Process development for automated solar cell and module production. Task 4: automated array assembly. Quarterly report No. 5

Construction of an automated solar cell layup and interconnect system is now complete. This system incorporates a Unimate 2000 B industrial robot with an end effector consisting of a vacuum pick up and induction heating coil. The robot interfaces with a smart cell preparation station which correctly orients the cell, applies solder paste and forms and positions the correct lengths of interconnect lead. The system is controlled and monitored by a TRS-80 micro computer. The first operational tests of the fully integrated station have been run. These tests proved the soundness of the basic design concept but also pointed to areas in which modifications are necessary. These modifications are nearly complete and the improved parts are being integrated. Development of the controlling computer program is progressing to both reflect these changes and reduce operating time

Process development for automated solar cell and module production. Task 4: automated array assembly

The scope of work under this contract involves specifying a process sequence which can be used in conjunction with automated equipment for the mass production of solar cell modules for terrestrial use. This process sequence is then critically analyzed from a technical and economic standpoint to determine the technological readiness of each process step for implementation. The process steps are ranked according to the degree of development effort required and according to their significance to the overall process. Under this contract the steps receiving analysis were: back contact metallization, automated cell array layup/interconnect, and module edge sealing. For automated layup/interconnect both hard automation and programmable automation (using an industrial robot) were studied. The programmable automation system was then selected for actual hardware development. Economic analysis using the SAMICS system has been performed during these studies to assure that development efforts have been directed towards the ultimate goal of price reduction. Details are given. (WHK