31 MW.

Q. Why are diodes used in junction box?A: For creating bypass routes for the flow of power in

case one of the string or cell in the module gets damaged.

Q. How many modules of 60 cells , 72 cells and 48 cells can be sent into the laminator for one cycle?A: For 60 cells & 48 cells = 4 modules ; For 72 cells = 3 modules .Can be calculated from the size of the glass and laminator heating plate accordingly.Q. Cell capacity for rapid two stringer per hour?A: for rapid two cell loading per hour is 1200cells, for rapid four it is 2400 cells per hour.Q. Is it possible to install air condition inside PASAN tunnel?A: No obstacles can be installed in the tunnel.Q. Will RFID data software be provided by PASAN?A: currently a feature they do support.

Frequently asked questions continued…

A WARM THANKS FOR ALL YOUR ATTENTION…

any questions…..please!