Method for producing a solar cell device

Abstract

Method for the at least partially automated production of a solar cell device (1) with a plurality of electrically interconnected solar cells (7) which are attached to a carrier (2) via an adhesive layer (11), wherein a) in the method, a multi-axis robot (18) is used, in which a contact force acting on a tool interface (26) of the robot (18) is controlled by means of a contact force control, b) the same robot (18) performs at least two of the following work steps: ba) creating a weld (13) to bring about an electrical contact between at least one solar cell (7) by means of a welding tool (23) which is held on the tool interface (26) of the robot (18), wherein a contact force acting on an electrode of the welding tool (23) during the creation of the weld (13) is controlled by the contact force control, wherein the welding process is monitored by evaluating a contact resistance between the electrodes of the welding tool (23) and the at least one solar cell (7), and / or bb) handling a component or subassembly of the solar cell device (1) by means of a first handling tool (24) with a pressing of the component or subassembly into the adhesive layer (11), wherein the first handling tool (24) is held on the tool interface (26) and a contact force acting during the pressing is controlled by the contact force control, and / or bc) picking up and / or handling and / or depositing the solar cell device (1) or a component or subassembly thereof by means of a second handling tool (24) which is held on the tool interface (26) of the robot (18), wherein a contact force acting during the picking up and / or handling and / or depositing is controlled by the contact force control, and / or bd) bringing about an electrical contact between at least one solar cell (7) by pressing a contact (40) of a first functional testing tool (29) to perform a functional test, wherein the first functional testing tool (29) is held on the tool interface (26) of the robot (18) and a contact force acting on the contact (40) during the pressing is regulated by the contact force control, wherein the pressed contact (40) brings about an electrical contact between the first functional testing tool (29) and contacts of the at least one solar cell (7), so that the at least one solar cell (7) is electrically energized by means of the first functional testing tool (29), wherein the electrical energization of the at least one solar cell (7) leads to an electroluminescence image which is recorded by means of a sensor or a camera (56) of the first functional testing tool (29),wherein, based on the signal of the sensor or an image evaluation of the image of the camera (56), a conclusion is drawn as to the functionality of the at least one solar cell (7), whereby a quality check of the at least one solar cell (7) and the assembly carried out is carried out, and / or , be) pressing on a shielding body (39) of a second functional testing tool (29) to carry out a functional test, wherein the second functional testing tool (29) is held on the tool interface (26) of the robot (18) and a contact force acting on the shielding body (39) during the pressing is regulated by the contact force control, wherein the second functional testing tool (29) has a lighting means which illuminates the at least one solar cell (7) under defined conditions ensured by the shielding body (39), so that the at least one solar cell (7) generates a predetermined electrical signal when functioning properly, which is evaluated and with which a conclusion is drawn about the functionality of the at least one solar cell (7), In each case one of the steps ba), bd) and be) is carried out.

Description

TECHNICAL FIELD OF THE INVENTION

[0001] The invention relates to a method for producing a solar cell device comprising a plurality of electrically interconnected solar cells. The solar cells in the solar cell device can be arranged, for example, in a straight, strand-like configuration or in any desired curved configuration with equal or different spacing (also referred to as a "string" of solar cells), or in a regular matrix, in which the solar cells are arranged in "rows" and "columns," or in an irregular matrix. The solar cells of the solar cell device are attached to a carrier via an adhesive layer. The carrier can be designed, for example, as a rigid substrate, e.g., as a honeycomb substrate with plate-shaped cover layers, or as a flexible substrate, in particular as a spacecraft membrane (cf., for example, DE 10 2021 108 420 A1).

[0002] During the manufacture of the solar cell device, special attention must be paid to ensuring that the solar cells provided as semi-finished products are not damaged, which requires that the mechanical stresses (e.g. during handling) and thermal stresses (e.g. during welding for contacting) are kept low.

[0003] US 10 930 812 B1 discloses a system for the fully automated production of a photovoltaic device, in particular a solar cell array or panel, using an additive manufacturing process. The system comprises a robot arm controlled by a computer. The robot arm has six axes. The robot arm carries a camera in its free end region for capturing two-dimensional shapes, markings on a substrate or solar cells, or for capturing corners of the substrate and solar cells. Furthermore, an automatic tool changing device is mounted on the free end of the robot arm, by means of which different tools can be attached to the end of the robot arm. Each tool has a positive connection element that enables detachable coupling to the tool changing device. The tool changing device is pneumatically controlled.The tool changing device also has connections through which compressed air or a vacuum can be transmitted to a coupled tool in order to actuate the tool. The camera can be used to identify different tools in a tool holder. A heatable carrier plate has a temperature sensor, based on which the temperature of the heatable carrier plate is regulated by a temperature control device. The heatable carrier plate is intended to enable and accelerate the curing of polymers and adhesives used during additive manufacturing. The computer, which controls the movement of the robot arm along its axes, also controls electrically controlled valves of a valve device.The valve device is connected to a vacuum pump on the one hand and to a compressed air source on the other hand and, depending on the valve position, controls the supply of compressed air for the tool changing device and for the tool. The tool can have a holding tool to which a workpiece can be sucked when a vacuum is applied. In this way, workpieces designed as a polymer substrate and solar cells can be picked up by the robot arm. A vacuum device controlled by the valve device can also be arranged in the area of ​​the heatable carrier plate, which ensures that the polymer substrate is pressed against the heatable carrier plate. The tool can also have a micro-spray valve, the operation of which is also controlled by the valve device.Using compressed air, atomized material, in particular liquid polyimide, can be applied from the micro-spray valve onto the substrate. To provide the applied material, the tool is connected to a supply line for this material. Another tool has a dispensing valve with a spray tip. An electrically conductive liquid is fed into the dispensing valve via a supply line, which is then dispensed from the dispensing valve under pneumatic control of the dispensing valve by the valve device. For automatic production, a substrate, in particular made of a polyimide film, is used. This substrate is provided with markings that can be recognized by the camera of the robot arm. In a first process step, the heatable carrier plate is regulated to the predetermined temperature. The substrate is sucked onto the carrier plate using the suction device.The robot arm picks up the first tool. The adhesive is then applied to the substrate via the dispensing device of the first tool, using which adhesive the solar cells are to be glued to the substrate. In the next step, the robot arm uses the suction cups on the first tool to pick up four solar cells that have already been arranged relative to one another as intended. The robot arm is moved into the correct relative position above the substrate under the control of the robot arm's camera. The negative pressure of the suction cups is then released, releasing the solar cells and bonding them to the substrate via the adhesive layer. In a subsequent process step, additional adhesive can be sprayed onto the substrate along the edges of the solar cells in the manner of a fillet weld, which is intended to ensure sealing and electrical insulation.While the material is curing, the first tool is replaced with a second tool. The second tool is then used to dispense the electrically conductive, curing material via the dispensing device to create the electrical bridges. The tool is then changed again, and the first tool is mounted on the robot arm. The first tool is then used to encapsulate the solar cells with a protective coating. This completes the production of the photovoltaic device. For an alternative production method, the top layer of the substrate is dissolved using a solution to create a liquid bed, into which the solar cells are then embedded. It is possible to use a third tool, via which the solution is dispensed to create the liquid bed.In this case, the robot arm holds the solar cells in the liquid bed while the solvent evaporates due to heating by the heated support plate. On the website

[0004] https: / / www.youtube.com / watch?v=K5Z_pmBNrP8 (video from January 19, 2016) presents a load cell that is designed to be attached to a free end of a robot arm and by means of which forces and moments can be recorded in all spatial directions.

[0005] US 2015 / 0 004 737 A1 discloses a method for metallizing a photovoltaic cell, in which a transparent layer, an adhesive layer, and a solar cell are stacked on top of one another. Additionally, a metal foil is placed on the solar cell so that uniform contact is maintained. Welding, for example, using a laser source, creates an electrical connection between the solar cell and the metal foil. Before one or more solar cells are bonded to the transparent layer, the solar cells can be pre-sorted based on visual quality or the results of photoluminescence or electroluminescence tests.

[0006] The publication by IQBAL, Jamshed et al.: Robotics Inspired Renewable Energy Developments: Prospective Opportunities and Challenges. In: EEE Access, 7, 2019, 174898-174923, discloses the use of various robots in performing tasks in the field of renewable energy. It describes how robots can perform individual tasks in the manufacture of solar cell devices, for example, in production, handling, installation, inspection, or maintenance. Robots are known to perform process steps such as welding, transporting, assembly, picking and placing operations, or testing. OBJECT OF THE INVENTION

[0007] The invention is based on the object of proposing a method for producing a solar cell device, which is particularly suitable with regard to - partial automation or automation and / or - a process hardness and / or - avoiding impairments due to mechanical and / or thermal damage and / or - the costs and / or - manufacturing costs and / or - enabling even complex geometries of the string or matrix and / or - easy adaptability to different geometries and / or - reproducibility and / or - enabling even small batches and / or - provision of prototypes to improve. SOLUTION

[0008] The object of the invention is achieved by the features of the independent patent claim. Further preferred embodiments of the invention can be found in the dependent patent claims. DESCRIPTION OF THE INVENTION

[0009] The invention relates to a method for the at least partially automated production of a solar cell device, such as that described above. The solar cell device comprises a plurality of solar cells. The solar cells are electrically connected to one another. Furthermore, the solar cells are attached to a carrier via an adhesive layer.

[0010] According to the invention, it is proposed that a multi-axis robot be used in the method. As a non-limiting example, the robot can be a collaborative 7-axis robot, which can be designed as a conventional industrial robot.

[0011] The robot used has a tool interface via which different tools can be attached to the robot. The tool interface can be designed to be multifunctional, allowing the mechanical attachment of various tools, whereby fully automated tool changing may be possible. Furthermore, the tool interface can be designed to transmit at least one signal, for example a pneumatic and / or electrical signal, between the robot and the tool. The transmission can be unidirectional from the robot to the tool or bidirectional, both from the robot to the tool and from the tool to the robot.

[0012] In the robot used according to the invention, a contact force acting on the tool and thus also on the tool interface is controlled by means of a contact force controller. The robot's drives thus feature force-torque control. The contact force within the meaning of the invention is understood to be a generalized force, which can thus include an arbitrarily oriented force and / or an arbitrarily oriented torque. Because the contact force is controlled by the robot, the contact force is also known in the method according to the invention and can then be used for further processing.

[0013] According to the invention, the robot is used multifunctionally in that the robot carries out at least two of the following work steps: a) It is possible for the robot to create a weld, which could, for example, be a weld to establish electrical contact between adjacent solar cells and / or between a solar cell and an electrical supply or discharge line, or an electrical line connecting several strings of solar cells. It is also possible for a contact tab of a solar cell to be welded to a conductor or contact tab of the adjacent solar cell or to one of the aforementioned lines. It is also possible for the weld to be made to a cable harness. For this step, a welding tool is connected to the robot's tool interface. During the weld, the robot's existing force and torque control can be used to regulate the contact force acting on an electrode of the welding tool, which is caused by the electrode's contact with the components to be welded. Ensuring the predetermined contact force is important for the welding result achieved with the electrode. It is possible, for example, that if it is detected that the electrode is being pressed against the components to be welded with a contact force within a predetermined contact force range, the electrical application of the electrode is triggered, which then initiates the welding. This can be triggered by a circuit or a control unit of the welding tool. It is also possible for the welding process to be triggered by a central control unit of the robot, from which the electrical current to the electrode is then transmitted via the tool interface. Alternatively or additionally, the contact force can be regulated during the electrical application of the electrode during the welding process so that it remains within a predetermined contact force range. The welding process is, for example, a spot weld. b) It is possible for the robot to handle a component or subassembly of the solar cell device in a single work step using a handling tool. This handling then involves pressing the component or subassembly into an adhesive layer. The handling tool can be held at the tool interface. The contact force acting during the pressing process is controlled by the contact force control, which ensures that the component is pressed into the adhesive layer with the correct pressing force, resulting in increased process reliability.One criterion for the dimensioning of the contact force acting during press-fitting can be that the pressing should result in as complete a wetting of the adhesive surface(s) of the component or subassembly with the adhesive as possible, and / or the contact force is selected such that after the adhesive has set, a maximum adhesive force can be achieved and / or a lateral outflow of excess adhesive from the components to be bonded is avoided. It is possible that the handling and pressing step into the adhesive layer is preceded by another step, which can also be performed by the robot: In this case, the adhesive can be applied using an adhesive applicator to create the adhesive layer. For example, the adhesive layer can be created on the carrier or the solar cell. In this case, the adhesive applicator can be held at the tool interface of the robot. c) It is also possible that the robot is used in one work step to pick up, handle and / or deposit the solar cell device, a component or a subassembly of the solar cell device. The pickup can consist of the solar cell device, component, or subassembly being picked up from a feed device or storage facility and then transported to an assembly or work station. The pickup requires the creation of a holding connection with the solar cell device, component, or subassembly, whereby the holding connection can be a positive connection, a frictional connection, an under-grip connection, a suction connection, or similar. Handling includes, for example, moving the solar cell device, component or subassembly between two locations such as the storage or feeding device and the work or assembly station and / or changing the orientation of the solar cell device, component or subassembly. The storage of the solar cell device, component or subassembly includes the transfer of the same to a removal facility or another storage facility or the storage of the same at a work or assembly station. A handling tool is used for picking, handling, and / or placing, which is held at the robot's tool interface. During picking, handling, and / or placing, an acting contact force is controlled by the contact force control. For example, a collision check can be performed during picking, handling, and / or placing based on the contact force control: If the contact force exceeds a threshold value while the controller itself assumes free movement of the solar cell device, component, or subassembly, it can be concluded that an undesired contact or collision has occurred. As a result, the movement can then be stopped or modified. If a positive connection between the solar cell device, component, or subassembly and the environment is broken or established (for example, establishing or removing a positive connection with a storage matrix, establishing a positive connection for assembly, etc.), the contact force control can be used to detect whether the handling tool is being moved in the correct joining direction. An increase in the contact force can then be used to adjust the joining direction. Accordingly, the end of the joining movement can also be detected using a contact force, for example when a stop defining the end position or a bottom of the storage matrix is ​​reached, which is associated with an increase in the contact force. It is also possible, for example, to additionally check whether the robot head has reached a position that correlates with the joined position.If the contact force increases at the end of the joining movement and the position correlating to the joined position is reached at the time of this increase, this can be considered an indication that proper assembly has taken place. d) A further work step that can be performed using the functional robot is establishing electrical contact with at least one solar cell by pressing a contact of a functional testing tool against the solar cell to perform a functional test. The pressed-on contact can establish electrical contact between the functional testing tool and the contacts of the at least one solar cell, so that the solar cell can be electrically energized using the functional testing tool. This electrical energization of the solar cell results in an electroluminescence image, which can be captured using a suitable sensor or camera of the functional testing tool.Based on the sensor signal or an image analysis of the camera image, a conclusion can then be drawn about the functionality of at least one solar cell, which allows a quality check of the solar cell and the assembly to be carried out. Within this framework, it is also possible for the functional testing tool to have a sensor for detecting an identification of the solar cell or a type of solar cell. To name just one non-limiting example, the solar cell can be identified by a QR code, which can then be detected by the sensor, in particular the camera, which also captures the electroluminescence image. The test result can then be assigned to the specific solar cell identified by the QR code. Within the scope of the invention, the functional testing tool is held at the tool interface of the robot. By means of contact force control, the contact force acting on the electrical contact is regulated during pressing, so that defined contact conditions are present and damage to the solar cell contact due to excessive contact force is avoided. e) In an optional work step, the robot is also used to press a shielding body of a functional testing tool onto the solar cell to perform a functional test. In this case, the functional testing tool can have a light source that illuminates the solar cell under defined conditions guaranteed by the shielding body, so that the solar cell generates a predetermined electrical signal when functioning properly. This electrical signal can be evaluated, allowing conclusions to be drawn about the functionality of the solar cell. For example, in this case, the functional testing tool can also have an electrical contact through which the electrical signal is tapped. In this case, too, the functional testing tool is held on the tool interface of the robot.The shielding body is pressed against the at least one solar cell to be tested, thereby shielding the at least one solar cell to be tested from the environment, so that the at least one solar cell is exclusively or primarily exposed to light from the lamp of the functional testing tool. While the shielding body is being pressed against the surface, the contact force acting on the shielding body is regulated by the contact force control, ensuring defined contact conditions that prevent damage to the solar cell device, subassembly, or component, in particular the solar cell.

[0014] Within the scope of the invention, the contact force control can be used to ensure a predetermined contact force or a predetermined contact force range. However, it is also possible for a signal present in the contact force control, which correlates with or corresponds to the contact force, to be used for further control and for the execution of the work steps. For example, as mentioned, the contact force can be used to trigger the welding to bring about an electrical contact according to a) and / or to specify the insertion depth or the insertion pressure into the adhesive layer according to b) and / or to control the picking up, handling or depositing or to bring about a positive connection according to c).

[0015] A further proposal of the invention is dedicated to securing the solar cell device, component or subassembly relative to a work surface which is used, for example, for assembling different components together, so that a predetermined relative position of the component must be specified and secured to enable assembly. For one proposal of the invention, the solar cell device, component or subassembly thereof is prevented from moving relative to the work surface in a form-fitting receptacle or storage matrix of the work surface as a result of the acting contact force or an interaction caused by the contact. In this case, a receptacle or storage matrix can be provided at a specific location on the work surface. It is possible for multiple receptacles or storage matrices to be provided for alternative specific locations in the work surface.It is also possible for a receiving matrix to be provided in the working surface, via which several components or subassemblies of the solar cell device are simultaneously received by the working surface, whereby the receiving matrix ensures the alignment and relative position of the individual components or subassemblies. Alternatively or additionally, it is possible for the solar cell device, component, or subassembly to be secured by means of a negative pressure on the working surface, by means of which the solar cell device, component, or subassembly can be pressed against the base of the receiving matrix or against the working surface.

[0016] There are many different options for designing the robot's tool interface for connecting to the various tools (in particular, the welding tool according to a), the handling tool according to b), c), and the functional testing tool according to d), e)), whereby the tool interfaces known from the prior art can be used. According to one proposal of the invention, the robot's tool interface has two grippers. The grippers each have a gripping element. When the grippers are in a gripping position, a tool is caught between the grippers in the area of ​​two tool receptacles. The gripping elements of the grippers engage positively in the tool receptacles. In this way, the tool can be reliably held on the tool interface at a predetermined position and with a predetermined orientation. In the tool interface, the grippers can also be moved into a release position.In the release position, the tool is no longer caught in the area of ​​the tool holders between the grippers and the positive connection between the gripping elements and the holders is eliminated. To pick up a tool, the tool interface is first moved to the release position and the tool interface is moved into the position required to pick up the tool. The tool interface is then moved into the gripping position, whereby the gripping elements engage positively in the holders. In this state, the tool can then be picked up by the tool interface and machining can take place using the tool. The same applies in reverse for the storage of a tool by the tool interface after it has been used.

[0017] In a method according to the invention, the welding tool, the adhesive applicator, the handling tool, and / or the functional testing tool are / are arranged in a tool magazine. In this case, the welding tool, the adhesive applicator, the handling tool, and / or the functional testing tool can be fed into the tool magazine while regulating the contact force by means of a contact force control. The contact force control can, on the one hand, prevent damage resulting from a collision and, on the other hand, regulate the movement for proper feeding. Alternatively or additionally, the contact force is controlled for the removal of the tool from the tool magazine.

[0018] The invention proposes an embodiment in which, when a weld is created between contacts of components of the solar cell device, the achievement of a predetermined contact force or a predetermined contact force range triggers an activation or "triggering" of an electrical application to the electrodes of the welding tool, whereby optimal welding conditions can be ensured.

[0019] There are many options for the design of the adhesive applicator. For example, the adhesive applicator can have a pneumatic dispensing system that is controlled or regulated depending on the position of the robot's tool interface and the contact force. The pneumatic dispensing system can communicate via the tool interface, whereby, for example, a pneumatic pressure or an electrical signal can be sent via the tool interface to control a valve of the pneumatic dispensing system and / or to control an extruder of the dispensing system.

[0020] According to a further proposal of the invention, a turning comb is used in the method. The turning comb can then have receptacles for a component or subassembly of the solar cell device between its prongs, wherein a plurality of receptacles for the component or subassembly are then provided in the adjacent spaces between the prongs separated by the prongs. The components or subassemblies can then be arranged in these multiple receptacles with a defined spacing and an orientation predetermined by the prongs. The components or subassemblies arranged in the receptacles can be independent of one another. However, it is also possible for them to already be connected to one another, in which case the multiple supports on the individual prongs can ensure that damage to this subassembly is avoided.Using a handling tool, the solar cell device, component, or subassembly thereof is placed in a first orientation on the turning comb. The handling tool can extend from the side below the turning comb through the gaps of the turning comb between the prongs to a first side of the solar cell device or a component or subassembly thereof (in particular an underside). Alternatively, for this embodiment of the method, it is possible for the solar cell device, or a component or subassembly thereof, to be picked up or placed from the side above the turning comb using the same handling tool or a different handling tool.It is also possible for the handling tool to be used to place the solar cell device or a component or subassembly thereof in a second orientation on the turning comb. In this case, the handling tool extends on the side facing away from the turning comb to a second side of the solar cell device or a component or subassembly thereof. The turning comb thus enables the solar cell device, component, or subassembly to be placed on the turning comb in different orientations.On the other hand, it is also possible for the turning comb to ensure that the solar cell device, component, or subassembly is placed on the turning comb in a first relative orientation to the handling tool and, by a type of "grasping," the handling tool can be released from the solar cell device, component, or subassembly and can then interact with the solar cell device, component, or subassembly in a different relative orientation. If the solar cell device, component, or subassembly is then picked up in the changed relative orientation, processing or assembly can also take place in the area of ​​the solar cell device, component, or subassembly that was covered or restricted by the handling tool for the first relative orientation.

[0021] According to one aspect of the invention, the functional testing tool comprises a camera or a sensor. The camera or sensor evaluates an electroluminescence image resulting from the electrical action of the contact body. For the functional test, for example, an evaluation of the strength or characteristics of the electroluminescence image (in particular by comparison with a threshold value) can then be carried out in order to distinguish between a functioning and a non-functioning solar cell. However, it is also possible that such a binary assessment is not carried out, but rather an assessment is carried out in several stages or even continuously, for example via a percentage for the generated electroluminescence. It is also possible within the scope of the invention that qualitative statements are made on the basis of the electroluminescence image using image recognition software. If, for example, the image recognition software is usedIf it is detected that the electroluminescence in the area surrounding an electrical contact is lower than specified, it can be concluded that damage occurred in this area during assembly during the electrical contact, in particular during welding of the electrical contact. It is possible for several solar cells to be exposed to light simultaneously using the functional testing tool and for the electrical exposure resulting from the several solar cells to be evaluated, whereby a cumulative brightness of the electroluminescence images of the solar cells is then evaluated, which provides information about the several solar cells. If the method according to the invention successively scans several individual solar cells, a string of several solar cells, or a matrix of solar cells, a large number of solar cells can also be tested in an automated manner.An evaluation of individual electroluminescence images is then possible. To give just one more example, the cumulative evaluation of several such tests can also be performed by checking whether the sum of the individually tested solar cells or solar cell arrays results in the minimum required electrical energy. This can then even allow for the possibility that individual solar cells or solar cell arrays may generate significantly less energy.

[0022] In a further embodiment of the invention, the functional testing tool can include a light source. In this case, the power response of at least one solar cell is determined via the contact body as a result of exposure to the light source.

[0023] The invention also proposes that the tool or a robot head have a QR code detection device. In this way, an identification of the solar cell device, component, or subassembly can be detected. The detected identification can then be used, for example, to select a work step that is specific to the type assigned to the identification and different from a work step for another type. On the other hand, functional test results can then be assigned to the solar cell device, component, or subassembly specifically identified by the QR code and stored with this assignment, thus enabling improved process documentation and / or quality assurance and also enabling error analysis.

[0024] For this embodiment, the result of the functional test can be evaluated and / or stored by the functional test tool in conjunction with an identification of the solar cell device, component or subassembly thereof, which is determined on the basis of the QR code captured by the QR code capture device.

[0025] Advantageous further developments of the invention emerge from the patent claims, the description and the drawings.

[0026] The advantages of features and combinations of several features mentioned in the description are merely exemplary and can be used alternatively or cumulatively without the advantages necessarily having to be achieved by embodiments according to the invention.

[0027] With regard to the disclosure content – ​​not the scope of protection – of the original application documents and the patent, the following applies: Further features can be found in the drawings – in particular the illustrated geometries and the relative dimensions of several components to one another, as well as their relative arrangement and operative connection. The combination of features of different embodiments of the invention or features of different patent claims is also possible, deviating from the selected references of the patent claims, and is hereby suggested. This also applies to features that are illustrated in separate drawings or mentioned in their description. These features can also be combined with features of different patent claims.Likewise, features listed in the patent claims may be omitted for further embodiments of the invention, but this does not apply to the independent patent claims of the granted patent.

[0028] The number of features recited in the claims and the description should be understood as meaning that exactly this number or a greater number than the stated number is present, without the need for the explicit use of the adverb "at least." Thus, for example, if reference is made to one element, this should be understood as meaning that exactly one element, two elements, or more elements are present. The features recited in the claims may be supplemented by further features or may be the only features present in the subject matter of the respective claim.

[0029] The reference signs contained in the patent claims do not represent a limitation of the scope of the subject-matter protected by the patent claims. They serve only the purpose of making the patent claims easier to understand. BRIEF DESCRIPTION OF THE CHARACTERS

[0030] In the following, the invention is further explained and described with reference to preferred embodiments shown in the figures. Fig. Figure 1 shows a highly schematic cross-sectional view of a solar cell device with a string of several solar cells on a carrier. Fig. 2 shows a workstation at which the method according to the invention can be carried out, in a spatial representation. Fig. 3 shows a three-dimensional representation of a robot that is in the workstation according to Fig. 2 multifunctional use, with a tool held on a tool interface of the robot (here a welding tool). Fig. 4 shows a detail IV of the robot with the tool according to Fig. 3 in the tool interface area. Fig. 5 shows a three-dimensional representation of a tool magazine holder with a tool held on it (here a function testing tool). Fig. 6 shows a three-dimensional representation of a tool designed as a welding tool. Fig. 7 shows a three-dimensional representation of a tool designed as an adhesive application device, here with a dispensing head. Fig. 8 shows a tool magazine holder with a tool held thereon, which is designed as a handling tool with suction devices. Fig. 9 shows a schematic block diagram for working steps of a method for manufacturing a solar cell device. Fig. 10 shows a schematic diagram of a workstation during a functional test using a functional test tool. Fig. 11 shows a three-dimensional view of a handling tool with solar cells held thereon before they are placed on a turning comb. Fig. 12 shows the handling tool with the solar cells and the turning comb according to Fig. 11 in a side view. Fig. 13 shows the handling tool with the solar cells and the turning comb according to Fig. 11 and Fig. 12 in a front view. Fig. 14 shows the handling tool with the solar cells in a spatial representation in an operating state immediately before the solar cells are deposited on tines of the turning comb, with arms of the handling tool extending through the spaces between the tines of the turning comb. Fig. 15 shows the handling tool with the solar cells and the turning comb according to Fig. 14 in a side view. Fig. 16 shows the handling tool, the solar cells and the turning comb in a spatial view in an operating state in which the solar cells are placed on the tines of the turning comb and the handling tool has been removed from the solar cells. Fig. 17 shows the handling tool, the solar cells and the turning comb according to Fig. 16 in a side view. Fig. Figure 18 shows the handling tool after turning it with an approach from above to the solar cells placed on the turning comb in a spatial view. Fig. 19 shows the handling tool, the solar cells and the turning comb according to Fig. 18 in a side view. Fig. Figure 20 shows in a spatial view the establishment of the connection between the handling tool and the solar cells when approached from above in a spatial view. Fig. 21 shows the handling tool, the solar cells and the turning comb according to Fig. 20 in a side view. Fig. Figure 22 shows a spatial view of the lifting of the solar cells using the handling tool. Fig. 23 shows the handling tool, the solar cells and the turning comb according to Fig. 22 in a side view. FIGURE DESCRIPTION

[0031] In the figures, some components that are at least partially corresponding or identical in design and / or function are in some cases identified by the same reference numerals, whereby these can then be distinguished from one another by the additional letters a, b, .... In this case, reference can be made to the components with or without the additional letters a, b, ..., which can then refer to one such component, several such components, or all such components.

[0032] Fig. 1 shows a solar cell device 1. The solar cell device 1 has a carrier 2, which can also be designed as a substrate. The carrier 2 can be rigid or flexible. For the Fig. In the embodiment shown in Figure 1, the carrier 2 has a lower cover layer 3 and an upper cover layer 4, between which a honeycomb material 5 is arranged. In this case, the carrier 2 can be made of aluminum. However, it is also possible, for example, for the carrier 2 to be a flexible spacecraft membrane.

[0033] A glass fiber mat 6 can be bonded to the upper cover layer 4. The glass fiber mat 6 is impregnated with a room-temperature-curing silicone adhesive and then applied to the carrier 2. The glass fiber mat can, for example, provide a protective function, in particular protection against atomic oxygen.

[0034] Solar cells 7a, 7b, ... are located on the carrier 2 (and in particular on the glass fiber mat 6). The solar cells 7 can be arranged in a row as a string or distributed over the surface in a matrix, whereby they can be distributed evenly or non-uniformly and can have the same or different distances from one another.

[0035] The solar cells 7 each have a (particularly gold-plated or silver-plated) back contact layer 8, a photosensitive layer 9 and an outer glass layer 10 (where these layers are Fig. 1 are identified only for one solar cell 7b). The photosensitive layer 9 is contacted by means of a contact element 12, in particular a contact ribbon ("KOVAR", registered trademark). The solar cells 7 formed in this way are provided as semi-finished products for the method according to the invention.

[0036] The carrier 2 can also be produced as any other sandwich panel, for example with cover layers 3, 4 made of a carbon fiber material or a composite material and aluminum material arranged therebetween, in particular in honeycomb form.

[0037] For the manufacture of the solar cell device 1 according to Fig. 1 In particular, the following steps must be carried out: a) An adhesive layer 11a, 11b, ... is to be created, via which the solar cell 7 is glued to the carrier 2, in particular with the glass fiber mat 6 arranged thereon. The adhesive layer 11 can either be applied to the back contact layer 8, whereby the solar cell 7, with the adhesive layer 11 on the back contact layer 8, is then pressed onto the carrier 2 (optionally with the glass fiber mat 6 arranged thereon). Alternatively, it is possible for the adhesive layer 11 to be applied to the carrier 2 (optionally with the glass fiber mat 6 arranged thereon) and then for the solar cell 7 to be glued to the carrier 2 (optionally with the glass fiber mat 6). Small gaps result between adjacent solar cells 7a, 7b, ... The adhesive layers 11a, 11b, ... assigned to the solar cells 7a, 7b, ... extend only in the area of ​​the solar cells 7a, 7b, ..., without being arranged in the area of ​​the spaces between adjacent solar cells 7a, 7b, ... The adhesive from which the adhesive layer 11 is made is preferably a silicone adhesive. b) Furthermore, an electrical contact must be established between the back contact layer 8a of a solar cell 7a and the contact element 12b of the adjacent solar cell 7b. This is achieved by a weld 13, which is in particular a spot weld.

[0038] As in Fig. As can be seen in Figure 1, the solar cells 7a, 7b, ... are connected to one another in electrical series. However, one or more such solar cells 7 can also be connected via the contact element 12 to a central electrical line 14 or a cable harness 15 via a weld 13.

[0039] In Fig. 1, the external solar cells 7a, 7d are only indicated. Instead of these solar cells 7a, 7d, the cables 14 or cable harnesses 15 can also be arranged here, which in Fig. 1 are marked with reference symbols in brackets.

[0040] Fig. Figure 2 shows a workstation 16 by means of which the method according to the invention can be carried out. The workstation has a central electronic control unit 17, which can also be designed as a so-called "Modbus controller." The control unit 17 serves to control the individual work steps of the method according to the invention and has suitable control logic.

[0041] The workstation 16 has a robot 18 controlled by the control unit 17. The control unit 17 controls the movement of the robot 18 and performs force and torque control. The robot 18 can be a force-torque controlled, collaborative 7-axis industrial robot ("COBOT").

[0042] The workstation 16 has a tool magazine 19. In the tool magazine 19, several tools are held and stored via tool magazine holders 20. For the Fig. In the embodiment shown in Figure 2, the tools are an adhesive applicator 21 with dosing system 22, a welding tool 23, a handling tool 24 and a functional testing tool 29.

[0043] The robot 18 has a robot head 25 with a tool interface 26. In Fig. 2 it can be seen that the tool interface 26 has two grippers 27, 28, the design and function of which will be explained in more detail below.

[0044] The workstation 16 has a work surface 30, which can be formed by a vacuum table 31, so that a workpiece can be held on the work surface 30 by means of a negative pressure. Preferably, the work surface 30 forms a storage matrix 32. Components of the solar cell device 1 can be stored in the storage matrix 32, with the storage matrix 32 receiving these components in a form-fitting manner, so that the components are located in the storage matrix 32 in predetermined positions and with predetermined orientations.

[0045] Preferably, the solar cells 7 are deposited in the deposition matrix 32 with the photosensitive layer 9 facing downwards and fixed in the deposition matrix 32 by means of a vacuum. The welds 13 can then be produced using the welding tool.

[0046] Fig. 3 shows the robot 18 with the robot head 25 and the tool interface 26 with the two grippers 27, 28. According to Fig. 3, the welding tool 23 is held on the tool interface 26.

[0047] Fig. 4 shows the detail IV according to Fig. 3, namely the connection of the robot head 25 to the tool (here the welding tool 23): The grippers 27, 28 each have a gripping element 33, 34 in their end regions facing away from the robot head 25. The robot head 25 has a drive by means of which the distance between the grippers 27, 28 and thus the gripping elements 33, 34 can be changed between a gripping position and a release position (and vice versa).

[0048] In the gripping position, the gripping elements 33, 34 each engage in a form-fitting manner in an associated receptacle 35, 36 of the respective tool. For the illustrated embodiment, the gripping elements 33, 34 are each designed as a truncated cone or truncated pyramid with a corresponding design of the receptacles 35, 36. By means of the form-fitting receptacle of the gripping elements 33, 34 in the receptacles 35, 36, the relative position of the tool with respect to the robot head 25 can be precisely specified, and the orientation of the tool relative to the robot head 25 can also be positively specified. In the gripping position, the tool is captured in the area of ​​the receptacles 35, 36 between the grippers 27, 28 and the gripping elements 33, 34.

[0049] In Fig. 5 shows a tool configured as a functional testing tool 29, which is held on a tool magazine holder 20 in the tool magazine 19. The tool magazine holder 20 is plate-shaped and has a fastening area 37, in the area of ​​which the tool magazine holder 20 is fastened in the tool magazine 19. The tool magazine holder 20 forms a receptacle 38 for the tool. Preferably, the different tools are equipped with the same holding area, in the area of ​​which they can then be held in the same receptacles 38.

[0050] For the Fig. In the embodiment shown in Figure 5, the tool magazine holder 20 forms a U-shape in the region of the receptacle 38, into which the fastening area of ​​the tool can be inserted from the open side. On the side of the tool magazine holder 20 facing away from the functional area of ​​the tool, the tool forms a receiving area with the receptacles 35, 36.

[0051] The Fig. The functional testing tool 29 shown in Figure 5 has a shielding body 39 that has an interior space that is only open at the bottom. It is possible for the shielding body 39 to have electrical contacts 40 in the lower end region. The cross-section of the shielding body 39 is dimensioned such that a solar cell 7 or a string with multiple solar cells 7 or even a matrix with multiple solar cells 7 can be shielded with the shielding body 39, so that no light from the environment can penetrate into the interior space delimited by the at least one solar cell 7 and the shielding body 39. A sensor or a camera can then be arranged in the functional testing tool 29. When thus slipped onto the at least one solar cell 7, the contacts 40 of the shielding body 39 can form an electrical contact with the associated contact elements 12 of the solar cell(s) 7.

[0052] Fig. Figure 6 shows a tool designed as a welding tool 23. It can be seen that this tool also has the fastening area for holding it on the tool magazine holder 20 and, above it, the receptacles 35, 36 for optional coupling with the gripping elements 33, 34.

[0053] The welding tool 23 can have electrode holders 41, 42 to which the electrodes are held. An adjustment device 43 can be used to adjust how far the two electrodes extend downward from the electrode holder 41, 42. The electrode holders 41, 42 can each be supported on a housing 46 of the welding tool 23 via spring-loaded linear guides 44, 45. It is possible to evaluate the contact resistance for the arc between the electrodes across the workpiece (for example, by means of a control unit of the welding tool 23 or by means of the control unit 17).

[0054] Fig. Figure 7 shows a tool configured as an adhesive applicator 21 with a dosing system 22. A premixed adhesive can be arranged in a container of the adhesive applicator 21, which is then dispensed via a dispensing nozzle 47, or the adhesive applicator 21 can have a static mixer in which two (or more) adhesive components are continuously mixed.

[0055] Fig. 8 shows a tool designed as a handling tool 24, which is held in a tool magazine holder 20. The handling tool 24 has a plurality of receiving devices 49a, 49b, ..., which are arranged evenly distributed along an elongated base body. For the illustrated embodiment, the receiving devices 49 are designed as suction devices. Workpieces (in particular solar cells 7), which are separate from one another or already connected to one another, can be received via the receiving devices 49. The workpieces are preferably held on the receiving device 49 by means of a negative pressure. The receiving devices 49 extend from the base body 48 parallel to one another like the teeth of a comb.It is possible for the handling tool 24 to be designed in a split manner so that, as required, a different number of base bodies 48 can be connected to one another, whereby the number of receiving devices 49 can be adjusted.

[0056] Fig. 9 shows a highly schematic block diagram with work steps for producing a solar cell device 1 using a method according to the invention.

[0057] In a work step 50, the robot 18 places several solar cells 7 in the deposition matrix 32 of the work surface 30, in particular a vacuum table 31, and fixes them there. The solar cells 7 are preferably placed on the work surface 30 with the photosensitive layer 9 facing down, so that the back contact layer 8 is arranged on the side facing away from the work surface 30.

[0058] In a work step 51, the welds 13 are then produced.

[0059] In a work step 52, the carrier 2, possibly with the glass fiber mat 6, is placed on the or a work surface 30 at another location, and the adhesive layers 11 are applied to the carrier 2 by means of the adhesive applicator 21.

[0060] In a work step 53, the solar cells 7 connected to one another via the welds 13 are removed from the deposition matrix 32 by means of a handling tool 24 and placed by the handling tool 24 on a turning comb 58. After the handling tool 24 is released, it comes into operative connection with the welded solar cells 7 placed on the turning comb 58 on the other side, whereby the relative position of the welded solar cells 7 is rotated by 180° with respect to the robot head 25, thus holding the solar cells 7 on the opposite side. The back contact layer 8 is thus arranged on the side facing away from the robot head 25.

[0061] In a work step 54, the welded solar cells 7 are pressed into the adhesive layers 11 by the handling tool 24 pressing the solar cells 7 into the adhesive layer 11. In this process, the back contact layers 8 of the solar cells 7 interact with the associated adhesive layers 11.

[0062] The functional test then takes place in a work step 55.

[0063] It is understood that the explained work steps do not necessarily have to be carried out in the described and Fig. 9 must be carried out in the order shown.

[0064] In the following, possible configurations of work steps 50 to 55 are explained in more detail: In method step 50, the solar cells 7 are fed to the storage matrix 32 by means of a handling tool 24, which picks up the solar cells 7 from a warehouse or other feed device, moves them to the storage matrix 32, aligns them appropriately with respect to the storage matrix 32, and deposits them in the storage matrix 32. The force control of the robot 18 can be used to adjust or interrupt the movement in the event of an undesired collision of the solar cells 7 held on the handling tool 24 or the robot head 25. Furthermore, the force control of the robot 18 can be used to push the solar cells 7 into the storage matrix 32 with a predetermined force.If the force during the pushing-in increases to a value above a threshold before a specified insertion depth into the storage matrix 32 is reached, the force control can detect that the solar cell 7 is obviously not designed or aligned appropriately for the storage matrix 32. At the end of the work step 50, the handling tool 24 is then released from the solar cells 7.

[0065] In all work steps, the kinematics in all axes of the robot 18 are equipped with force and torque sensors, so that the forces acting (including torques) at the Tool Center Point (TCP) are known in the control unit 17 at all times. For method step 51, the TCP is the workpiece-side end of the electrode. If the electrode of the welding tool 23 is pressed in the area of ​​the weld 13 to be created onto the contact element 12 with the underlying back contact layer 8 or the underlying cable 14 or the underlying cable harness 15, the control unit 17 can regulate the contact force. If a threshold value of a predetermined contact force is reached, the control unit 17 can trigger the welding pulse of the welding tool 23. If the weld 13 has been completed as a result of this welding pulse, corresponding feedback can be sent to the control unit 17.If the welding process is monitored by evaluating the contact resistance between the electrodes and the workpiece, the evaluation result, whether the welding process was carried out correctly or not, can also be transmitted to the control unit 17. It is also possible for this evaluation to take place in the control unit 17. In the method according to the invention, the robot kinematics are thus directly coupled to the welding process and the control of the welding tool 23 is directly coupled to the welding pulse.

[0066] In method step 52, the free positioning of the robot 18 in combination with a pneumatic dispensing system 22 controlled by the control unit 17 enables the free generation of adhesive patterns for the adhesive layers 11, for example in point, line, or surface form. This enables, on the one hand, the automated construction of solar cell fields in grid geometry or the assembly of free-form surfaces (so-called "body-mounted solar arrays"). The pattern generation is controlled by the XYZ coordinates and the Euler angles of the dispensing system 22, the actuation duration of the dispensing system 22 and the delivery pressure of the dispensing system, as well as the Cartesian speed of the TCP of the dispensing head of the dispensing system 22.

[0067] During handling in work step 53, the robot's force control enables sensitive workpieces such as a matrix or a string of solar cells 7 to be safely handled, picked up, and placed. This is achieved by a targeted application of force along the tool's thrust direction at the TCP, which enables the application of contact pressure to any target geometry. Furthermore, the safety features of the control logic of the control unit 17 allow a reaction to unwanted and unexpected external disturbances by setting a torque threshold value for the robot axes. This allows, for example, a collision or placement in the wrong location to influence or stop the movement.

[0068] The functional test in method step 55 is shown schematically in the block diagram according to Fig. 10. Visible here are the shielding body 39, the contacts 40a, 40b arranged at the end region of the shielding body 39 facing the workpiece, and a sensor or a camera 56 arranged inside the shielding body 39. By means of the control of the robot 18, the shielding body 39 is pressed against the solar cells 7 such that the at least one solar cell 7 whose functionality is to be tested is located inside the shielding body 39 and the contacts 40a, 40b interact with the contact elements 12 of the solar cell 7, so that the solar cells 7 arranged between the contacts 40 are energized and generate a luminescence image. This luminescence image can then be recorded by the camera 56, and an evaluation can be carried out by the control unit 17 using suitable image acquisition software in order to check whether the solar cells 7 are functioning properly.Alternatively, it is possible for a light source 57, rather than a camera 56, to be arranged in the shielding body 39. In this case, the contacts 40 do not serve to electrically supply the solar cells 7. Rather, in this case, the contacts 40 pick up the electrical signals generated by the solar cells 7 as a result of the light from the light source 57, the evaluation of which can then be used to check whether the solar cells 7 are functioning properly.

[0069] Fig. 11-23 show, by way of example, a handling of several solar cells 7 welded together, in particular with a twisting according to work step 53.

[0070] In Fig. 11 shows a reversible comb 58, which is constructed in several parts to allow for variability and has a base body 59 and prongs 60 extending therefrom. Gaps 61 are formed between the prongs 60.

[0071] Furthermore, in Fig. 11 the robot head 25 with the handling tool 24 held thereon according to Fig. 8. The handling tool 24 has Fig. 11, the solar cells 7, which are connected to one another via the welds 13, have already been picked up by the picking devices 49 on the side of the back contact layer 8 being sucked onto the solar cells 7. While the robot head 25 was oriented downwards for picking up the solar cells 7, the robot head 25 is in Fig. 11 is already twisted upwards so that (when the solar cells 7 extend horizontally) the glass layers 10 of the solar cells 7 are at the top.

[0072] In Fig. 12 it can be seen that the receiving devices 49 interact with the solar cells 7 via a suction plate 62.

[0073] As in the transition from the Fig. 11-13 to the Fig. 14, Fig. 15, the receiving devices 49 enter the spaces 61 of the turning comb 58 as a result of the movement of the robot head 25 in the horizontal direction parallel to the tines 60, the base body 48 of the handling tool 24 being arranged below the plane defined by the tines 60, while the solar elements 7 are arranged above this plane.

[0074] As in Fig. 15, the solar elements 7 are placed on the upper sides of the tines 60 of the turning comb 58 by moving the handling tool 24 downwards and releasing the suction cups 62 from the solar cells 7 (cf. Fig. 16 and Fig. 17).

[0075] According to Fig. 18 and Fig. 19, the robot head 25 is then rotated again so that the receiving devices 49 extend downwards, and the handling tool 24 is arranged above the solar cells 7 placed on the turning comb 58. If the handling tool 24 is now moved downwards by the robot head 25 into the Fig. 20 and Fig. 21, the suction cups 62 can interact with the solar cells 7 in the area of ​​the glass layer 10. The solar cells 7 can then be lifted by means of the handling tool 24 (cf. Fig. 22, Fig. 23). In this state, the solar cells 7 can then be pressed into the adhesive layer 11 using the handling tool 24.

[0076] The control unit 17 can be a central control unit. It is also possible for several sub-control units responsible for different functions to be present, which can communicate with each other in any way. It is also possible for a sub-control unit to be integrated into the robot head 25 and / or integrated into the tool.

[0077] It is possible for the tool to communicate with the robot 18 and / or the control unit 17 via an electrical and / or pneumatic interface, whereby the interface can also be integrated into the tool interface 26, whereby the electrical and / or pneumatic connections can also be created automatically if a mechanical coupling of the tool to the tool interface 26 takes place. However, it is also possible for the interface to be designed independently of the tool interface 26, whereby lines connected to this interface can then be fed to the interface via the arms of the robot 18 or independently thereof.

[0078] Via the aforementioned connections, for example, tool operations can be triggered when the specified TCP positions are reached. Energy can be provided in the form of electrical power and / or pneumatic pressure. Furthermore, the valve position of valves can be controlled to control the tool's functions. Switch actuation is also possible. In this way, for example, the robot 18 can switch vacuum and compressed air tools or valves and control the welding tool 23.

[0079] The tools preferably have a uniform tool head 63. The tool head 63 can, on the one hand, have a receiving body 64 that forms the receptacles 35, 36. The receiving body 64 is preferably designed as a receiving cube. Furthermore, the receiving body 64 can also have an alignment surface 65, via which (in addition to the interaction of the gripping elements 33, 34 with the receptacles 35, 36) the orientation of the tool relative to the robot head 25 is specified. The alignment surface 65 preferably interacts with a side surface or underside or counter-alignment surface 67 of the gripping elements 33, 34. In addition, the tool head 63 forms a magazine holder receptacle 66, which is, for example, a dovetail guide.In the area of ​​the magazine holder receptacle 66, when the tool head 63 is inserted into the U-shaped receptacle 38 of the tool magazine holder 20, a positive fit is created, which secures the tool against falling out of the tool magazine holder 20. It is possible that the interaction of the gripping elements 33, 34 with the receptacle 35, 36, on the one hand, and of the alignment surface 65 with the counter-alignment surface 67, on the other hand, results in a double fit. Thus, in particular, the X, Y, and Z planes of the TCP and the three Euler angles of the tool can be aligned with the robot coordinate system with high repeatability.

[0080] The robot 18 used according to the invention thus serves not only for handling and joining, but also for other work steps, in particular welding, creating the adhesive layer, pressing into the adhesive layer, and functional testing, whereby these work steps are then carried out partially or fully automatically. Controlling the robot 18 via the XYZ coordinates and the Euler angles of the TCP enables the fully automated production of freeform geometries ("body-mounted solar arrays").

[0081] Preferably, the contacts 40 are elastically supported on the shielding body 39. Accordingly, the machining elements of other tools that interact with the workpiece can also be elastically supported.

[0082] For functional testing, a database of good and bad parts can be created after a certain process runtime. This dataset can then be used to train artificial intelligence for detailed defect detection, increasing the process robustness of image assessment.

[0083] If a light source is used in the functional test tool 29, it can be a xenon lamp, for example.

[0084] According to the invention, solar cell strings of any geometry can be welded and / or bonded. Handling of the sensitive electronics of the solar cell device 1 is possible within automated processes. The invention enables in-line testing of the solar cell device 1 and / or the solar cells 7 during the process.

[0085] The inventive design can lead to a reduction in complexity, a reduction in required calibration processes, a reduction in maintenance, improved product safety through automatic data collection by the robot 18, and to the use of the robot's complete force-torque control. When fully automated, rapid response is possible even to complex geometries in small batches. The robot 18 can also be used for semi-automatic production, in which interaction with the operator takes place. Nevertheless, a high level of reproducibility is then achieved. Frequent geometry changes can also be accommodated in an automated manner, thus avoiding manual work. Direct programming by importing CAD data is also possible.

[0086] Within the scope of the invention, for example, a solar cell device 1 can also be manufactured in the form of a spacecraft membrane, as described in particular in the document DE 10 2021 108 420 A1. LIST OF REFERENCE SYMBOLS 1 solar cell device 2 carriers 3 lower cover layer 4 upper cover layer 5 Honeycomb material 6 glass fiber mat 7 solar cells 8 Back contact layer 9 photosensitive layer 10 glass layers 11 Adhesive layer 12 Contact element 13 Welding 14 Line 15 Wiring harness 16 workstations 17 Control unit 18 robots 19 Tool magazine 20 tool magazine holders 21 Adhesive applicator 22 Dosing system 23 Welding tools 24 Handling tools 25 Robot head 26 Tool Interface 27 grippers 28 grippers 29 Functional test tool 30 work surface 31 Vacuum table 32 filing matrix 33 Gripping element 34 gripping element 35 recording 36 recording 37 Mounting area 38 recording 39 Shielding body 40 Contact 41 Electrode holder 42 electrode holders 43 Adjustment device 44 Linear guide 45 Linear guide 46 housings 47 Dispensing nozzle 48 base bodies 49 Recording device 50 work steps 51 work steps 52 work steps 53 work steps 54 work steps 55 work steps 56 Camera 57 Light source 58 turning ridge 59 Base 60 tines 61 space 62 suction cups 63 Tool head 64 receiving bodies 65 alignment surface 66 Magazine holder 67 Counter-alignment surface

Claims

[1] Method for the at least partially automated production of a solar cell device (1) with a plurality of electrically interconnected solar cells (7) which are attached to a carrier (2) via an adhesive layer (11), wherein a) in the method, a multi-axis robot (18) is used, in which a contact force acting on a tool interface (26) of the robot (18) is controlled by means of a contact force control, b) the same robot (18) performs at least two of the following work steps: ba) creating a weld (13) to bring about an electrical contact between at least one solar cell (7) by means of a welding tool (23) which is held on the tool interface (26) of the robot (18), wherein a contact force acting on an electrode of the welding tool (23) during the creation of the weld (13) is controlled by the contact force control, wherein the welding process is monitored by evaluating a contact resistance between the electrodes of the welding tool (23) and the at least one solar cell (7), and / or bb) handling a component or subassembly of the solar cell device (1) by means of a first handling tool (24) with a pressing of the component or subassembly into the adhesive layer (11), wherein the first handling tool (24) is held on the tool interface (26) and a contact force acting during the pressing is controlled by the contact force control, and / or bc) picking up and / or handling and / or depositing the solar cell device (1) or a component or subassembly thereof by means of a second handling tool (24) which is held on the tool interface (26) of the robot (18), wherein a contact force acting during the picking up and / or handling and / or depositing is controlled by the contact force control, and / or bd) bringing about an electrical contact between at least one solar cell (7) by pressing a contact (40) of a first functional testing tool (29) to perform a functional test, wherein the first functional testing tool (29) is held on the tool interface (26) of the robot (18) and a contact force acting on the contact (40) during the pressing is regulated by the contact force control, wherein the pressed contact (40) brings about an electrical contact between the first functional testing tool (29) and contacts of the at least one solar cell (7), so that the at least one solar cell (7) is electrically energized by means of the first functional testing tool (29), wherein the electrical energization of the at least one solar cell (7) leads to an electroluminescence image which is recorded by means of a sensor or a camera (56) of the first functional testing tool (29),wherein, based on the signal of the sensor or an image evaluation of the image of the camera (56), a conclusion is drawn as to the functionality of the at least one solar cell (7), whereby a quality check of the at least one solar cell (7) and the assembly carried out is carried out, and / or, be) pressing on a shielding body (39) of a second functional testing tool (29) to carry out a functional test, wherein the second functional testing tool (29) is held on the tool interface (26) of the robot (18) and a contact force acting on the shielding body (39) during the pressing is regulated by the contact force control, wherein the second functional testing tool (29) has a lighting means which illuminates the at least one solar cell (7) under defined conditions ensured by the shielding body (39), so that the at least one solar cell (7) generates a predetermined electrical signal when functioning properly, which is evaluated and with which a conclusion is drawn about the functionality of the at least one solar cell (7), In each case one of the steps ba), bd) and be) is carried out. [2] Method according to claim 1, wherein the solar cell device (1) or a component or subassembly thereof a) in a form-fitting receptacle or storage matrix of a work surface (30) and / or b) a negative pressure on the working surface (30) prevents a relative movement with respect to the working surface (30) as a result of the acting contact force and / or an interaction caused by the contact and / or as a result of the action of a tool. [3] Method according to one of the preceding claims, wherein the tool interface (26) of the robot (18) has two grippers (27, 28), each having a gripping element (33, 34), wherein a) in a gripping position of the grippers (27, 28), a tool is caught in the area of ​​two receptacles (35, 36) of the tool between the grippers (27, 28) and the gripping elements (33, 34) engage positively in the receptacles (35, 36), and b) the grippers (27, 28) are moved into a release position in which the tool is not caught in the area of ​​two receptacles (35, 36) of the tool between the grippers (27, 28) and the gripping elements (33, 34) do not engage positively in the receptacles (35, 36). [4] Method according to one of the preceding claims, wherein a) in a tool magazine (19) aa) the welding tool (23) and / or ab) an adhesive applicator (21) and / or ac) the first or second handling tool (24) and / or ad) the first or second functional test tool (29) is / are arranged, b) wherein the welding tool (23) and / or the adhesive applicator (21) and / or the first or second handling tool (24) and / or the first or second functional testing tool (29) is fed to the tool magazine (19) and / or removed from the tool magazine (19) while regulating the contact force by means of the contact force control. [5] Method according to one of the preceding claims, wherein, during the creation of the weld (13), the achievement of a predetermined contact force or a predetermined contact force range triggers the activation of an electrode of the welding tool (23). [6] Method according to one of the preceding claims, wherein an adhesive applicator (21) has a pneumatic dosing system (22) which is controlled or regulated as a function of a position of the tool interface (26) of the robot (18) and the contact force. [7] Method for the at least partially automated production of a solar cell device (1) with a plurality of electrically interconnected solar cells (7) which are attached to a carrier (2) via an adhesive layer (11), in particular method according to one of the preceding claims, wherein a) in the method, a multi-axis robot (18) is used, in which a contact force acting on a tool interface (26) of the robot (18) is controlled by means of a contact force control, b) the same robot (18) performs at least two of the following work steps: ba) creating a weld (13) for bringing about an electrical contact between at least one solar cell (7) by means of a welding tool (23) which is held on the tool interface (26) of the robot (18), wherein a contact force acting on an electrode of the welding tool (23) during the creation of the weld (13) is controlled by the contact force control, and / or bb) handling a component or subassembly of the solar cell device (1) by means of a first handling tool (24) with a pressing of the component or subassembly into the adhesive layer (11), wherein the first handling tool (24) is held on the tool interface (26) and a contact force acting during the pressing is controlled by the contact force control, and / or bc) picking up and / or handling and / or depositing the solar cell device (1) or a component or subassembly thereof by means of a second handling tool (24) which is held on the tool interface (26) of the robot (18), wherein a contact force acting during the picking up and / or handling and / or depositing is controlled by the contact force control, and / or bd) bringing about an electrical contact between at least one solar cell (7) by pressing on a contact (40) of a first functional testing tool (29) to carry out a functional test, wherein the first functional testing tool (29) is held on the tool interface (26) of the robot (18) and a contact force acting on the contact (40) during the pressing is controlled by the contact force control, and / or be) pressing a shielding body (39) of a second functional testing tool (29) to carry out a functional test, wherein the second functional testing tool (29) is held on the tool interface (26) of the robot (18) and a contact force acting on the shielding body (39) during the pressing is controlled by the contact force control, in each case one of the steps ba), bd) and be) is carried out, whereby a) a turning comb (58) is present and b) the solar cell device (1) or a component or subassembly thereof is picked up by the turning comb (58) in a first orientation or is placed on the turning comb with the second handling tool (24), wherein the second handling tool (24) extends from the side below the turning comb (58) through gaps (61) of the turning comb (58) to a first side of the solar cell device (1) or a component or subassembly thereof and c) the solar cell device (1) or a component or subassembly thereof is picked up or placed from the side above the turning comb (58) with the second handling tool (24) and / or the solar cell device (1) or a component or subassembly thereof is placed in a second orientation on the turning comb (58) with the second handling tool (24), wherein the second handling tool (24) extends on the side facing away from the turning comb (58) to a second side of the solar cell device (1) or a component or subassembly thereof. [8] Method according to one of the preceding claims, wherein the second functional testing tool (29) has a light source (57) and an electrical power response of at least one solar cell (7) which is exposed to light from the light source (57) is determined via the contact (40). [9] Method according to one of the preceding claims, wherein the tool interface (26) or a robot head (25) has a QR code detection device. [10] Method according to claim 9 in dependence on claim 8, wherein a result of the functional test by the first and / or second functional test tool (29) is evaluated and / or stored in conjunction with an identification of the solar cell device (1) or component or subassembly thereof, which is determined on the basis of the QR code detected by means of the QR code detection device.

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