Automated Solar Cell Stringing for Space Arrays
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Solution Overview
Problem
Current methods for manufacturing photovoltaic arrays are labor-intensive and costly, with high cell damage rates due to manual handling and limited automation, especially in assembling standard power modules for space solar arrays.
Innovation Solution
An automated manufacturing system and method that uses a SCARA robotic system with end effector tools, adhesive dispensers, and welding stages to assemble photovoltaic standard power modules efficiently, reducing labor and cell damage by robotic positioning and welding of solar cells, interconnects, and cover glass, and integrating acceptance testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual handling and limited automation are used in assembling standard power modules, then ease of operation is maintained, but productivity is low and cell damage rate is high
Solution Approach 1:
The manufacturing system is divided into distinct functional modules: a SCARA robotic system for positioning, a separate welding station for interconnect attachment, and individual stations for applying adhesive and placing cover glass. This segmentation allows each module to be optimized independently while maintaining overall system productivity and reducing the complexity of any single component.
2Loss of time
If multiple separate operations are used for assembling PV arrays, then manufacturing precision can be maintained, but loss of time is excessive
Solution Approach 1:
Multiple previously separate operations—positioning solar cells, applying adhesive, placing interconnects, attaching cover glass, and welding—are merged into a single integrated automated work cell. The SCARA robotic system coordinates all these operations in sequence without removing components between stations, eliminating transfer time while maintaining precision through programmable positioning and controlled dispensing.
Solution Approach 2:
Adhesive is applied to the substrate in advance before the solar cells are positioned, and the system is configured with all necessary components (interconnects, cover glass) ready for immediate placement. This preliminary preparation eliminates waiting time during the assembly process while ensuring proper bonding and alignment.
3Reliability
If automated robotic positioning and welding are used, then productivity increases and cell damage decreases, but device complexity increases
Solution Approach 1:
The SCARA robotic system serves multiple functions: positioning solar cells, positioning interconnects, positioning cover glass, and coordinating the welding process. This multi-functionality reduces the need for multiple specialized robotic systems, thereby increasing reliability through consistent handling while limiting the growth of overall system complexity.
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
The system significantly reduces production time and cost while ensuring high-quality, repeatable photovoltaic panels with lower cell damage, enabling efficient assembly of solar arrays for space applications in both rolled and z-folded configurations.
Implementation Method 1
robotic positioning of the string adjacent to an integral welder and welding the front side of the string
Implementation Method 2
adhesive dispensers
Data Source
AI summary
An automated system provides automated manufacturing of photovoltaic standard power modules for utilization in a space solar array, in both rolled blanket and z-folded configurations. The automated system provides robotically controlled systems for CIC-ing, glassing, stringing, laydown and acceptance testing of interconnected photovoltaic devices. A method of manufacturing the photovoltaic standard power modules includes the steps of robotic positioning of diodes, interconnects and busbars onto a SPM stringing tray followed by the robotic positioning of bare cells into position adjacent to the diodes, interconnects and busbars to form strings. The SPM stringing tray is thereafter robotically positioned adjacent to an integral welder for welding of the front side of the string. Cover glass is thereafter robotically placed over the cells. The string is flipped and the backside of the string is robotically positioned for welding.