Engineering topics
Publications and source records attributed to Bycer, M..
Large arrays are rapidly assembled from individual solar cells by automated production line developed for NASA's Jet Propulsion Laboratory. Apparatus positions cells within array, attaches interconnection tabs, applies solder flux, and solders interconnections. Cells are placed in either straight or staggered configurations and may be connected either in series or in parallel. Are attached at rate of one every 5 seconds.
Vacuum "lance" picks up assembled chain of solar cells from string conveyor without disturbing cells or interconnecting tabs. Lance has 2 vacuum pickups per cell, for total of up to 32 pickups. Positions and number of pickups can be varied. Lance can be adjusted for range of cell sizes, shapes, and spacings.
The solar module assembly machine which Kulicke and Soffa delivered under this contract is a cell tabbing and stringing machine, and capable of handling a variety of cells and assembling strings up to 4 feet long which then can be placed into a module array up to 2 feet by 4 feet in a series of parallel arrangement, and in a straight or interdigitated array format. The machine cycle is 5 seconds per solar cell. This machine is primarily adapted to 3 inch diameter round cells with two tabs between cells. Pulsed heat is used as the bond technique for solar cell interconnects. The solar module assembly machine unloads solar cells from a cassette, automatically orients them, applies flux and solders interconnect ribbons onto the cells. It then inverts the tabbed cells, connects them into cell strings, and delivers them into a module array format using a track mounted vacuum lance, from which they are taken to test and cleaning benches prior to final encapsulation into finished solar modules. Throughout the machine the solar cell is handled very carefully, and any contact with the collector side of the cell is avoided or minimized.
The gathering of information that led to the design approach of the machine, and a summary of the findings in the areas of study along with a description of each station of the machine are discussed. The machine is a cell stringing and string applique machine which is flexible in design, capable of handling a variety of cells and assembling strings of cells which can then be placed in a matrix up to 4 ft x 2 ft. in series or parallel arrangement. The target machine cycle is to be 5 seconds per cell. This machine is primarily adapted to 100 MM round cells with one or two tabs between cells. It places finished strings of up to twelve cells in a matrix of up to six such strings arranged in series or in parallel.