100MW solar panel production line 90% automatically

Please watch the video on Youtube:

https://youtu.be/6APp5aZI5-8

100MW Solar panel production line

Design 1, 90% Automatically

It is a complete solar panel prodcution line, base on turn-key solution . 

Production capacity : 100MW per year ( 1 working shift ) ~ 300 MW per year ( 3 working shift ).

Production speed : 24 pcs solar panel per hour depend on producing 550 w solar panel.

Building space :  More than 4000 sqm ( Include office , do not include warehouse ).

Working people : More than 16 persons.

Power consumption : Maximum :300KW, Average.

Investment for machine : Around 2,493,500 USD.

Delivery time :  Less than 60 working days .

Service supply : Lay out desigh, Location installation,

 Location training, Location trial prodution. After service.

Equipment configuration

1, Solar panel laminator     

 Video :  https://youtu.be/8TBkdLs0EMY

USE : As the equipment of manufacturing solar module limited to laminate glass, EVA (Ethylene Vinyl Acetate Sheet), solar cell and back sheet

Dimension : 32000mmx 3380mm x1300mm 

Laminating area:  5500mm x 2400mm.

Laminating height: 25mm

Double chamber, First chamber for EVA film melting, Second chamber for EVA solidify .

Total power consumption: 150 KW ( AC380V, 60 Hz, or according to customer's nee)

 Air source: 0.6 - 1.0 MPa. 200L/ min .

Operating mode: Manual / Automatic.

Control system :  PLC ( Seimens). HIM system: Touch screen ( Seimens )

Heating mode: Oil Heating ( SD320 heat conducting oil, capacity: 170 L, flow pressure:0.3 Mpa.), include: main heating and adjustable heating.

Temperature control: PID intelligent temperature control system.

Temperature uniformity in working area: ≤ ±1.5 ℃

Temperature control accuracy:≤± 1 ℃.

Temperature control range: 30℃ - 180 ℃

Pumping rate:  70 L/s .Laminating time: 2 - 4 min ( excluding solidificationtime )

Heating rate: 140℃ at room temperature with 50 to 60 minutes

Vacuum rate: 200 L / S, the limit vacuum 70 ~ 90 Pa, Vacuum time: 90 seconds

Silicone membrane size:8200mm * 3200mm, 5 mm thickness. The laminating times more than5000 times.

Quick replace silicon membrane design.

Lid opening: Straight from the hydraulic, the biggest opening height: 200 mm

Total weight: 30,000Kg.

Production capacity:

Conventional 550 Wp (2279*1134) solar module, 4 pcs in a cycle time.

Production Capacity:

550 WP *4 pcs/ Cycle * 6 Cycles/h * 8 hours* 300days=31.6 MWp / year.

2, Tabbing and string machine  

Speed :  Max 2s / pc . or 4000 pcs / h

Applied to cell : 156~185mm silicon cell.

Cell busbar : 3BB-12BB (tooling replacement is required for cells with different busbar number or different busbar distance).

Cell thickness : 170um to 200 um.

Ribbon size : Width 0.8 - 3.0 mm, Thickness 0.18 - 0.32mm .

Cell string: Max.length 2200mm

Capacity：

1）Traditional cell

Cell size: 156mm-171mm

Half-cut cell: 3600 cells/hour(depending on the soldering process)

Cell size: 180mm-185mm

Half-cut cell: 3400 cells/hour(depending on the soldering process)

2）MBB cell

Cell size: 156mm-171mm

Half-cut cell: 3400 cells/hour (depending on the soldering process)

Half-cut Gapless: 3000 cells/hour (9BB cell, depending on the soldering process)

Cell size: 180mm-185mm

Half-cut cell: 3200 cells/hour (depending on the soldering process)

Half-cut Gapless: 3000 cells/hour (9BB cell, depending on the soldering process)

Installation (including operation) space shall be.

Note: The production capacity depends on the solder process. If the required solder time is too long, it may affect the production capacity.

3, EVA / BACKSHEET cutting machine     More detail

Video : https://youtu.be/D3EsR66WwoE

4, Glass loading machine 

Loading PV glass by Pneumatic chuck.

Shifting suction cup will absorb the glass from the pallet and put it on the conveying line

The equipment is equipped with double photoelectric switch confirmation, which can avoid the protection of glass collision caused by wrong action

Put the paper between the glass into the isolation box

Automatic warning of material shortage (sound and light)

The feeding area has a protection grating or safety door

With ionic fan for dust blowing glass

Can meet different specifications of glass use

With paper separation recycling function

Meet the 150P (3.2mm) one drag glass size, and 2 torches directly seamless switch.

5, Laying up machine

Use whole servo closed loop control and robot.

Adopt vacuum check technology

Servo lateral locating,digital locating.Set location distance just on the upper computer,be capable of setting every lateral locating distance separately,high efficient in servo location.

Spinning part adopts electronic control and cooperates with robot joint reducer(back interval less than 1arc.min).Be capable of setting spinning degree randomly(set by upper computer) and setting each string’s spinning angle separately.

Glass location device is hand wheel type and intensifying type.The time to change glass is short and no need to use other tools like wrench.

6 opening system and reserving about 30 percent hardware interfaces,which is convenient to the interface control of equipment and auxiliary devices.

6, Bussing machine

Product features:

1, it can complete the welding of all the bus-band of the middle outlet plate of half piece and the welding of the bus-band of the three-outlet assembly at the head of the whole piece of double glass

2, vacuum adsorption grab battery string, empty welding

3. The position of 12 and a half battery strings can be corrected twice

4, the bush-belt coil feeding, automatic preparation of folding TYPE L bush-belt

5, automatic spraying flux in the welding area

6, the components into the equipment have visual normalization function

7, single side feeding, easy to operate

Product parameters:

Rated 25 seconds Max. 21 seconds (Limite Speed)

The soldering way:  Electromagnetic induction welding

Component input and output height : 950 + 20 mm

The component version : The 156/5BB is standard, and the 10 and 12 string configurations of all batteries in 156-170mm sizes are customizablematerial

Confluence with reel feeding, automatic feeding, cutting, size can be customized .

Power supply equipment: 380 v / 220 v 50/60 hz

Power : Peak 35KW average 25KW

Air supply : Pressure 0.5-0.7mpa flow 1.8m³/min

Equipment weight : 3500Kg .

7, Sticking machine

Use to stick high temperature for fixing cell stringer .

1. Function

The automatic adhesive tape between the cell strings is realized. When the number of adhesive tapes is pasted, the speed fast, replacing the manual labor greatly and improves the working efficiency, and the adhesive position is accurately, without causing secondary damage to the battery.

2.Technical Indicators

ITEM Specification

Working voltage AC220V，3 Phase 5 Lines,50/60Hz

Rated power 4KW

Working air pressure 0.6‐0.8MPa

Average Air Consumption ≥220L/min

Tape Types

L≥15mm‐25mm W≥5mm 3Muv‐1Applicable

3V‐1 standard hardness tape

Tape width

Applicable for adhesive tape width of 5‐10mm

Driving Mode Synchronous belt

Control mode PLC+HMI+Servo control

Manipulator repeated positioning

Accuracy ±0.2mm

Adhesive accuracy  ±1.5mm

Module Size Length（1630‐2500mm）×Width (950‐1400mm)

Tact 22S.  The number of adhesive tape is different, and the beat is different

Overall Dimensions 3360*2160*1840(L*W*H)

Total Weight About 2000kg

The scissors can be changed within 5 minutes. After replacement, the scissors can be used normally

3. Set multiple sticking head, adapt to different type, strong compatibility; Special cutting device, tape applicability is wider, not easy to stick knife;

The patented press device can not only achieve the stability of sticking, but also not easily cause the crack and damage of the battery.

The steel frame structure prevents the tape head from shaking in the high speed operation.

Reasonable configuration of slide track, quick change of glass, convenient for customers to switch version.

4. Safety precautions

Paste installation and warning labels;

Set the emergency button, when an emergency occurs, the operator can press it in time to realize the emergency shutdown;

The three‐color alarm lamp accurately provides the operating status of the equipment and provides the operator with timely and accurate alarm information;

It is equipped with safety guardrail and safety light screen to ensure the safety of personnel during operation and material replacement;

When air source, vacuum and sensor are abnormal, visual and audio alarm can be realized.

 8, EL&VI tester

Electroluminescent inspection for detect solar panel before laminating and after laminating.

To check solar panel of secluded split, cracked cell, rosin joint, wire break and other defects.

Can testing module: 2600mm x 1400mm

Maximum current: 10A，Maximum voltage: 60V

Include：Cabinet（Include infrared camera）+ Computer + Software

4 cameras, take 12 pictures for one solar module , the pixel get 20 million.

Time of exposure：0.1 S-25.5 S Adjustable

Power:  220V 10A or customize.

Working environment temperature ：10 - 30 ℃

Humidity: 20 - 70%

Main function of characteristics:

By using images can find: material other defects. the sides of the pneumatic feeding short, art and craft contamination

Testing fast and convenience was longtime 1s - 25s （ adjustable ）

It is testing on line.

Power consume : 2 KW 

9. Trimming machine

Work beat： 20 seconds

Suitable size ：Length: 1650-2500 - mm ; width : 990-1400 - mm

The maximum weight: 50Kg

Power supply AC 380V 3-phase 5-wire 380V 50HZ/60HZ

Rated power: 3KW

Working pressure 0.6-0.8 Mpa

The gas consumption of 500  L / min.

The maximum weight of a single device is 1500kg.

10. Inspection machine

Turning over for visual inspection solar panel after trimming .

Automatic turning by PLC control .

Be apply to the solar panel 990 x 1890 mm ~ 2600 x 1400mm.

11. Gluing and framing machine

Technical Specification

1) Solar Panel Minimum size 1650X990X50 (35) mm;

2)  Solar Panel maximum size 2500X1400X50 (35) mm

3) Compatible with a maximum weight:50kg

4) Rated power: framing machine 13kw,machine hand 5kw

5) Working power: AC 380V 3-phase 5-wire system 380V 50HZ/60HZ

6) Air consumption: Framing machine 800L/min Manipulator 20L/min

7) The maximum weight of a single device: Framing machine 4000kg Manipulator 2000kg

8) Working noise ≤72db

9)  Source of compressed air cylinders volume: air Source: 0.6 ~ 0.8 Mpa;

10)  PLC program.

11)  Auto loading .

12)  The heavy screw mechanism makes the frame error very small.

Features of the machine

Strong point , the width dimension can be adjust.

Distinctive allocation is locked up. The multiple spot assists pressure the head handle simple, convenient.

12. JB gluing machine      More detail

Video:  https://youtu.be/jBdHW68SgOQ

13.  Gel Injection machine                       More detail

14. Unloding machine                  More detail

15. Grinding machine              More detail

16. Solar module tester         More detail

 Video:  https://youtu.be/bwuWdhUHSCY

17. Hlpot &resistance test

The tester is an equipment for measuring withstand voltage, and it intuitively actually quickly and reliably tests a variety of electrical safety performance indicators, such as breakdown voltage, leakage current etc. of equipments under test and it also tests performance of components and the whole machine as AC high voltage source. ET2670A withstand voltage tester is designed according to the International and national safety standard such as IEC，ISO，BS，VL，JIS, and its withstand voltage AC is 0~5kV, leakage current AC is 0.1~20mA. The tester is widely used in measuring safety withstand and leakage current tests for different electrical apparatus, insulation materials, high-low voltage switchgear, low voltage bus, electric machine and components. At the same time, the tester is an integral withstand voltage test equipment for research laboratories and the department of technical supervision.

Test voltage, leakage current test and time are all-digital displayed. And rupturing current can be randomly and continuously set up depending on different safety standards and customers’ requirements that enriches its function. And the leakage current display actual value of testing leakage current and compare how well of withstand voltage between the same products of different bathes or products from different companies.

Technical specifications

1)  Voltage measuring range: AC≥6000V

2)   Leakage measuring range: AC：(0.1～2/20)mA  grade2±5%

3)   Leakage current alarm reset range: AC: ( 0.1～2/20)mA  grade2±5%（Continuously setting）

4)   Time test range: (1～99)s，±5% Continuously setting, manual test ∝

5)   Transformer Capacity: 500VA

6)   Output waveform: 50Hz, Sine wave

7)   Working condition: environment temperature 0~40℃

8)   Relative humidity ≤75%

9)   Atmospheric pressure: 101.25kPa

10)   Charge: AC:240V   (50±2.5)Hz

Notice before use

1)   User must understand operation manual

2)   The tester must use three cord power wires, and center ground wires need to connect well.

3)   When the tester connects to device under test, make sure the tester in reset mode and the output test current adjusted to “0”.

4)   Once test and owe resistance lights are damaged, they must be changed immediately in case misjudgment.

18, Automatic conveyor    

Before laminating

After laminating

Curing and sorting

 Technical Specification

1, Solar Panel Minimum size 1550X990X50 (35) mm;

2, Solar Panel maximum size 2500X1400X50 (35) mm

3, Source of compressed air cylinders volume: air Source: 0.6 ~ 0.8 Mpa;

4,Compatible frame maximum weight: 50Kg

5, Working power :AC 380V 3-phase 5-wire system 50HZ/60HZ

6,Rated power:2kw

7, The maximum weight of a single device : 2800kg

8, Working noise ≤ 75db

Features of the machine

Fully automatic control of the equipment, no human intervention is required during operation

Component feeding/discharging are protected by detection switch to prevent the hidden danger of debris caused by shield interference when the component is lifted

Equipment operation surface is simple, convenient and reliable

19. Air ompressor   ( It is nomally compressor , But will be lower price from China ).          More detail

You can Click each above equipments to check the specification detail .

This specification shall cover design, manufacture, shipping, oversea installation,oversea training and oversea after service. This solar panel production line should have a production capacity of  100 MW/year considering 80% uptime and single shift of operation. 

Workshop:

1. General requirements of workshop: more than 4000 square meter.

Requirements in warehouse: The soldering room and EVA storehouse temperature, keep in 25 ℃.

2. Infrastructure:

(1) Power source: 3 phase 5 line, more than 300 KW;

(2) Water supply: little need.

(3) Air source: 400L / min compressed air;

(4) Environment: (enclosed, dust-proof, anti-skid, temperature);

(5) The main production site layout plans.

Solar panel produce program 

1. Preparation: Preparation of raw materials.

2.  Cutting material: EVA. TPT. soldering wire.

3. Soldering solar cell. By tabbing and string machine.

4. Laying up:Tabbing solar cell on the EVA and glass.

5. Laminating: Laminate EVA , Solar cell and back sheet also glass by the laminator..

6. Fix junction box: Trim edge of the extra EVA and fix junction box on the panel.

7. Testing: Test laminated solar panel by EL tester and solar module tester.

8. Quality tests: In the process of making other tests, IV curves of the test, and the appearance of high-voltage isolation.

9. Warehousing: Qualified storage products, goods failed to repair.

 The main raw materials

 ① Tempered glass

 ② Solar cells

 ③ EVA film

 ④ TPT sheet

 ⑤ Junction Box

 ⑥ Soldering ribbon.

 ⑦ Aluminum alloy frame

 ⑧ Silicon gel

 ⑨Soldering flux.

 ⑩ High temperature tape

Layout:

We design the factory layout showing different machines for smooth production. The layout should show the all the machines including the store and office area in proposed layout plan.

Installation:

We send engineer or technicians to buyer’s factory to install machine. All expenditure on travel, food, accommodation and transportation of our engineers/ technicians for installation will be borne by buyer. REOO company borne the salary of engineer/technicians.

Training:

We supply both overseas and local training to the engineers and technicians on operation and maintenance. buyer borne air tickets, lodging, food and training material .

Minimum 12 (twelve) months warranty of all products and services and guarantee for the spares and required maintenance or replacement support are to be provided . Buyer borne the cost of the material for parts of maintenance.

Payment Terms:

40% of the contract value be pay by T/T advanced.

60%  before shipment.

Delivery time:

60 days after received the advance payment.

Insurance:

We borne insurance of goods under contract from the time these are loaded on board the ship.

Taxes and Duties:

Buyer shall pay all taxes and duties, payable under government laws, for all goods and materials imported under the contract into any port .

Packing:

All the equipment, tools, accessories and goods be suitably packed. All packages are liable to be opened for customs examination and packing shall therefore be designed to facilitate opening and repacking thereafter. Each package shall have the shipment information printed on it in bold letters.

Manuals/Documents:

Operational and maintenance manuals of all equipment is in English, along with a soft copy in a CD (compatible version: MS Word/ PDF).

Backup spares:

We supply essential backup spares. items beyond warranty periods, buyer borne the cost.

Raw material:  

We supply all the material for production solar panel from China for trial production and formal production, buyer pay for the cost.

Power consume: 

The total consume for electricity power: 300 KW, 3 Phase , 5 line .

Guarantee and after -sale service:

One year guarantee for whole machine except of consumable..

24 hours technical support by E-mail, Skype or QQ..

Calling or door-to-door service

Ues-friendly English software, user manual and detailed Video/CD.