Tsarin Samar da Faifan Rana: Matakai 10 da Injuna
Teburin Abubuwan Ciki
Tsarin Kera Panel Ɗin Hasken Rana: Matakai 10 da Injinan da Ke Bayan Kowanne
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 tsari da ke ƙasa yake kama da takardar farashi. Kowane ɗayan matakai goma yana da alaƙa da rukunin inji ɗaya tare da kewayon farashin kasuwa mai karko, FOB China: stringers na matakin shiga suna cikin $60k–70k, na'urar aiki ta 2,400-cell tsakanin $120k da $140k, injin laser scribing kusan $20k–25k, na'urar juyawa 'yan dubban daloli — kewayon da ba su canza sosai ba tsawon shekaru da yawa na farashi. Idan ka gama wannan shafi ya kamata ka iya kallon zanen tsari na kowane mai bayarwa kuma ka haɗa kewayon farashi da adadin ma'aikata ga kowane akwati a ciki.
2. Matakai Goma, Daga Gwajin Cell zuwa Pallet
| Mataki | Abin da ke faruwa | Inji (yawan FOB China band) | Lambar maɓalli |
|---|---|---|---|
| 1. Gwajin sel | Sel masu shigowa ana gwada su da walƙiya kuma a raba su bisa Isc, Voc, Pmax, FF, Rs, Rsh | Na'urar gwajin sel, OTCT-A class ($15k–18k) | Walƙiya 10 ms · sel har zuwa 210×210 mm |
| 2. Rubutu da laser da tsagawa | Cikakkun sel ana rubuta su da laser sannan a tsaga su rabin ko kwata | Rubutu da laser, OLS-20A class ($20k–25k) | 1,500 cikakkun sel/h · rubutu 40 μm · karyewa ≤0.3% a kan A-grade |
| 3. Tabbing da stringing | Ribbon ana solda daga gaba zuwa baya, sel zuwa sel, cikin strings | SS-1500 class ($60k–70k) / SS-2500 class ($120k–140k); ATW class ($380k–430k) | 2,400 sel/h (SS-2500) · solda ta IR · karyewa ≤0.2% |
| 4. Layup | Gilashi, EVA, strings, Layer na biyu na EVA da backsheet ana jera su bisa tsari | Mai ɗaukar gilashi $25k–30k · auto layup $50k–60k · EVA/TPT cutter $8k–35k · tashoshin layup na hannu daga ~$1.5k | Semi-auto: tashoshi 4 don fanel 16/h |
| 5. Bussing | An haɗa igiyoyi cikin cikakken da'ira; an shimfiɗa ribbon na j-box | Teburan bussing na hannu ($4k–5k) ko bussing ta atomatik ($130k–260k) | Babban bambancin iyaka ɗaya mafi girma tsakanin farashi |
| 6. Pre-lamination EL | Hoto na electroluminescence yana gano ƙananan tsagewa da ribbon ɗin da ba su daidaita ba | Mai gwada EL, aji na kyamara 8 ($25k–32k) | Dama ta ƙarshe kafin matakin da ba za a iya juyawa ba |
| 7. Lamination | An narke tari a ƙarƙashin vacuum da zafi zuwa laminate ɗaya da aka haɗa | Ajin OCY-2666 ($90k–105k) ɗakin guda; ɗakin biyu $150k–200k | 98 kW rated · 40 Pa vacuum · ±1–2 °C daidaito |
| 8. Trimming & framing | An cire gefen da ya wuce, an manna firam ɗin aluminum kuma an matse shi | Manual trim $4k–5k / auto $30k–35k · framing $6k–8k semi / $45k–52k auto / $140k–185k all-in-one | All-in-one yana ƙara sarrafa kwararar manne |
| 9. Akwatin haɗi & warkewa | An manna J-box, an yi waya, an zuba; manne yana warkewa a kan conveyor | Manne $5k–6k · zuba $12k–17k · walda ta atomatik $60k–70k · conveyor na warkewa $30k–70k | Ma'aikata 2 a kan shirin mu na 150 MW |
| 10. Gwajin IV & EL na ƙarshe, marufi | Sun-simulator flash yana ba da ajin wuta; EL na ƙarshe yana tabbatar babu sabbin tsagewa; an marufi module ɗin | IV tester, OTMT-A class ($20k–28k) ko Gsolar Class A ($60k–75k) · EL na ƙarshe 4-camera ($20k–23k) | 10 ms flash · modules zuwa 2500×1400 mm |
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
Na'urar 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 tare da daidaiton zafin da aka riƙe zuwa ±1–2 °C, vacuum har zuwa 40 Pa da zagayowar saukar da famfo na mintuna 5–30 — wanda shine dalilin da yasa lamination, ba soldering ba, ke tsara takt na layi akan ƙananan layukan. Hakanan ita ce injin da ya fi cin wuta a 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, raka'o'in ɗaki biyu mai Layer biyu suna gudana har 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 ajin $1,500 da kuma nau'in atomatik na $50,000–$260,000. 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.
| Albarkatu | 20 MW rabin-atomatik | 60 MW atomatik | 120 MW atomatik |
|---|---|---|---|
| Ƙarfin fitarwa | 16 panels/h, aiki ɗaya na awa 8 | ~24 panels/h aji | 32 panels/h, aiki na awa 24 |
| Zauren samarwa | ~600–800 m² class | ~800–1,000 m² class | ~1,000 m² (50×20 m) |
| Warehouse (cells in / modules out) | kusan irin wannan yanki kuma, duk matakan | — | — |
| Rufi / kofofi / ginshiƙai | Rufi 4.2–6 m · kofofi 5–6 m faɗi · ba a son ginshiƙai, in ba haka ba tazara ≥6 m (daga takardar shimfidar 120 MW) | ||
| Wutar da aka girka | ~150–200 kW class | ~350–500 kW class | ~700 kW |
| Iska mai matsewa | Dubbai na lita a minti a matakan atomatik — ana auna su bisa shimfida; silinda na huhu suna tafiyar da firam, na'urorin juyawa da masu ɗaukar kaya | ||
| Ma'aikata a kowane zamani | Semi yana ƙara wuraren aikin hannu, bussing, da gyaran gefe | Ƙwararrun ma'aikatan atomatik | Ma'aikata 12–15 + injiniyoyi 2; 24 a kowane zamani a shirin gilashi biyu na 150 MW |
| Yanayin zauren | Yankunan stringing da lamination suna son 25 °C ±2 da 50–60% RH — sau da yawa canza warehouse yana buƙatar gyara tsarin sarrafa yanayi | ||
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: ana samun lahani da arha kafin lamination kuma yana da tsada bayan haka. Ƙofar EL ta farko kafin lamination a mataki na 6 tana wanzuwa ne saboda stringing ba ya juyawa; ƙofar ƙarshe a mataki na 10 tana wanzuwa ne saboda lamination kanta, framing, da sarrafawa duk na iya haifar da sabbin tsage-tsage bayan ƙofar farko ta wuce. Tsakanin su, tashoshin EL biyu suna kashe ƙasa da $60k a haɗe kuma suna kama yanayin gazawar da in ba haka ba za su bayyana a matsayin da'awar garanti na shekara ta uku: microcracks a ƙarƙashin ribbon, cold solder joints, da sel da suka tsage yayin jigilar ta cikin 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 guda goma ba sa canzawa idan tantanin ya canza — amma dole ne a gaya wa injina biyu a cikin jerin abin da suke ciyarwa. Na'urar SS-2500 stringer tana rufe PERC da TOPCon a cikin tsarin 3–20BB a asali; bukatun HJT na ƙananan zafin jiki da tsarin back-contact (BC) suna buƙatar daidaitaccen tsarin stringer, wanda shine dalilin da ya sa masu siye da ke shirin BC ko HJT yakamata su tabbatar da dacewar stringer kafin komai a cikin takardar. Masu siye kuma suna tambayarmu, daidai, ko layi ɗaya zai iya gudanar da nau'ikan tantanin da yawa a lokaci ɗaya don aikin tolling — amsar ita ce eh tare da kayan tantanin da ake sauyawa da sauri da sake tabbatar da girke-girken soldering ga kowane tsari, a kan farashin lokacin sauyawa. Abin da tsarin ba ya jurewa shi ne haɗa nau'ikan a cikin string ɗaya: binning na mataki na 1 ya kasance daidai domin tantanin 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.
