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Benchmark quality by ALGATEC Solar AG

The ALGATEC Solar AG has set high standards for the production of solar modules.

Nothing is more important than giving the customer a product, that not only meets general standards of certification, but also convinces the customer completely through top performance, durability and clean processing.
We do not only attach to comply certifications, but also to be able to exclude defective modules right from the beginning.

The ALGATEC not only guarantees these services, but it also explains them in more detail below :

 

Goods receipt

Incoming inspection

For the production of high quality solar modules it is necessary to examine the used material for accuracy before processing. In order to create optimal conditions the ALGATEC Solar AG is proceeding as follows:

      

Each delivery of material is checked by the employees in the purchasing on the following points:

  • damage of the packaging

  • correct and complete delivery

  • random visual inspection of the material for damage and condition ( for example the re-measuring of the correct dimensions of the delivered frame components, status of the connection cable at junction boxes)

  • Material with a consumption date is noted in the checklist of the incoming inspection

 

The ALGATEC Solar AG uses climate data loggers to control the storage conditions(temperature, humidity) in their warehouses. Besides the daily visual inspection of the functionality the recording data is read out every week to be able to guarantee optimal storage conditions and required to meet the storage requirements of the material manufacturers ( for example the EVA- foil).
 

In addition to tests of the already used material the ALGATEC Solar AG is regularly testing the quality, the resilience and the accuracy of the information from the manufacturers to guarantee quality claims beyond the details needed for certifications.


Production

 

Glass washers

The delivered solar glass must be absolutely clean and free of grease for further processing. Dust particles and or oily residues can cause that the EVA- foil is not perfectly adhere to the glass or can be detached early from the glass in the worst case.

 

Glass printer

Before printing, each solar glass is optically controlled by two employees for possible damage. After that, each glass pane is printed with a unique serial number and a 2D-code on the glass printer.

With this unique serial number all relevant data of each module can be reconstructed in the electronic module consignment note, for example

  • what kind of material has been installed

  • the performance measurement of the module

After printing, each pane of glass is measured precisely by cameras (length and width of the pane of glass). The data obtained in this way are saved then. If this serial number is read from the automatically edge portion, the information is retrieved from the database to guarantee a correct edge portion on each laminate.

 

Motoman (=Stringer)

The individual cells are soldered to so-called “cell-strings” in the Motoman. The soldering of the cells is done computerized. In addition, the individual cells are examined (for example on cell fractures) and sorted by cameras.

The soldering of the cells is always controlled by an employee who is able to change the soldering temperature if it is necessary. This employee makes a deduction test to guarantee the correct soldering of the cells with the solder ribbon at the busbars.

This deduction tests are documented.
 

 

 

 

 EL Tester

At each of the individual production lines is an EL- tester docked in the ALGATEC Solar AG. The finished soldered laminate is set under electric current in the EL-tester. As a result the individual cells are heated and the built-in infrared cameras can produce an image of the laminate. The image is transmitted to a monitor where it is evaluated by well qualified employees.

Thus, various defects in the cells are recognized for example:

  • Fractures in the cells

  • Small hairline cracks invisible for the naked eye

If such errors are detected, the laminate can be discharged and repaired. Furthermore, there is a preliminary determination of the performance of the laminate. If the optical evaluation and the pre- determined performance parameters are kept the laminate is released for the lamination process (= laminator). All the data and pictures of the EL- tester to the laminate are permanently stored in a database.

 

2-step laminator + cooling

The lamination process is divided into three steps:

  • Fusion

  • Networking

  • Cooling of the laminate

 

The air is drawn by vacuum pumps from the laminate in each room of the laminator. Thus, an optimum networking of the entire area of the laminate can be guaranteed. The temperatures are monitored computerized during the whole time and they correspond exactly to the specifications of the manufacturers. Networking tests are performed at all laminators and given to an external laboratory for analysis at prescribed intervals or when materials are changing.

 

Visual inspection No. 1

At the first visual inspection, all laminates are checked for correct edge trim and possible errors (for example the distances between the strings) in optimal lighting conditions after the edge trim.
The employee works on the base of a criteria catalog that was specifically developed for the Algatec Solar AG by the Management Board and the quality manager. In this catalog of criteria all relevant criteria are described in detail to fulfill the quality standards to 100%.

Through constant monitoring of this station by the shift supervisor and the quality manager we are able to react to errors that may happen during the process as soon as possible.

 

Box mounting

First, the back sheet of the laminate is inspected for damage on this workstation. This position is cleaned with bio alcohol to make sure that it is completely clean if the back sheet is free from damage.

The box is fixed with an adhesive tape and additionally with silicone onto the laminate. The ports of the laminate are connected with the ports of the box, accordance to fixed standards, by a production employee. He controls the tightness of the connections and the correct fit of the diodes before applying the lid.

The connection cables are fixed to the laminate for protection.

 

Visual Inspection No.2

At the second visual inspection the framed module is subjected to further review under optimal lighting conditions. Thereby the frame is checked for damage too. Furthermore, the gap-free compression of the corner angle is checked. Before the module goes back into the production line the employees again check the module for errors and damages by considering the criteria list of Algatec Solar AG.
 

 

Flasher

Through the integrated camera of the “flasher” the serial number is detected and read in. After that the protection class test is performed on each module to determine the correct performance data of the module.

The module is flashed shortly under clearly defined criteria (standard test conditions for solar panels). The resulting values of the module are permanently saved then in the ” flash- list” and in the electronic module consignment note.

A label with the most important data is printed on each module ( for example nominal power = Pmax, short circuit current = Isc). This label is placed on the back of the module next to the junction box. Then the modules are sorted in performance classes and orders.

 

Classification

The modules marked as faulty during the both visual inspections are subjected to a further follow-up

by the quality manager. Here a distinction is made about the classification of the module into the various criteria ( like B-goods, C-goods or D-goods) accordance with the requirements of the criteria list. These modules are treated as carefully as A-goods-modules during the packaging.

 

Delivery

 

Cleaning + Visual inspection No. 3 + Packaging

The modules are fetched from the storage after the prescribed drying time for hardening silicone. Each module is cleaned with diluted organic alcohol ( solar glass and frame) ; each module is then again subjected a further visual inspection accordance with the requirements of the criteria list. It is priority for the ALGATEC Solar AG that only high quality modules are delivered to our customers.

Each module is read by the scanner after the last visual inspection ( to create the pallet note) . The modules are packed in the ASM- box with 6 slices of cork for protection of the frame.

Quality is when the customer returns – not the product!