I. Overall Positioning and Objectives of the Production Line

Production Line Positioning: A high-efficiency photovoltaic (PV) module production line that is technologically advanced, highly automated, stable in quality, and equipped with strong market competitiveness.
Designed Capacity: Annual output of 100MW, equivalent to approximately 200,000 standard modules (based on 500W per module).
Operation Mode: Adopt a two-shift system (16 hours per day) and 250 working days per year to maximize production capacity.
Product Direction: Focus on manufacturing high-efficiency modules using mainstream PERC and TOPCon solar cells. The line is compatible with large-size cells such as 182mm and 210mm, and can produce half-cut/multi-cut modules with power ranging from 450W to 580W+. Both single-glass and double-glass structures are available to meet the diverse needs of distributed and ground-mounted power plants.
Core Objective: Manufacture high-reliability, high-power products that comply with international standards such as IEC/UL/TÜV, with an optimal input-output ratio.

II. Introduction to Core Process Technology and Flow

This production line adopts mature and advanced production processes in the PV industry to ensure high conversion efficiency and long lifespan of products. The entire process is connected by automated equipment, and key stations are equipped with intelligent inspection systems to achieve full-process quality control.

Core Process Flowchart of the Production Line

Brief Introduction to Each Process

1. Input Testing & Sorting: Conduct 100% Electroluminescence (EL, for crack detection) and I-V (for electrical performance testing) inspections on incoming solar cells, and sort them by efficiency to ensure module efficiency and quality from the source.
2. Laser Cutting: Use precision laser technology to perform non-destructive cutting of complete solar cells into half-cuts, effectively reducing resistance loss and hot spot risks, and improving module output power and reliability.
3. High-speed Multi-Busbar (MBB) Stringing: Adopt advanced MBB stringers to achieve high-precision, zero-damage welding, significantly reducing silver paste consumption and enhancing the module’s anti-crack performance. EL re-inspection is automatically conducted after welding.
4. Layup and Stacking: Robotic arms automatically grab and lay cell strings on glass coated with EVA/POE. A visual positioning system ensures consistent string spacing, laying the foundation for subsequent lamination.
5. Lamination: As the core process determining the 25-year lifespan of modules, the laminator bonds cells, adhesive films, glass, and backsheets into an integrated structure under high-temperature and high-vacuum conditions, forming a highly weather-resistant sealed structure.
6. Framing & Junction Box Mounting: Fully automatic framing machines complete gluing and frame clamping to ensure the strength and sealing of the frame. Automated equipment performs welding and bonding of junction boxes to ensure reliable current output.
7. Curing & Cleaning: Sealant is fully cured through a curing tunnel, and then the module surface is thoroughly cleaned to ensure cleanliness.
8. Final Testing: Each module must undergo I-V testing under a solar simulator to accurately measure parameters such as peak power and open-circuit voltage, and be graded by power based on the results. Simultaneously, a final EL inspection is conducted to ensure no internal defects in delivered products.
9. Automated Packing: Automatic labeling, packing, and film wrapping are performed, and data is entered into the system for easy traceability.

III. Characteristics and Advantages of the Production Line

• High Level of Automation: Key processes from stringing to packing are completed by automated equipment, connected via intelligent logistics lines (conveyor belts, AGV trolleys). This greatly reduces manual intervention and ensures consistency in production rhythm and product quality.
• Excellent Quality Control: Implement the quality philosophy of "full-process monitoring and two-way traceability". Four quality inspection checkpoints (EL/I-V) are set up for incoming materials, post-stringing, post-lamination, and final testing to ensure timely detection and handling of any defects, guaranteeing high reliability and long lifespan of products.
• Advanced Technological Processes: Adopt mature and advanced processes such as MBB, half-cut technology, and non-destructive cutting to ensure modules have excellent performance of high power, high efficiency, and low attenuation.
• Flexibility and Scalability: The line is designed to be compatible with 182mm and 210mm cell sizes, capable of producing modules based on different technology routes (PERC/TOPCon), and can quickly switch between single-glass and double-glass production to adapt to market changes. The current layout reserves space for future capacity ramp-up (e.g., upgrading to 200MW).
• Intelligent Production Management (MES): It is recommended to integrate a Manufacturing Execution System (MES) to real-time monitor equipment status, production progress, material consumption, and product quality data, realizing digital and transparent management of the production process and providing data support for decision-making.

IV. Workshop and Infrastructure Requirements

• Recommended Area: ≥ 4,000 square meters (including production, warehouse, and power areas).
• Environmental Requirements: Key areas (stringing, layup) require Class 10,000 cleanliness, constant temperature (22±5℃), and constant humidity (humidity < 60%).
• Energy Requirements: Electrical load of approximately 300-400KVA, stable compressed air supply, and pure water system.

Summary

This 100MW solar module production line solution is a modern production line integrating automation, intelligence, and flexibility. It not only can stably and efficiently produce high-quality, high-reliability PV modules but also builds core advantages for customers in the fierce market competition through excellent process control and cost management.

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