Detailed Project Report on solar module manufacturing unit (250-300 mw/annum)

The thin silicon disks called photovoltaic solar cells are known to convert sunlight into electricity. These are known to act as efficient energy sources for various uses such as calculators and other devices used for telecommunication, pumping, lighting, refrigeration, roof top panels, power satellites, to provide electricity to power plants and miscellaneous other uses.  Let us have a look at the solar module / panel manufacturing process. 

 

The Manufacturing Process of Solar Modules

After production of the solar cells, they are placed as electrical contacts between the cells. Thereafter, they are wired and arrayed subsequently. The solar cells are then sealed into ethylene vinyl acetate. Then, they are framed and sealed with silicon glue. Subsequently, they are covered with Mylar back on the backside and a glass plate on the front – termed as ‘lamination’. This step is indeed considered to be utmost important in the process of solar module manufacturing. This structure is then known to be supported with frames made up of aluminum. The figure below depicts the precise steps in solar module manufacturing process. 

It is also important to have an appropriate power output check. A testing procedure needs to be done to ensure the power output. 

The testing procedures include the flash test that measures voltage of open circuit (VOC), current at maximum power point, short-circuit current, voltage at maximum power point (VMP), the fill factor (FF) as well as the maximum power. Standard testing conditions are always put forth for the measurement of the parameters of the modules.

The standard testing conditions correspond to the irradiance and spectrum of sunlight incident on a clear day with the sun at a specific angle above the horizon. The solar cell manufacturing processes take into consideration the quality control processes. This is because the discrepancy in the various factors and processes can adversely affect the cell efficiency. It is important to find various ways to improve the efficiency and lifetime of the solar cells. It is normally observed that the silicon is tested much for crustal orientation, resistivity and purity at the same time. The presence of oxygen and carbon is also observed much by the manufacturers. The silicon disks are observed and inspected much for bending, flaking, damage, polishing, sawing, etching an dother factors.

It is important to monitor the temperature, pressure, speed and quantities of dopants during the entire silicon disk manufacturing process. It is important that the semiconductors undergo various important electrical tests to see that appropriate standards are maintained for the current, voltage and resistance. The dangerously high voltages of the cells are avoided by the use of shunt diodes.

The final step involves field site testing wherein the finished modules are placed where they are actually supposed to be used. The efficiency of the solar cells can then be determined under ambient conditions. Thus, we have hereby understood the solar module/panel manufacturing process in detail, so as to always run them efficiently and productively.