What should I do if the PV module fails to repair? Include the following steps: 1) remove the assembly frame; 2) Use the rework heating station to heat the assembly; 3) Uncover the backplane; 4) Use electroluminescence tester to test components; 5) Remove fragmented cells; 6) cutting EVA; 7) Replace broken pieces of cells; 8) repair plastic pit; 9) Test components using electroluminescence tester; 10) Laminate rework assembly; 11) Test components using electroluminescence tester; 12) Frame the tested components. The method can quickly and accurately repair the fragmented cells and ensure the quality and use performance of the solar cell module. technical background It is well known that the working principle of solar cells is to use the photoelectric effect: when the sun shines on the semiconductor pn junction, new hole-electron pairs are formed. Under the action of the pn junction electric field, holes flow from the n region to the p region. The p zone flows in the n zone and forms a current after the circuit is turned on. Solar cell modules are formed by tempered glass, battery strings, and backplanes bonded together by EVA at high temperatures. The solar cell module packaging adhesive film is based on EVA, supplemented with several modifiers, and is hot-rolled into a film-type product by a film forming apparatus. The product is heated in the solar cell module packaging process, resulting in cross-linking reaction, is a thermosetting hot melt adhesive film. The cured film has a relatively high light transmittance, adhesive strength, thermal stability, airtightness, and aging resistance. After the components are laminated by EVA, the cells may be chipped by humans or equipment. Since the entire module is a series structure of cells, fragmented cells can affect the power generated by the entire module. Therefore, if the laminated battery pack has to be replaced, it must be replaced before it can be used normally. An EL tester, also called an electroluminescence tester, is used during the rework process of the solar module to clearly show the splinters (including cracking and cracking), defects, and welding defects in the assembly; this improves the process and improves the components. Quality and long-term benefits. It is considered to be the "eye" of the solar cell production line; it can promptly identify problems existing in production and eliminate them in time, thereby increasing the average efficiency and improving the benefits. Requirements for operators 1) Familiar with the equipment safety operation regulations, can use the equipment correctly. 2) Perform routine maintenance and repair during the use of the equipment. 3) Operation workers should stick to their posts, and be “three good†and “four meetingsâ€, and abide by “five disciplinesâ€. 4) Strictly follow the design drawings, process documents, production according to technical standards, and record. Pre-post preparation Safety precautions Sleeves: Avoid heating the laminator to burn the arm when wearing summer clothes to lift the back plate Rubber gloves: The high temperature of the back panel is to prevent the hands from being burned; the blade of the wallpaper may touch the hand and reduce the damage. Process Equipment material EVA, battery, backplane, solder ribbon, flux, alcohol, wood tape. Product/In-Process Production Environment Ambient temperature: 20°C-35°C; Relative humidity: 70% or less. Steps A method for repairing a solar cell module includes the following steps: In the first step, remove the frame of the solar cell module and wipe the silicone on the module clean. The second step, refer to the nonconformity information attached to the component (determined by the workshop technician), determine the content of the repair, and specify the rework plan. The third step is to repair components that do not require internal processing (such as scratches on the backplane, edge debris, etc.). 1) The first two flat lift components are placed on the rework heating table. The large size components under the support should be supported with aluminum to prevent the components from bending and cracking. Pay attention to whether there is foreign matter on the non-stick cloth on the heating platform, confirm the back cover, and start heating. 2) After the heating is completed, the EVA is fully melted and several people cooperate to uncover the backplane on the heating table. Use a knife tip or needle nose pliers to open the corner of the back panel and then quickly pull the back panel away. During the process of uncovering the backplane, components should be avoided from being bent so that they will not be cracked when the backplane is lifted, allowing the user to hold down the other end of the module. For difficult to lift the components, you can use a wallpaper knife to draw a light stroke on the back panel to expose the back panel. 3) After the components of the backplane are lifted and cooled to room temperature after cooling, the components are subjected to an EL test. 4) Make sure that the components are not fragmented and their appearance conforms to the component inspection standards, re-lay a layer of EVA and backplane (consistent with the original component material), and secure the lead wires with wood tape. If fragments appear in the process, follow the instructions in this document. In the fourth step, the components after the removal of the frame are placed on the rework heating table for heating, and the process parameters of the rework heating station are set. The heating time is 120-180s and the heating temperature is 150-180°C. Carefully handle it, avoid bumping the unit, clean foreign objects on the surface of the unit, and close the cover of the rework station. In the fifth step, after the heating is over, use the tool to uncover the backplane on the assembly. Several people cooperate to open the backplane on the heating table, use a needle-nose pliers to open a corner of the backplane, and then quickly pull the backplane away. During the process of uncovering the backboard, the components should be prevented from being bent to produce cracks. For the hard-to-open back panel, you can use a wallpaper knife to draw a light stroke on the backboard to uncover the back panel. In the sixth step, after the components of the backplane are lifted and cooled to room temperature after being cooled, an electroluminescence tester is used to test the components, and the test results show that the fragmented cells are marked; Seventh step, remove fragmented cells 1) First use a knife blade along the side of the battery to cut the EVA on the outside of the battery to avoid damage to the nearby battery when the blade is scraped. 2) Use the wallpaper knife to remove the problematic backside of the battery plate. 3) In order to prevent the cell debris generated during the process of chipping from sticking to other parts of the assembly, wood tape can be used to stick to the location of the tape. 4) Scoop the battery slice to avoid hurting the Pro slice and avoid pressing the other battery slice with your hands or elbows to avoid debris. In the eighth step, according to the size of the cleaned cell, cut the EVA with proper size to the place where the cell is removed; In the ninth step, select the same grade, color, and specifications of the battery to be placed on the re-layed EVA in the sixth step, and use the welding tape to weld with the adjacent battery. In the tenth step, check whether the entire module exists in the rubber pit formed during the process of uncovering the backplane. If there is any, use a suitable EVA block to repair it; In the eleventh step, use an electroluminescence tester to test the components of the replaced solar cell and check whether it is qualified. If the above steps are not acceptable, repeat step 5 to step 8 above. If it is acceptable, continue the following steps; In the twelfth step, for the component that has passed the ninth step of testing, re-lay a back sheet and laminate the reworked component using a laminator. The lamination process is laminating at a lamination temperature of 145°C to 150°C. °C, pumping time 210s-330s, lamination time 450s-630s, pressure 101.3KPa; The thirteenth step, the use of electroluminescence test instrument to test the laminated cell assembly, the qualified components for the test box, repeat the above steps for the second step to the twelfth step; In the fourteenth step, frame the tested components. Process control points 1) When the backplane is lifted, cracks are avoided when the components are deformed too large. 2) The EL test shall be carried out after the components are lifted off the board, after repairs and after lamination, and the quality of the repairs shall be checked. 3) After the problem site has been treated, the purpose of reworking the repair marks is not visible after lamination. Test the repaired components to avoid undetected problems. Special problem solutions: 1) For splits, cracks, and invalids, if the number of slices is small (the entire assembly is small or there is only one or two slices on a string), the split-and-change method is used. That is, remove the defective cell and replace it with a wattage cell that matches the component. If there are a large number of problematic cells on a string, remove the entire string of cells and apply the disassembler to the template. (Note that the battery is positive and negative and cannot be welded back) 2) For dummy pads, if the backside of the battery is blanked, it can be directly soldered with a soldering iron. If the battery is positively soldered, you need to remove the blanked cell, solder it on the template, and then solder it. Return to the original place. (Note: Welds will generally appear on both sides of the cell sheet under normal circumstances and must be returned to the operator for inspection.) 3) For exposed white cells, they can also be treated as dummy pads. 4) For the short circuit, the general situation is divided into two cases of the whole string short circuit and single chip or multiple chip short circuit. The whole series of short circuit is mainly the case of typesetting error. Simply remove the relevant short-circuit string and adjust the positive and negative poles to re-weld, and pay attention to the spacing between strings and strings during welding. One or more pieces of short circuit is likely to be caused by the lack of welding or dew, which requires the rework operator to carefully check, and then deal with according to different situations. 5) For unsuitable components, you need to remove the relevant string, adjust the distance, reattach the tape and re-weld it. The advantages of this method The beneficial effect produced by adopting the above technical scheme lies in that the method for repairing a solar cell module of the method mainly reworks the laminated solar cell module, and mainly has the following three advantages. Advantage 1: The process parameters of the reworking worktable in the method, the heating time is 120-180s, and the heating temperature is 150-180°C, which can make the backboard and the battery slice more easily detached, which improves the repair speed and prolongs the service life of the equipment. Advantage two: The method uses three times of electroluminescence tester to test, effectively monitor the components, reduce the generation of broken battery cells, detect broken battery cells in time, and improve the solar cell module. The quality of repairs. Advantage 3: The lamination parameters of the reworked components in the method can be used to laminate the reworked components reasonably, reduce cracking, and further improve the quality of the components. In summary, the method can quickly and accurately repair broken battery cells and ensure the quality and usability of the solar cell module.
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