New EFRE Project APPEAL Gets Rolled Out

Subproject: Gripping Systems and Ultrasonic Welding/Forming for PV Modules

To enable the automated production of PV modules with customized designs for building applications in small batches, two key innovations are being pursued here. Economical production of the modules requires automation of the process chain. This automation must offer a high degree of flexibility with regard to the materials used and the geometry. Consequently, the project is developing handling and control systems that not only ensure flexibility but also incorporate sensor technology to meet the high precision requirements. In addition, the application of ultrasonic technology for optimizing the solar modules is being investigated. The second key innovation is the new combined ultrasonic welding and forming process, which efficiently forms triangular aluminum cell connectors while simultaneously bonding them to the cell. The shape minimizes light reflections from the module, thereby increasing its efficiency. Another aspect is the parallel processing of the cell connectors using the new process to significantly increase speed. In addition to the process itself, a key challenge is the design of the rotating sonotrode, which provides a uniform vibration amplitude. The flexible application for various cell types using as few sonotrodes as possible is also being addressed.

Funding: Funds from the European Regional Development Fund (EFRE) and the State of Lower Saxony, Program Area: More Developed Region