LSM Shuttle Handling for PV Cell Printing
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Solution Overview
Problem
Conventional silk-screen printing systems for photovoltaic cells and wafers face issues with contamination, low printing quality due to instability and rigidity of support elements, poor repeatability, high breakage rates, and complex, costly handling systems that are not versatile or efficient, particularly in large production volumes.
Innovation Solution
An integrated handling system using linear synchronous motor (LSM) moving coils with on-board coils and permanent magnets, allowing multiple shuttles to operate independently and coordinatedly on a rail, providing precise and flexible positioning, automatic alignment, and easy maintenance, while minimizing contamination and downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional conveyor belts and rotary tables are used for handling photovoltaic cells, then the system structure is simple, but the positioning accuracy and repeatability are insufficient
Solution Approach 1:
The patent replaces conventional mechanical conveyor belts and rotary tables with an electromagnetic drive system using linear synchronous motors. The moving magnets on shuttles interact with stationary coils on the rail to provide precise, cable-less positioning of photovoltaic cells, eliminating mechanical wear and improving positioning accuracy while reducing system complexity.
Solution Approach 2:
The shuttles are self-propelled with onboard magnets that interact with the stationary coil system. Each shuttle independently controls its own movement along the rail without requiring external mechanical drive mechanisms, cables, or complex synchronization systems, thereby simplifying the overall handling system while maintaining high positioning precision.
2Productivity
If multiple shuttles with independent missions are used, then productivity increases, but communication reliability between shuttles and control system deteriorates
Solution Approach 1:
Each shuttle is self-propelled with independent electromagnetic drive and onboard control electronics. The shuttles communicate with the central control system through wireless or simplified signaling mechanisms, eliminating the need for complex cable connections while maintaining reliable communication for coordinating multiple shuttles' independent missions and maximizing productivity.
3Ease of repair
If conventional mechanical handling systems are used, then device complexity is low, but maintenance frequency and costs increase
Solution Approach 1:
The patent eliminates mechanical contact between moving and stationary components by using electromagnetic fields for propulsion. The linear synchronous motor system with moving magnets and stationary coils has no wear-prone mechanical connections, cables, or moving parts requiring lubrication and adjustment, dramatically reducing maintenance frequency and costs while simplifying the overall system structure.
4Manufacturing precision
If high precision positioning systems are implemented, then printing quality improves, but energy consumption increases
Solution Approach 1:
The electromagnetic drive system provides precise positioning through controlled interaction between onboard magnets and stationary coils. The system consumes energy only when acceleration or positioning adjustments are needed, and maintains position without continuous energy input, reducing overall energy consumption compared to mechanical systems requiring constant power for motors and drives while achieving high printing precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances printing quality, reduces breakage rates, and decreases production costs by improving handling stability and repeatability, enabling high-speed, precise, and flexible operation with reduced maintenance needs and energy consumption.
Implementation Method 1
An integrated handling system using linear synchronous motor (LSM) moving coils with on-board coils and permanent magnets
Implementation Method 2
multiple shuttles to operate independently and coordinatedly on a rail, providing precise and flexible positioning
Data Source
AI summary
A method and related automatic production plant are disclosed for the silk-screen printing of inks or conductive pastes on photovoltaic cells or wafers, with an integrated handling system of the LSM moving coils drive type, wherein multiple shuttles with on-board coils act on a rail with permanent magnets in an independent but coordinated way, synchronous and/or asynchronous with respect to each other, to simultaneously perform missions different from each other in such a way as to advantageously carry out the printing operating steps provided by the method. Each shuttle is provided with an equipped tray of the removable type which is specifically configured to carry out the automated processing of the single cell, it also being intended to interact with the plant.