Solar Cell Tabbing Alignment With Integrated Wire Jig Transfer
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Solution Overview
Problem
In the process of tabbing solar cells, where wires are connected to form solar cell modules, the relative positions of solar cells, wire jigs, and wires often go uncorrected, leading to improper connections and reduced quality of the solar cell module due to floating or deviated wires.
Innovation Solution
A tabbing apparatus and method that includes a solar cell transportation apparatus, a wire transportation apparatus, a wire jig transportation apparatus, an alignment apparatus with displacement devices, and a delivering apparatus, utilizing a position identification sensor and controller to correct the position of the solar cell before bonding, ensuring precise alignment and simultaneous transportation of the solar cell and wire jig onto the wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the solar cell and wire jig are transported separately and positioned manually, then the alignment can be adjusted, but the manufacturing time and process complexity increase
Solution Approach 1:
The patent combines the solar cell and wire jig into a single integrated assembly that is transported together by the delivering apparatus. This merging eliminates the need for separate positioning operations, reduces manufacturing time, and maintains alignment precision through the integrated transport mechanism.
Solution Approach 2:
The alignment apparatus performs preliminary alignment of the solar cell before the delivering apparatus transports the integrated assembly. This preliminary action ensures that the alignment is established in advance, allowing subsequent transport to maintain the predetermined positional relationship without requiring complex real-time adjustments.
2Reliability
If the solar cell position is not corrected before bonding, then the manufacturing process is simpler and faster, but the connection quality degrades due to misalignment
Solution Approach 1:
The alignment apparatus performs preliminary correction of the solar cell position before the bonding process. This preliminary action ensures that the solar cell is properly aligned with the wire jig, guaranteeing connection quality while keeping the overall process efficient through a single-pass correction approach.
Solution Approach 2:
The alignment apparatus acts as an intermediary between the solar cell transportation apparatus and the delivering apparatus. It corrects the solar cell position in between these stages, ensuring that the subsequent bonding process receives properly aligned components without requiring the bonding apparatus itself to be complex.
3Ease of manufacture
If separate transportation apparatuses are used for solar cell and wire jig, then each can be optimized independently, but the synchronization and alignment become more difficult
Solution Approach 1:
The delivering apparatus merges the transport of the solar cell and wire jig into a single coordinated operation. By transporting them together as an integrated assembly, the system maintains the ability to independently optimize each component's design while ensuring precise relative positioning through the unified transport mechanism.
Data Source
AI summary
A tabbing apparatus for forming a solar cell module by connecting a solar cell with a wire includes: a solar cell transportation apparatus configured to transport the solar cell; a wire transportation apparatus configured to transport the wire; a wire jig transportation apparatus configured to transport a wire jig that is configured to support the wire; an alignment apparatus configured to mount thereon the solar cell transported by the solar cell transportation apparatus, and correct a position of the solar cell; and a delivering apparatus configured to support the solar cell mounted on the alignment apparatus and having the corrected position and the wire jig transported by the wire jig transportation apparatus, and mount the solar cell and the wire jig on the wire on the wire transportation apparatus.