Solar Array PCB Integration for Automated Assembly
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Solution Overview
Problem
Current methods of manufacturing space-grade solar arrays are limited by a lack of automation and modularization, leading to high labor costs and errors due to manual processes, which can result in solar array failures.
Innovation Solution
The method involves manufacturing small solar cells with integrated back-side electrical contacts and integrated coverglass at the wafer level, using automated pick and place technology and printed circuit boards with embedded wiring, eliminating the need for manual connection and reducing human error.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual processes are used to connect solar cells with wire harness, then flexibility in assembly is maintained, but labor costs increase and human error occurs
Solution Approach 1:
The patent combines the electrical connection function and mechanical support function into a single integrated PCB structure. The PCB serves as both the substrate for mounting solar cells and the electrical interconnect replacing traditional wire harnesses, eliminating manual wiring operations and enabling automated assembly processes.
Solution Approach 2:
The patent replaces the mechanical wire harness system with an integrated PCB-based electrical interconnect system. This substitution eliminates the need for manual wire manipulation and connection, allowing for automated pick-and-place assembly of solar cells onto the PCB.
2Extent of automation
If highly customized automated manufacturing systems are used, then automation extent increases, but system complexity and scalability worsen
Solution Approach 1:
The PCB design incorporates universal mounting structures and standardized electrical interfaces that can accommodate different solar cell types and configurations. This universality allows a single automated manufacturing system to produce multiple solar array variants without requiring highly customized equipment for each configuration.
Solution Approach 2:
The patent segments the solar array into modular units based on PCB assemblies, where each PCB can be independently manufactured and tested before final integration. This segmentation enables standardized automated production processes that can be scaled and replicated across different array sizes and power requirements.
3Manufacturing precision
If manual assembly processes are used, then adaptability to various configurations is maintained, but manufacturing precision and quality consistency worsen
Solution Approach 1:
The PCB is pre-designed with precisely positioned mounting holes, conductive traces, and electrical contacts before solar cells are attached. This preliminary preparation ensures that automated assembly processes can place solar cells with high precision without requiring manual adjustment, maintaining both quality consistency and configuration flexibility.
Data Source
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AI summary
A space-grade solar array includes relatively small cells with integrated wiring embedded into or incorporated directly onto a printed circuit board. The integrated wiring provides an interface for solar cells having back side electrical contacts. The single side contacts enable the use of pick and place (PnP) technology in manufacturing the space-grade solar array. The solar cell is easily and efficiently packaged and electrically interconnected with other solar cells on a solar panel such as by using PnP process. The back side contacts are matched from a size and positioning standpoint to corresponding contacts on the printed circuit board.