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Efficiency, quality and competitiveness at the customer’s service

The strength of PANAMAC is the ability to install complete lines, guaranteeing a fast start-up and high qualitative standard on the final product, besides a great flexibility of integration.

From skills PANAMAC a highly flexible product is created so far not present on the market.

Since the PV module market is constantly in growth, the engineering staffs of PANAMAC have developed two layout solution that offer competitive advantages and allow minimising the investment in the upgrade phase and complying immediately with the market requirements, without upsetting layout and with negligible production stops.

FIRST LEVEL OF PRODUCTION
SECOND LEVEL OF PRODUCTION
MODULAR 1200 - 1800 - 2400

 

A – SELECTION OF THE PHOTOVOLTAIC CELLS (OPTIONAL)
This stage of the process makes it possible to classify the cells acquired from the external supplier. The subdivision can be carried out in two ways:

  1. Testing at a pre-established voltage value and subdivision into classes on the basis of the current value measured.
  2. Testing at the maximum power point. The subdivision makes it possible to prevent the formation of strings with nonuniform current values which would provoke a power loss in the module, an excess working temperature and accelerated deterioration of the module itself.

B – WELDING THE CELLS
This stage consists of welding tinned copper ribbons onto the front of the solar cell in correspondence with the print on the cell. Two methods can be used:

  1. Manual, using electric welders and deposit of flux.
  2. Automatic, with induction welding by infrared lamps, heated prods.

C – WELDING THE STRINGS AND BRASSES (CONNECTIONS)
This involves welding the cells and connections together in order to make the connections between the cells and the junction box. During this stage the operator must supervise to insure correct welding of the grid and between the grid and the connections. The latter are made by the operators at the equipped workstations.

D – VISUAL INSPECTION AND OPERATING TEST
During this stage the operator checks the cells and can repair or replace any damaged cells before final lamination, thereby preventing the production of rejects.

E – LAMINATION
The stage during which the sandwich is prepared: this is composed of hardened glass, a layer of EVA, cells, another layer of EVA and, finally, the appropriately treated backsheet/tedlar (or another glass sheet). The glass must be cleaned before lamination to aid the lamination stage and ensure the life and performance of the modules themselves.
When the sandwich has been prepared, it is placed in the laminator in order to:
1. Create a vacuum inside the chamber
2. Heat the panel to the polymerization temperature
3. Press the sandwich
4. Cool the panel (optional)

F – TRIMMING, FRAMING, SEALING AND MOUNTING THE DIODE BOX
This is the stage during which the sandwich obtained is trimmed, framed in the special aluminium frames and sealed, and the junction box is fitted on it.

G – CONTROL BY MEANS OF A SOLAR SIMULATOR
Using the simulator, the operator checks that the finished panel meets the electric specifications and technical parameters declared for marketing it, and that it complies with the relevant reference standards.

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Costs of process defect
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Production costs
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Plant efficienty


All the options may be applied regardless of the chosen solution. The options are configured according to the three fundamental strategic choices, which are:

  1. Product quality
  2. Reduction of production costs
  3. Total plant efficiency on temporary production stops

The product quality is guaranteed by the tests carried out by our check posts before and after lamination and by inspections.

The reduction of production costs is effected by automating those processes that, under standard conditions would have been manual. The systems of automatic evacuation, accumulation and operator visit arrangement allow an assessment of the anomaly in real time and an automatic reinsertion in line for completing the cycle of assembly and test.

The total efficiency of the plant on temporary production stops is guaranteed by the insertion of accumulation systems on strategic zones, that is to say before and after the technological processes. The dimensioning of said systems is based on the customer’s request, autonomy of operation, normally used to face possible production stops, varies between 30 and 60 minute. Besides production stops, these systems guarantee an autonomy of operation even in the event of loading raw materials on technological machines.

  • Additional glass loading post for module production under glass-glass solution
  • Third bus bar welding group
  • Linear vision check for string integrity
  • Automatic system of JB contact arrangement in pre-lamination
  • Checks n pre-lamination welding
  • Checks on post-lamination welding
  • Management of anomalies with automatic line evacuation and pre-lamination modules accumulation
  • Checked and suitable modules reinsertion in pest-lamination
  • Management of anomalies with line evacuation, overturning, visit
  • Check up and suitable modules reinsertion in post-lamination
  • Check modules with Solar Simulator

 

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