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20/03/2023
The manufacturing of solar panels is a complex process that involves multiple stages and technologies. Solar panels, also known as photovoltaic modules, are made up of solar cells that convert solar energy into electricity.
The manufacturing process begins with the selection and preparation of the materials used in the construction of the solar cells. The most common materials are silicon, which is extracted from sand and purified to high purity, and conductive materials, such as silver or copper, used to connect cells.
What materials are used to make solar panels?
Solar cells: Solar cells are the main component of solar panels and are responsible for converting sunlight into electricity.
Support Frame: The support frame holds the solar cells in place and protects the panel from mechanical damage.
Glass: Glass protects the solar cells from weather and damage.
Laminating and sealing: Laminating and sealing protects the solar cells and the support frame against moisture and dust.
Cables and Connectors: The cables and connectors connect the solar cells and transmit the generated electricity.
In addition to components, it is also necessary to have specialized equipment to assemble and manufacture solar panels, including welding machines, laser cutting, drilling, and laminating equipment. It is important to note that solar panel manufacturing is a specialized, technical process that requires specialized knowledge and skills, as well as access to high-quality equipment and materials.
Industrial solar panels, processes and equipment necessary for their manufacture
- Cutting the raw material
- Solar cell lamination
- Assembly of solar cells
- Encapsulation
- Wiring and testing
- Framed
The first part that must be taken into account for the manufacture of solar panels is the cutting of the raw material, mainly polycrystalline or monocrystalline silicon, into ingots or blocks of the appropriate size for the manufacture of solar panels.
After cutting the raw material, solar cells are created using a process called lamination. Conductive metal layers are applied to solar cells, which are then cut and assembled into solar panels.
Solar cells are mounted on a rigid frame and are electrically connected by soldering.
The next step is encapsulation, which involves placing a protective coating over the solar cells. The aforementioned coating is made of a transparent material that protects the solar cells from humidity and other elements in the environment.
Once the encapsulation is done, we proceed to the wiring and electrical tests of the solar panels. The quality of the weld, the current and voltage produced by each cell are verified, and the overall performance of the panel is checked.
Lastly, a frame is placed around the solar panel to protect it and make it easier to handle and install.
The entire process must be carried out by professionals to ensure that all steps are carried out with precision and quality guarantees in the manufacture of solar panels.
How long can a solar panel last?
Innovations in the manufacture of solar panels to make them more efficient
- Bifacial solar panels
- Multi-junction solar cells
- Concentrating solar panels
- Thin film technology
- Organic solar panels
- Quantum dot technology
They have solar cells on both sides of the panel, which allows them to capture more sunlight and generate more power.
These solar cells are designed to capture different wavelengths of sunlight, allowing them to more efficiently convert solar energy into electricity.
They use lenses or mirrors to focus sunlight onto smaller, more efficient solar cells.
This technology involves the application of a thin layer of semiconductor material to a substrate, enabling the fabrication of lighter, more flexible, and less expensive solar panels.
They use organic materials instead of silicon, which allows them to be manufactured at a lower cost and with processes that are more respectful of the environment.
This technology uses microscopic particles called quantum dots to improve the efficiency of solar cells and reduce their cost.
How is the quality of solar panels guaranteed during manufacturing?
Quality assurance is a critical aspect in the manufacture of solar panels, as it ensures that the panels meet the specifications and quality standards required to guarantee their long-term operation and durability. Some of the techniques and measures used to guarantee the quality of solar panels during their manufacture are the following:
- Visual inspection
- Electrical tests
- Stability tests
- Performance testing
- Certifications and standards
- Quality control in the supply chain
Production line operators perform visual inspections during the manufacturing process to detect any defects such as cracks, scratches, or blemishes on the solar cells or panel surface.
They are carried out on each solar cell and on the entire panel to verify that they produce the expected amount of energy and that there are no electrical connection problems.
They are used to verify the resistance of the panel to extreme conditions, such as changes in temperature and exposure to humidity.
They are in charge of verifying that the panel meets the specifications for efficiency and output power.
Solar panels must comply with a variety of certifications and standards, such as IEC, UL, and CE, which ensure that the panels have been tested and verified by an independent third party.
Solar panel manufacturers also implement quality control measures in the supply chain, making sure that the materials used to manufacture the panels meet the required specifications and quality standards.
Countries that manufacture solar panels
Among the main countries where there is a greater presence of the solar panel industry are China, Germany, the United States, India and Japan.
China: China is the world's leading producer of solar panels with a broad base of suppliers and manufacturers.
Germany: Germany is a major research and development center in the solar panel industry, with a large number of companies specializing in the manufacture of solar panels.
United States: The United States is a major market for solar panels and has a growing solar panel manufacturing industry.
India: India is a major emerging market for solar panels and is investing in solar panel manufacturing to meet its growing demand for renewable energy.
Japan: Japan is a major market for solar panels and has a well-developed solar panel manufacturing industry.
What happens to solar panels when there is no sun?
If there is no sun, solar panels cannot produce electricity. Solar panels work thanks to the energy of the sun, so there is no power available at night or on cloudy days.
However, this does not mean that solar systems are inactive during these periods. Most solar systems are designed to store the energy that is produced during the day in batteries or in the electrical grid, so that it can be used when there is no sun. This means that even though the solar panels are not producing power at the moment, the system can still provide electricity for the electrical needs of the house or building.
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