光伏組件生產(chǎn)線主要工序介紹

光伏組件加工工藝是太陽能光伏產(chǎn)業(yè)鏈的重要組成部分，通過將一片一片薄薄的太陽能電池片封裝，使其可在惡劣的戶外環(huán)境下可靠運行。

Photovoltaic module manufacturing process is an important part of the solar photovoltaic industry chain. By encapsulating thin solar cells, it ensures their reliable operation in harsh outdoor environments.

當(dāng)前主流光伏組件的加工工藝采用的封裝形式是EVA膠膜封裝，它由電池片檢測、電池片單焊、電池片串焊、組件層疊、組件層壓、安裝邊框和安裝接線盒、成品測試和包裝入庫等多道工序構(gòu)成。各道工序環(huán)環(huán)相扣，因此，各道工序工藝水平（一致性和良率）高低都直接影響產(chǎn)品的質(zhì)量和檔次。

The current mainstream photovoltaic module manufacturing process uses EVA film encapsulation. It consists of several processes, including cell inspection, single cell welding, cell string welding, module lamination, module pressing, frame installation, junction box installation, finished product testing, and packaging for storage. Each process is closely linked, and the level of process technology (consistency and yield) in each process directly affects the quality and grade of the product.

第1道工序

Process 1

第1道工序為電池片檢測。作為光伏組件加工環(huán)節(jié)的主要原材料——電池片的性能直接決定光伏組件質(zhì)量好壞，因此，除對它的外觀、色差和電阻率檢測外，還要測試電池在特定光照、溫度條件下的輸出電流、輸出電壓和穩(wěn)定耐用性等參數(shù)，它的測試主要通過專業(yè)儀器和設(shè)備完成。

The first process is cell inspection. As the main raw material in the photovoltaic module manufacturing process, the performance of the cell directly determines the quality of the photovoltaic module. Therefore, in addition to inspecting its appearance, color difference, and resistivity, it is also necessary to test the output current, output voltage, and stability and durability of the cell under specific light and temperature conditions. These tests are mainly completed using professional instruments and equipment.

第2道工序

Process 2

第2道工序為電池片單片焊接。焊接時，左手捏壓焊帶一端約1/3處，將焊帶平放在電池片的主柵線上，焊帶的另一端接觸到電池片上的柵線上；右手拿烙鐵，從左至右用力均勻地沿焊帶輕輕壓焊。焊接時，烙鐵頭的起始點應(yīng)在單片左邊處，焊接中烙鐵頭的平面應(yīng)始終緊貼焊帶。焊接應(yīng)牢固、無毛刺、無虛焊及錫渣，表面光滑美觀。

The second process is single cell welding. During welding, hold one end of the solder ribbon (about 1/3 of its length) with the left hand and place the ribbon flat on the main grid line of the cell, ensuring that the other end of the ribbon contacts the grid line on the cell. Hold the soldering iron with the right hand and gently press weld along the ribbon from left to right with even force. The starting point of the soldering iron should be on the left side of the cell, and the flat surface of the soldering iron should always be in close contact with the ribbon during welding. The welding should be firm, without burrs, false soldering, or solder residue, and the surface should be smooth and aesthetically pleasing.

第3道工序

Process 3

第3道工序為電池片的串焊。操作工藝為：將規(guī)定數(shù)量已焊好的電池片，背面向上排在模板上，用一只手輕壓住2塊電池片，使其貼在加熱模板上，相互緊靠，依照規(guī)定間距（2士0.5 mm）將后一電池片引出的焊錫條用烙鐵壓焊在前一電池片的背電極上。在焊接時要求焊錫條焊接平整，外觀平直，無凸起焊錫疙瘩，無虛焊現(xiàn)象。

The third process is cell string welding. The operation procedure is as follows: Place the specified number of welded cells with their backs facing up on the template. Use one hand to gently press two cells to keep them attached to the heating template and close to each other. According to the specified spacing (2 ± 0.5 mm), use a soldering iron to press weld the solder ribbon from the subsequent cell onto the back electrode of the preceding cell. The solder ribbon should be flat and straight in appearance, without protruding solder lumps or false soldering.

第4道工序

Process 4

第4道工序為層疊。將鋼化玻璃抬到疊層工作臺上，鋼化玻璃的絨面朝上，在鋼化玻璃上平鋪一層EVA。EVA在鋼化玻璃四邊的余量≥5mm。注意要將EVA的光面朝向鋼化玻璃絨面，在EVA上放好符合組件板型的定位模板，電池串分別與頭、尾端模板對應(yīng)，根據(jù)模板上所標(biāo)識的正負(fù)極符號，將電池串正確擺放在EVA上，電池串的減反射膜面朝下。

電池串放置到位后，按照圖樣要求及定位模板，用鋼板尺對電池片的距離進行測量，并調(diào)整電池串的位置。按照組件拼接圖及電壓要求，正確焊接匯流帶，將條形碼貼于規(guī)定位置上。鋪好EVA，其絨面朝向電池串，再鋪好TPT，進行EL測試，確認(rèn)無隱裂、虛焊、脫焊、黑片等不良。

The fourth process is lamination. Lift the tempered glass onto the lamination worktable with the textured surface facing up. Lay a layer of EVA flat on the tempered glass, ensuring that the excess EVA on all four sides of the glass is ≥5 mm. Note that the smooth surface of the EVA should face the textured surface of the tempered glass. Place a positioning template that matches the module board type on the EVA. Align the cell strings with the head and tail templates according to the positive and negative symbols marked on the template, and place the cell strings correctly on the EVA with the anti - reflection film surface facing down.

After the cell strings are properly positioned, measure the distance between the cells using a steel ruler according to the drawing requirements and positioning template, and adjust the position of the cell strings. Weld the bus ribbon correctly according to the module assembly drawing and voltage requirements, and attach the barcode to the specified location. Lay the EVA with its textured surface facing the cell strings, then lay the TPT. Conduct an EL test to ensure there are no hidden cracks, false soldering, de - soldering, or black cells.

第5道工序

Process 5

第5道工序為層壓。按照層壓機設(shè)備操作規(guī)程啟動層壓機，根據(jù)EVA特性調(diào)整層壓溫度和抽空時間，在操作記錄單上記錄溫度、壓力等技術(shù)參數(shù)；在層壓機內(nèi)加熱板上放1層高溫不粘布，將拼接好的組件鋼化玻璃朝下送入層壓機加熱板中間，再放上一層高溫不粘布，按下合蓋按鈕，層壓機進入自動控制系統(tǒng)。當(dāng)層壓結(jié)束后，層壓機自動開蓋，及時取出加工完成的組件，要求組件內(nèi)芯片無異物、碎片、裂紋等。

The fifth process is pressing. Start the pressing machine according to the operating procedures of the pressing machine, adjust the pressing temperature and vacuum time according to the characteristics of EVA, and record the technical parameters such as temperature and pressure on the operation record sheet. Place a layer of hightemperature nonstick cloth on the heating plate of the pressing machine, put the assembled module with tempered glass facing down into the middle of the heating plate of the pressing machine, then place another layer of hightemperature nonstick cloth, press the coverclosing button, and the pressing machine enters the automatic control system. After the pressing is completed, the pressing machine automatically opens the cover, and the processed module is promptly taken out. It is required that there are no foreign matters, fragments, or cracks in the chips inside the module.

第6道工序

Process 6

第6道工序為裝框。在鋁合金邊框凹槽內(nèi)均勻地打上硅膠，將組件嵌入鋁合金凹槽中，啟動裝框機完成裝框。在組件背面TPT與鋁合金交界處均勻涂上硅膠，在相應(yīng)規(guī)格的接線盒背面和引出線根部，周圍均勻打上硅膠，粘上接線盒，把引線接人接線盒。在室溫一定濕度下進行固化。要求：邊框安裝平整不彎曲，鋁合金直角連接處縫隙不大予0.2mm，鋁合金框2條對角線誤差小于4 mm。

The sixth process is framing. Apply silicone evenly in the aluminum alloy frame groove, embed the module into the aluminum alloy groove, and start the framing machine to complete the framing. Apply silicone evenly at the junction of TPT and aluminum alloy on the back of the module, apply silicone evenly around the back and the root of the leadout wire of the junction box of the corresponding specification, stick on the junction box, and connect the leadin wire to the junction box. Cure under room temperature and certain humidity. Requirements: The frame should be installed flat without bending, the gap at the rightangle connection of the aluminum alloy should not exceed 0.2 mm, and the diagonal error of the aluminum alloy frame should be less than 4 mm.

第7道工序

Process 7

第7道工序為清洗。撕掉鋁型材表面的塑料膜，并用酒精液清洗組件表面的各種污染物，確保組件外觀干凈無污染。

The seventh process is cleaning. Remove the plastic film from the surface of the aluminum profile and clean various pollutants on the surface of the module with alcohol to ensure that the appearance of the module is clean and free of pollution.

第8道工序

Process 8

第8道工序為成品組件測試。按照太陽能組件測試儀操作規(guī)程進行測試，首先用標(biāo)準(zhǔn)組件在相同環(huán)境下對太陽能組件測試儀進行校準(zhǔn)，并做好校準(zhǔn)記錄，放入待測試的光伏組件，連接好正負(fù)極，對組件進行測試，通過對比和分析，計算出組件的電性能參數(shù)，并進行記錄。

The eighth process is finished module testing. Conduct the test in accordance with the operating procedures of the solar module tester. First, calibrate the solar module tester with a standard module in the same environment and keep a record of the calibration. Place the photovoltaic module to be tested into the tester, connect the positive and negative poles, and perform the test. Calculate the electrical performance parameters of the module through comparison and analysis, and record them.