Compact Multi-Function Workstation for Photovoltaic Panel Assembly
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Solution Overview
Problem
Current systems for assembling photovoltaic panels, especially those with back-contact cells, face challenges in precision, repeatability, and versatility, making them unsuitable for laboratory research and development due to high costs, space requirements, and complexity, and are not easily adaptable for industrial use.
Innovation Solution
A compact, semi-automatic, multi-function workstation integrates multiple operations on a single surface, using mobile gantries and optoelectronic control for precise assembly of photovoltaic panels with cells of various types, reducing manual handling and enabling efficient testing of different technologies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional separate workstations are used for assembling photovoltaic panels, then each operation can be performed with dedicated equipment, but the apparatus occupies large space and requires multiple manual transfers
Solution Approach 1:
The patent combines multiple separate workstations (cell loading, ribbon loading, contacting, encapsulant application, glass application) into a single integrated apparatus with a common working surface. This merging eliminates the need for manual transfers between separate stations, reduces overall space occupation, and maintains assembly precision through coordinated robotic end-effectors that operate simultaneously on the same panel.
Solution Approach 2:
The apparatus is designed as a multi-functional system where a single apparatus performs all assembly operations. The mobile gantries with interchangeable end-effectors can adapt to different panel types and assembly configurations, providing universal functionality across various photovoltaic panel assembly tasks while occupying minimal space.
2Productivity
If manual handling is used for transferring panels between workstations, then equipment complexity is reduced, but productivity decreases and precision is compromised
Solution Approach 1:
The patent replaces manual mechanical handling with automated robotic end-effectors mounted on mobile gantries. These robotic systems use optoelectronic control and vision systems to automatically load cells, apply adhesives, and assemble panel components with high precision and speed, eliminating manual transfers while managing complexity through integrated control systems.
3Manufacturing precision
If multiple separate devices are used for different assembly operations, then each device can be optimized for its specific function, but the overall system becomes complex and expensive
Solution Approach 1:
The apparatus segments assembly functions into modular robotic end-effectors (cell loading, ribbon loading, contacting, encapsulant application, glass application) that can be independently optimized for their specific functions. Each end effector is a self-contained module that can be mounted on mobile gantries, allowing functional optimization while managing overall system complexity through modularity and a common control platform.
4Manufacturing precision
If conventional systems are used for back-contact panel assembly, then standard assembly processes can be applied, but precision and repeatability are insufficient
Solution Approach 1:
The patent employs mobile gantries with dynamically adjustable end-effectors that can adapt their position, orientation, and function based on the specific panel type being assembled. The system uses optoelectronic control and vision systems to dynamically adjust parameters for different panel configurations, enabling high precision contacting for back-contact panels while maintaining versatility across various panel types.
Data Source
AI summary
Compact apparatus for the semi-automatic horizontal assembly of photovoltaic panels with solar cells, made up of a multi-function workstation in the form of a pilot system integrating multiple working and conveying means which carry out the various operations concomitantly and in a coordinated way. On the sides of the working surface there is the loading zone of the cells, the loading zone of the conductive ribbons and a pair of longitudinal rails which are intended to guide two mobile gantries, which roto-translate above the working surface, from one loading zone to the other, being equipped for the purpose of assembly. In particular, the compact apparatus is versatile in use and allows to obtain already in the experimental laboratory phases the levels of accuracy and control of an industrial system, for the purpose of optimizing the product and the assembly technologies reducing wastes and faults.