200MW 光伏組件生產線設備特點介紹

電池檢測與焊接相關設備

Battery Testing and Welding Related Equipment

? 電池檢測設備： 由于電池片制作條件隨機，生產出來的電池性能不盡相同，所以需通過測試電池的輸出參數（電流和電壓）的大小對其進行分類，以提高電池的利用率，做出質量合格的電池組件。

? Battery Testing Equipment: Due to the random production conditions of battery cells, the performance of the produced batteries varies. Therefore, it is necessary to classify them by testing the output parameters (current and voltage) of the batteries to improve battery utilization and produce qualified battery modules.

? 正面焊接設備： 將焊帶焊接到電池正面（負極）的主柵線上，焊帶為鍍錫的銅帶，焊接機可將焊帶以多點的形式點焊在主柵線上。

? Front Welding Equipment: Weld the solder strip to the main grid line on the front (negative electrode) of the battery. The solder strip is a tinned copper strip, and the welding machine can spot-weld the solder strip to the main grid line in a multi-point form.

? 匯流焊接設備： 將已經串連焊接的電池串，經過自動排版后，形成一個整體的組件，把電池串進行并聯(lián)焊接，接通正負極，以保障完成發(fā)電后電流的輸出。

? Busbar Welding Equipment: After automatically typesetting the series-welded battery strings, form an integral module, perform parallel welding on the battery strings, and connect the positive and negative electrodes to ensure the current output after power generation is completed.

層壓敷設與層壓設備

Lamination Laying and Lamination Equipment

? 層壓敷設設備： 背面串接好且經過檢驗合格后，將組件串、玻璃和切割好的 EVA、背板按照一定的層次敷設好，準備層壓。敷設時保證電池串與玻璃等材料的相對位置，調整好電池間的距離，把電池片組串貼上光伏組件專用膠帶固定位置，為層壓打好基礎，敷設層次由下向上為玻璃、EVA、電池、EVA、背板。

? Lamination Laying Equipment: After the backside is connected in series and passes the inspection, lay the module string, glass, and cut EVA and backsheet in a certain layer to prepare for lamination. During laying, ensure the relative position of the battery string and materials such as glass, adjust the distance between batteries, and fix the position of the battery string with special tape for photovoltaic modules to lay the foundation for lamination. The laying layers from bottom to top are glass, EVA, battery, EVA, and backsheet.

? 層壓機： 將敷設好的電池放入層壓機內，通過抽真空將組件內的空氣抽出，然后加熱使 EVA 熔化將電池、玻璃和背板粘接在一起，后冷卻取出組件。層壓工藝是組件生產的關鍵一步，層壓溫度層壓時間根據 EVA 的性質決定，使用快速固化 EVA 時，層壓循環(huán)時間約為 15 分鐘，固化溫度為 150℃左右。

? Laminator: Put the laid batteries into the laminator, extract the air in the module through vacuuming, then heat to melt the EVA to bond the battery, glass, and backsheet together, and then cool and take out the module. The lamination process is a key step in module production. The lamination temperature and time are determined according to the properties of EVA. When using fast-curing EVA, the lamination cycle time is about 15 minutes, and the curing temperature is about 150°C.

修邊、裝框與接線盒焊接設備

Trimming, Framing, and Junction Box Welding Equipment

? 修邊設備： 層壓時 EVA 熔化后由于壓力而向外延伸固化形成毛邊，層壓完畢應將其切除。

? Trimming Equipment: During lamination, the melted EVA extends outward due to pressure and solidifies to form burrs, which should be cut off after lamination.

? 裝框設備： 給玻璃組件裝鋁框，增加組件的強度，進一步密封電池組件，延長電池的使用壽命。邊框和玻璃組件的縫隙用硅樹脂填充，各邊框間用角鍵連接。

? Framing Equipment: Install an aluminum frame on the glass module to increase the strength of the module, further seal the battery module, and extend the service life of the battery. The gap between the frame and the glass module is filled with silicone resin, and the frames are connected with corner keys.

? 焊接接線盒設備： 在組件背面引線處焊接一個外接線盒子，以利于電池與其他設備或電池間的連接。

? Junction Box Welding Equipment: Weld an external junction box at the lead-out position on the back of the module to facilitate the connection between the battery and other devices or batteries.

測試設備

Testing Equipment

? 絕緣耐壓測試設備： 測試邊框與內部帶電體（電池片、焊帶等）之間在高壓作用下的安全性。

? Insulation Withstand Voltage Testing Equipment: Test the safety between the frame and internal charged bodies (battery cells, solder strips, etc.) under high voltage.

? IV 測試儀： 在 STC 標準測試條件（溫度 25℃，光強 1000W/㎡，AM1.5）下對組件的功率進行測試。

? IV Tester: Test the power of the module under STC standard test conditions (temperature 25°C, light intensity 1000W/㎡, AM1.5).

? EL 測試儀： 根據半導體輻射復合釋放光子的特點，對組件施加正向電壓注入非平衡載流子，并通過光子探測器接收非平衡載流子輻射復合釋放的光子，非平衡載流子濃度越高（正常區(qū)域）釋放的光子越多，EL 顯示圖像越亮，非平衡載流子濃度越低（缺陷區(qū)域）釋放的光子越少，EL 圖像越暗，通過圖像明暗關系即可反應組件內部電池缺陷情況。

? EL Tester: According to the characteristics of photon release by semiconductor radiative recombination, apply a forward voltage to the module to inject non-equilibrium carriers, and receive the photons released by the radiative recombination of non-equilibrium carriers through a photon detector. The higher the concentration of non-equilibrium carriers (normal area), the more photons released, and the brighter the EL display image. The lower the concentration of non-equilibrium carriers (defect area), the fewer photons released, and the darker the EL image. The internal battery defects of the module can be reflected through the light and dark relationship of the image.

其他設備

Other Equipment

? 全自動分檔設備：根據組件檢測結果，對組件進行最后的分檔與封裝，一般分檔為 7 檔，每≥±5W 為一個等級標準。

? Fully automatic grading equipment: According to the module detection results, carry out the final grading and packaging of the modules. Generally, the grading is 7 grades, and each ≥±5W is a grade standard.

? 硅片劃片機：用于硅片的切割。

? Wafer dicing machine: Used for cutting wafers.

? 自動排版機器人：實現(xiàn)電池片等組件的自動排版。

? Automatic typesetting robot: Realize the automatic typesetting of components such as battery cells.

? 固化線：用于組件的固化處理。

? Curing line: Used for curing treatment of modules.

? 電池 IV 測試儀：對電池進行性能測試。

? Battery IV tester: Test the performance of batteries.

? 自動組框組角裝框機：實現(xiàn)組件的自動組框和組角。

? Automatic framing and corner assembling machine: Realize automatic framing and corner assembling of modules.

? 紅外檢測儀：用于組件的紅外檢測。

? Infrared detector: Used for infrared detection of modules.

? 自動測試儀：實現(xiàn)組件的自動測試。

? Automatic tester: Realize automatic testing of modules.

? 焊接匯流傳輸臺：用于焊接匯流過程中的傳輸。

? Welding busbar transmission table: Used for transmission during the welding busbar process.

? EAV/TPT 敷設單元：用于 EAV/TPT 材料的敷設。

? EAV/TPT laying unit: Used for laying EAV/TPT materials.

? 排序分流單元：實現(xiàn)組件的排序和分流。

? Sorting and diverting unit: Realize sorting and diverting of modules.

? 多功能輸送單元：用于組件的多功能輸送。

? Multi-functional conveying unit: Used for multi-functional conveying of modules.

? 自動翻轉機：實現(xiàn)組件的自動翻轉。

? Automatic turnover machine: Realize automatic turnover of modules.

? 緩存堆棧機：用于組件的緩存和堆棧。

? Buffer stacker: Used for buffering and stacking of modules.

生產線特點

Production Line Characteristics

? 自動化程度高： 光伏組件自動化生產線將光伏組件生產過程全部自動化，由各種作業(yè)單元組合完成，能夠實現(xiàn)上料后的光伏組件全部過程自動化。作業(yè)單元包括功能單元與傳輸單元，功能單元屬于自動化生產線的核心單元，如層壓機、紅外檢測儀、自動測試儀、自動串焊機、自動組框組角裝框機等；傳輸單元包括焊接匯流傳輸臺、EAV/TPT 敷設單元、排序分流單元、多功能輸送單元、自動翻轉機、緩存堆棧機及其他輔助設備。一條傳統(tǒng)的 150MW 手動生產線大約需要 200 名工人，全自動生產線僅需 15 - 20 名工人，可大大降低封裝工序的人工成本。

? High degree of automation: The automated production line for photovoltaic modules fully automates the production process of photovoltaic modules, which is completed by a combination of various operation units, and can realize the full automation of the photovoltaic module process after feeding. The operation units include functional units and transmission units. The functional units are the core units of the automated production line, such as laminators, infrared detectors, automatic testers, automatic string welders, automatic framing and corner assembling machines, etc.; the transmission units include welding busbar transmission tables, EAV/TPT laying units, sorting and diverting units, multi-functional conveying units, automatic turnover machines, buffer stackers, and other auxiliary equipment. A traditional 150MW manual production line requires approximately 200 workers, while a fully automated production line only requires 15-20 workers, which can greatly reduce the labor cost of the packaging process.

? 產能較大： 以 BC 全自動高速串焊機為例，其產能可達≥6000 片 /h，適用于 166 - 210mm 尺寸的電池片，柵線 5 - 20BB，厚度 120 - 220um，電池片定位精度 ±0.08mm，串直線度≤0.5mm（12 半片 / 串），焊帶鋪設精度 ±0.1mm，碎片率≤0.1%，串不良率≤3%，稼動率≥95%。

? Large production capacity: Take the BC fully automatic high-speed string welder as an example. Its maximum production capacity can reach ≥6000 pieces/h, suitable for battery cells with sizes of 166-210mm, grid lines 5-20BB, thickness 120-220um, battery cell positioning accuracy ±0.08mm, string straightness ≤0.5mm (12 half pieces/string), solder strip laying accuracy ±0.1mm, fragment rate ≤0.1%, string defect rate ≤3%, and operation rate ≥95%.