Tsarin Samar da Faifan Rana: Matakai 10 da Injuna

Amsa mai sauri: Kera fale-falen hasken rana yana gudana ne a matsayin tsari mai ci gaba wanda ake auna shi da takt, ba a matsayin injuna goma masu zaman kansu ba. Akwatin sel da aka tantance yana shiga, kuma pallet ɗin da aka gwada yana fita, ta hanyar gwajin sel, yankan, stringing, layup, lamination, trimming, framing, sanya junction-box, curing da gwajin IV na ƙarshe. Yawan kayan da ake samarwa ana ƙayyade shi ne ta tashar da ta fi jinkiri, don haka layi ana bayyana shi da ƙarfin shekara-shekara — layin 120 MW da layin 20 MW suna amfani da jerin iri ɗaya a adadin tashoshi da sauri daban-daban. Sanya ribbon da soldering a stringer, da vacuum da yanayin zafi a laminator, su ne inda yawancin lahani ke tasowa; ƙofofin electroluminescence guda biyu suna kama micro-cracks da voids kafin su isa abokin ciniki. Wannan tsari ɗaya yana hidimar PERC, TOPCon da sel back-contact, tare da tsarin sel da adadin busbar a matsayin manyan masu canji.

Abin da a zahiri ke faruwa tsakanin akwatin tantanin halitta da ke shigowa da module ɗin da aka jera a kan pallet — kowane mataki tare da injinsa, lokacin zagayowar, amfani da wuta, sararin bene da adadin ma'aikata, daga mai kaya wanda layukansa ke gudanar da wannan tsari kullum.

Samar da PV Module · Jagorar Tsari & Kayan Aiki · daga Jerry, Ooitech

Layin atomatik na 120 MW yana kammala module kusan kowane minti biyu. Matakai goma suna tsakanin akwatin tantanin halitta da ke shigowa da wannan module ɗin da aka jera a kan pallet, kuma kowane mataki yana da inji, lokacin zagayowar, farashi da yanayin gazawa. Yawancin bayanan da ke cikin tsarin kera panel ɗin hasken rana tsaya kan kimiyya. Wannan shafi yana bin ta yadda za ka duba ta a kan bene na masana'anta — domin wannan ita ce sigar da kake buƙata kafin ka sanya hannu kan kwangilar kayan aiki.

1. Yadda Tsarin Ke Gudana a Haƙiƙa: Takt, Ba Injuna Goma Dabam Ba

Kalmar da ke jagorantar komai ita ce takt — ƙarar da kammalallen modules ke barin layin. A kan tsarinmu na 20 MW mai rabin-atomatik, layin yana kammala panels 16 a kowace awa; a kan layin atomatik na 120 MW, panels 32 a kowace awa yana aiki awanni 24 a rana. Duk tashar da ke sama dole ta bi wannan ƙarar ko ta zama cikas, kuma ayyuka biyu mafi jinkiri — soldering da lamination — su ne ke saita takin komai.

Wannan kuma shine dalilin da yasa jerin matakai da ke ƙasa ke karanta kamar takardar faɗi. Kowanne daga cikin matakai goma yana da alaƙa da rukunin inji ɗaya tare da tsayayyen rukunin farashin kasuwa, FOB China: masu haɗa igiyoyi na matakin shiga suna cikin kewayon $60k–70k, aji na 2,400-cell mai aiki tsakanin $99,000–120,000 da $140,000–150,000, injin rubutu na laser kusan $20k–25k, na'urar juyawa 'yan dubban daloli — rukunan da ba su canza sosai ba cikin shekaru da yawa na faɗi. Idan ka gama wannan shafin ya kamata ka iya kallon zanen tsarin kowane mai kaya ka haɗa rukunin farashi da adadin ma'aikata ga kowane akwati a cikinsa.

2. Matakai Goma, Daga Gwajin Cell zuwa Pallet

Hudu daga cikin waɗannan matakan suna yanke shawarar yawancin tattalin arzikinka, don haka sun cancanci dubawa na kusa.

Mataki na 3 — stringing, wanda ba a iya juyawa

Yin siyar da ribbon zuwa fuskar gaban tantanin halitta da kai shi zuwa bayan tantanin halitta na gaba shine inda ingancin lantarki na module ke tabbatarwa. SS-2500 na yin hakan a tantanin halitta 2,400 a kowace awa tare da daidaita kyamarar CCD da mutum-mutumi da ke kula da kowane tantanin halitta, yana riƙe karyewa a ƙasa da 0.2% akan tantanin halitta na A-grade a tsarin busbar 3–20 daga 156 zuwa 210 mm. Da zarar haɗin solder mara kyau ko ɓoyayyen microcrack ya wuce wannan tasha, babu wani mataki na gaba da zai iya gyara shi — wanda shine dalilin da yasa mataki na 6 yake. Lokacin da wani abu ya karkata, alamar cutar ta keɓance: wayoyi suna zaune a kan gurbin solder ɗinsu, ana iya gani a matsayin haɗin da ya yi baki ko ba a jika ba a gefen igiyar. Maganin kusan koyaushe shine daidaita ciyarwar ribbon ko girke-girken zafin solder, ba tantanin halitta ba.

Mataki na 7 — lamination, mai tsara lokaci

The injin lamination ita ce injin da kowane module dole ya zauna a ciki. Ajin OCY-2666 yana ba da filin aiki na 2600 × 6600 mm, dumama mai da kiyaye daidaiton zafin jiki zuwa ±1–2 °C, vacuum har zuwa 40 Pa da zagayowar saukar da famfo na minti 5–30 — wanda shine dalilin da yasa lamination, ba soldering ba, ke saita lokacin layi akan ƙananan layukan. Hakanan ita ce inji mafi yawan amfani da wutar lantarki: 98 kW rated, 72 kW daga cikinsu dumama ne. A matakin 120 MW takardar yawanci tana ƙaura zuwa injin ɗaki biyu ($150k–200k) domin ɗaki ɗaya ya warke yayin da ɗayan ke saukar da famfo; a 300–600 MW, na'urorin ɗaki biyu mai Layer biyu suna gudana zuwa kusan $400k kowanne.

Matakai 4, 5 da 8 — inda ajiyar kuɗi da farashi na rabin-atomatik suke

Layup, bussing da trimming su ne matakai uku da suke wanzuwa a cikin nau'in tashar hannu na aji $1,400–1,700 da kuma nau'in atomatik na $45,000–290,000. The tsarin samar da panel ɗin rana yana da sinadari ɗaya ko ta yaya; abin da ke canzawa shi ne wanda ke yin aikin. Layin rabin-atomatik na 20 MW yana sanya ma'aikata huɗu a teburin layup, biyu a teburin bussing, ɗaya a trimming — kuma dukan layin yana kashewa tsakanin ƙananan zuwa matsakaicin $300k. Abubuwan da suka dace na atomatik suna cire waɗannan wuraren kuma suna ƙara conveyors, na'urorin juyawa da tashoshin daidaitawa maimakon. Babu wanda ya fi ɗayan "kyau": inda albashin ma'aikata ke gudana $400–700 a wata, nau'in hannu yana biya, kuma inda suke gudana a matakan Turai, nau'in atomatik ne kawai tsarin da ya dace.

Matakai 1, 6 da 10 — ƙofofin inganci

Uku daga cikin matakai goma suna gwadawa maimakon canzawa, kuma tare suna kashe wani abu a cikin dala $60k–100k na kayan aiki: mai gwada tantanin halitta, EL kafin lamination, na'urar kwaikwayo ta IV da EL ta ƙarshe. Masu siye da ke ƙoƙarin daidaita kasafin kuɗi suna sha'awar yanke ɗaya. Kada ka yi. Ba tare da rarraba tantanin halitta mai shigowa ba za ka haɗa maki a cikin igiya ɗaya; ba tare da EL kafin lamination ba za ka lamination tsagewar rufewa kuma ka same su bayan mataki mafi tsada; ba tare da walƙiya ta IV ta ƙarshe ba za ka aika azuzuwan wutar da ba ka taɓa auna su ba. Ƙofofin su ne mafi arha injuna a cikin masana'anta dangane da asarar da suke hana.

3. Abin da Tsarin Ke Cinyewa: Sarari, Wuta, Iska, Mutane

Masu siye da gaske suna aiko mana da jerin abubuwan da ake dubawa wanda kusan iri ɗaya ne kowane lokaci: ƙarfin samarwa kowace inji, lokacin zagayowar, buƙatar wuta, amfani da iska, adadin ma'aikata da ake buƙata, girman inji, matakin sarrafa kansa. Ga wannan jerin an amsa shi don matakan daidaitattun uku, daga takardun ƙididdiga namu da zanen shimfidar masana'anta.

Game da ma'aikata, shirin ma'aikata na 150 MW gilashi biyu ya cancanci karantawa tasha zuwa tasha, domin yana nuna inda mutane suke tafiya da gaske: ma'aikaci ɗaya a stringer, ɗaya kowanne a ciyar da gilashi, ciyar da EVA, sanya spacer da ciyar da busbar/tape, ɗaya a pre-lamination EL, uku a sake aiki, ɗaya kowanne a edge taping, trimming, flip inspection da glue/frame, biyu a tashar junction-box, ɗaya yana sanya murfin akwatin da tsaftace baya, ɗaya yana tsaftace gaba, ɗaya yana musanya kayan gwajin IV/EL, ɗaya kowanne a IV da EL na ƙarshe, biyu suna sanya farantin suna da barcode, biyu suna sauke kaya. Mutane ashirin da huɗu, kuma babu ɗayansu da ba dole ba a layin gilashi biyu a wannan matakin na'ura — sake aiki kaɗai yana ɗauke da uku, domin mataki na 6 da mataki na 10 suna ci gaba da ciyar da shi.

4. Inda Laifuka Suke Haihuwa — da Ƙofofin EL Biyu

Kowane ƙwararren injiniyan tsari a wannan masana'antar yana faɗin abu ɗaya game da samarwa: kuskure mai arha a kama kafin laminating kuma mai tsada bayan haka. Ƙofar EL ta kafin laminating a mataki na 6 tana wanzuwa ne saboda stringing ba ta iya juyawa; ƙofar ƙarshe a mataki na 10 tana wanzuwa ne saboda laminating kanta, firam ɗin, da sarrafawa duk na iya haifar da sabbin tsage-tsage bayan ƙofar farko ta wuce. Tsakanin su, tashoshin EL biyu suna kashe ƙasa da $54,000–66,000 haɗe kuma suna kama hanyoyin gazawa waɗanda in ba haka ba za su bayyana a matsayin da'awar garanti na shekara ta uku: ƙananan tsage-tsage a ƙarƙashin ribbon, haɗin solder mai sanyi, da sel da suka tsage yayin jigilar kaya ta layin.

Tambayar da za a yi wa kowane mai kaya ita ce abin da ke faruwa tsakanin ƙofofin biyu idan an sami lahani. Sake yin aiki kafin lamination yana nufin sake shimfiɗa string — mintuna. Bayan lamination yana nufin zubar da laminate mai haɗe wanda ya riga ya ƙunshi gilashinsa, EVA, sel da backsheet: a kusan $55–60 na kayan a kowane module na aji 585 W, lahani uku da suka tsere a rana asarar kayan shekara-shekara ce ta adadi biyar da ba ta taɓa bayyana a cikin tayin kayan aiki ba.

5. Tsari Ɗaya, Hanyoyin Fasaha Uku

Matakan goma ba sa canzawa lokacin da tantanin ya canza — amma injina biyu a cikin jerin dole a gaya musu abin da suke ciyarwa. SS-2500 stringer yana rufe PERC da TOPCon a cikin 3–20BB formats natively; HJT's low-temperature requirements da back-contact (BC) formats suna buƙatar daidaitaccen tsarin stringer, wanda shine dalilin da ya sa masu siye da ke shirin BC ko HJT volume ya kamata su tabbatar da dacewar stringer kafin wani abu a kan takardar. Masu siye kuma suna tambayar mu, daidai, ko layi ɗaya zai iya gudanar da nau'ikan cell da yawa a lokaci ɗaya don aikin tolling — amsar ita ce eh tare da kayan aikin cell masu saurin canzawa da ingantaccen girke-girke na soldering ga kowane format, a farashin lokacin canzawa. Abin da tsarin ba ya jurewa shine haɗa maki a cikin string: binning na mataki na 1 ya kasance daidai domin sel da suka dace su shiga mataki na 3 tare.

Tambayoyi akai-akai — Tsarin Kera Solar Panel

Yaya tsawon lokacin da ake ɗauka don yin solar panel ɗaya?

Ana auna fitarwar layi da takt, ba lokacin kowane panel ba: layin atomatik na 120 MW yana kammala module kusan kowane minti biyu, layin Semi-atomatik na 20 MW kowane minti uku zuwa huɗu. Amma kowane module ɗaya yana ɗaukar lokaci mafi tsawo a cikin laminator — pump-down da curing suna gudana minti 5–30 a kowane zagaye — wanda shine dalilin da ya sa manyan layukan ke amfani da injina mai ɗaki biyu don haɗa zagaye.

Ma'aikata nawa ne layin samar da solar panel ke buƙata?

A kan shirin mu na 150 MW na gilashi biyu, ma'aikata 24 a kowane zamani da injiniyoyin layi; 120 MW atomatik takardar ta bayyana ma'aikata 12–15 da injiniyoyi 2; matakan rabin-atomatik suna ƙara matsayi na hannu a layup, bussing da trimming maimakon biyan kuɗin injunan atomatik. Adadin ma'aikata yana bin iyakar aikin atomatik, ba adadin ƙarfin ba.

Nawa ne sararin bene da tsarin ke buƙata?

Kusan 1,000 m² na ɗakin samarwa don layin 120 MW (50×20 m, rufi 4.2–6 m, kofofi 5–6 m faɗi, ginshiƙai a 6 m ko fiye), da kusan irin wannan yanki kuma don ajiyar kayan albarkatun ƙasa da kammalallen kayan. Don haka ɗakin 2,000 m² zai dace da layin 50–100 MW tare da ɗakin ajiya mai aiki amma matsi; ƙananan layukan suna raguwa daga nan. Sanya a bene na biyu yana aiki ne kawai ga ƙananan tashoshi — nauyin bene na lamination da kwararar layin madaidaici na shimfidar yawanci suna kafa ƙarshen nauyi a ƙasa.

Nawa wutar lantarki masana'antar hasken rana ke cinyewa?

Yi shiri don kusan 700 kW da aka girka a matakin atomatik na 120 MW, tare da laminator (98 kW da aka ƙididdige a aji 2666) da IR stringer a matsayin manyan masu jan wuta biyu. Matsakaicin amfani yana gudana ƙasa da ƙarfin da aka girka kuma yana ƙaruwa ƙasa da layi: alkaluman masana'antu da aka buga sun nuna layin 30 MW kusan 150 kW matsakaici da layin 400 MW kusan 360 kW.

Shin layin samarwa ɗaya zai iya sarrafa ƙwayoyin PERC, TOPCon da BC?

PERC da TOPCon suna aiki akan injin SS-2500-class stringer ɗaya (3–20BB, 156–210 mm). HJT da tsarin back-contact suna buƙatar ƙananan zafin jiki ko daidaitaccen tsarin stringer mai dacewa da BC — tabbatar da wannan kafin ka faɗi wani abu. Sauran matakai takwas ɗin ba su da bambanci da nau'in tantanin sai dai saitunan girke-girke da kayan gwaji.

Wane mataki ne ke haifar da mafi yawan lahani?

Stringing. Yana amfani da zafi akan wafer ɗin 130–180 μm kuma ba ya juyawa: rashin daidaiton ribbon daga pads ɗin solder, haɗin sanyi da ƙananan fashewa duk suna farawa ne daga nan. Shi ya sa ƙayyadaddun karyewa (≤0.2% akan ƙwayoyin A-grade na SS-2500) da ƙofar EL kafin lamination suka fi kowane adadin kayan aiki a takardar mahimmanci.

Wadanne albarkatun ƙasa ne tsarin ke cinyewa?

A kowane 585 W TOPCon module, kusan $55–60 na kayan a farashin kasuwa na tsakiyar 2025: ƙwayoyin kadai sun fi 40% na kuɗin, firam da gilashin tempered tare kusan 30%, sannan solder strip, backsheet, POE, EVA, akwatunan junction da sealant. Layin 120 MW yana cinye wannan ci gaba da 32 panels a awa, ana biya mafi yawa a gaba a matsayin mai siye na shekara ta farko — adadin jarin aiki da ke yanke shawarar ko tsarin zai ci gaba da aiki.

Shin da gaske ana buƙatar horo idan injinan na atomatik ne?

Ee. Injinan suna gudanar da kansu; tsarin ba ya. Ma'aikata suna buƙatar watanni biyu zuwa uku don riƙe yawan amfanin da aka ƙididdige — canje-canjen girke-girke bisa tsarin tantanin halitta, karanta hoton EL, duba daidaiton ribbon da abin yanka ƙwarewar ɗan adam ce. Aikinmu na yau da kullun ya haɗa da kwanaki 30 na ƙaddamarwa da horo a wurin da kuma tallafin tsari na nesa na tsawon rayuwa, saboda yawancin matsalolin amfani bayan wata ɗaya tambayoyin girke-girke ne da daidaitawa, ba gazawar kayan aiki ba.

Ƙayyadaddun bayanai suna nuni ga bayanan injin Ooitech; jeri na farashi yana nuna kewayon kasuwar FOB China na yau da kullun bisa kowane nau'in inji kuma yana canzawa da tsari da kuɗin musayar — tabbatar da farashi na yanzu kafin yin kasafin kuɗi.

Karatun da ke da alaƙa: yadda ake gina farashin inji, farashin masana'anta, kayan aiki da ma'aikata, da yadda ake fara kasuwancin kera hasken rana.

Wadanne injuna da kayan aiki ake buƙata don kera panel ɗin hasken rana don dalilai na kasuwanci?

Don samar da module na kasuwanci, jerin tushe shine: na'urar gwada da rarraba sel, na'urar tabber da stringer, tashar shimfiɗa, injin bussing ko auto-bussing, na'urar gwada EL bayan stringing, na'urar tara lamination, na'urar lamination, injin datsa, injin yin firam, tashar junction-box da potting, tanderun curing, na'urar gwada EL ta biyu, na'urar gwada IV tare da na'urar kwaikwayon rana, na'urar gwada hipot da insulation, da wurin tsaftacewa da tattarawa.

A kewayen wannan tushe akwai tsarin tallafi waɗanda ake sauƙin mantawa a cikin kasafin kuɗi: iska mai matsewa tare da bushewa, sanyaya tsari, fitar da hayaƙin flux da lamination, bene mai kariya daga ESD, da jigilar kayan da ke haɗa tashoshi. A aikace, waɗannan tsarin tallafi sune ke bambanta jerin injuna da layin aiki, kuma su ne dalilin da ya sa ya kamata a tsara masana'anta kafin a yi mata farashi.

Wadanne kayan aiki ake buƙata don panel ɗin hasken rana?

Mafi ƙarancin jerin gaskiya don yin cikakken module mai iya gwadawa ya fi ƙanƙanta fiye da yadda mutane suke tsammani: injin stringer, tsarin layup da bussing, injin laminator, injin firam, da na'urorin gwaji na EL da IV. Duk sauran abubuwa suna inganta yawan kayan da ake samarwa, yawan amfanin ƙasa ko maimaitawa maimakon sa samfurin ya yiwu kwata-kwata. Wannan bambanci yana da muhimmanci wajen tsara kasafin kuɗi, domin yana raba tashoshin da ba za ka iya farawa ba tare da su ba daga waɗanda za ka iya ƙarawa yayin da yawan samarwa ya sa su zama dole.

Abin da ba za a iya tsallakewa ba shi ne gwaji. Module da ba a gwada shi da EL da IV ba, samfur ne da ba a tabbatar da shi ba, kuma kuɗin wannan tabbacin ba shi da yawa idan aka kwatanta da kuɗin jigilar modules masu ɓoyayyun tsagewa ko rukunin wutar da aka yi kuskuren rarrabawa.

Me ake buƙata don kera na'urorin hasken rana?

Abubuwa huɗu, bisa ga yadda ake yawan raina su: gini da ya dace, kayan aiki, sarkar samar da albarkatun ƙasa, da mutane. Ginin dole ne ya ɗauki nauyin, ya samar da wutar lantarki kuma ya goyi bayan yanayin zafin lamination da curing. Kayan aiki shi ne mafi bayyane a cikin kuɗi kuma mafi daidaitaccen farashi. Sarkar samarwa — sel fiye da kome, sannan encapsulant, gilashi, ribbon da akwatunan junction — ita ce ke tantance ko layin zai iya aiki da ƙarfinsa da aka ƙididdige.

Bukatar mutane ita ce mai shiru. Layin da ke aiki da kansa gabaɗaya har yanzu yana buƙatar injiniyoyin tsari waɗanda za su iya karanta hoton EL, gano lahani na lamination da daidaita bayanin soldering. Automation yana cire hannaye, ba hukunci ba, kuma masana'antar da ba ta da wannan hukunci tana kashe lokacinta wajen sake gudanar da batches maimakon yin modules.

Masu alaƙa: Injin Kera Panel Solar: Tashoshi da Tsari yana bayanin yadda ake sake girman jerin tsari ɗaya daga 5 MW zuwa 1.2 GW da kuma waɗanne abubuwan shigarwa za a daskare kafin yin oda.

Ƙarin karatu da bayanan baya

Kayan tunani na jama'a kan wannan batu, wanda ƙungiyoyin da ke kula da taswirar fasahar masana'antar da bayanan kasuwa suka wallafa:

• VDMA — Taswirar Fasahar Ƙasa da Ƙasa don Photovoltaic (ITRPV)
• pv mujallar — labaran masana'antar PV na duniya da ɗaukar fasaha
• Fraunhofer ISE — Rahoton Photovoltaics