WO2011154910A2 - System and method for monitoring pv device - Google Patents

System and method for monitoring pv device Download PDF

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Publication number
WO2011154910A2
WO2011154910A2 PCT/IB2011/052504 IB2011052504W WO2011154910A2 WO 2011154910 A2 WO2011154910 A2 WO 2011154910A2 IB 2011052504 W IB2011052504 W IB 2011052504W WO 2011154910 A2 WO2011154910 A2 WO 2011154910A2
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WO
WIPO (PCT)
Prior art keywords
atleast
measurement
cells
solar cell
matrix
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PCT/IB2011/052504
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French (fr)
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WO2011154910A3 (en
Inventor
Cristelle Paccaud
Jonas Hiller
Original Assignee
Pasan Sa
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Publication of WO2011154910A2 publication Critical patent/WO2011154910A2/en
Publication of WO2011154910A3 publication Critical patent/WO2011154910A3/en

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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L21/00Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
    • H01L21/67Apparatus specially adapted for handling semiconductor or electric solid state devices during manufacture or treatment thereof; Apparatus specially adapted for handling wafers during manufacture or treatment of semiconductor or electric solid state devices or components ; Apparatus not specifically provided for elsewhere
    • H01L21/67005Apparatus not specifically provided for elsewhere
    • H01L21/67242Apparatus for monitoring, sorting or marking
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02SGENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S50/00Monitoring or testing of PV systems, e.g. load balancing or fault identification
    • H02S50/10Testing of PV devices, e.g. of PV modules or single PV cells
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/50Photovoltaic [PV] energy

Definitions

  • the present invention relates generally to PV device production monitoring, and, more particularly to system and methods for monitoring the quality of individual PV device over a number of stages during the whole PV device manufacturing process in an effective simple, optimised, controlled, cost effective, secure, and environmental friendly manner.
  • PV photovoltaic
  • materials are assembled to form solar modules.
  • Such materials may be adhesive sheets as EVA or PVB, solar cells, connected into a matrix, a back sheet to protect the back side of the module and a glass plate to protect the front side while letting light thru to the cells.
  • the most fragile component is the solar cell, for example, a thin film, crystalline or any other technology.
  • a solar cell typically experiences a number of operations before it is encapsulated inside the module. These operations include logistics, cell is picked up from the stack, transport to be stringed, making of the string, transport of the string, forming of the matrix, transport of the matrix, making of lay-up, and lamination, etc.
  • Transport to be stringed Once the cell has been picked of the stack, it is transported to the place it is connected to other cells by ribbons in order to form a string.
  • Making of the string The connection to the cell is normally done by some sort of soldering, i.e., the contact between the ribbon and the solar cell is normally prepared by applying a soldering flux and then that region is heated to form the connection.
  • the ribbons are plated with soldering tin so that no additional tin has to be added to the process.
  • the solar cells have 2 or three bus bars on each side that are connected to the corresponding bus bars on the adjacent cells. This way a string, for example, 9 solar cells, is formed.
  • the soldering heats up the cells, their bus bars and the ribbon that leads to stress in all materials and potential damage to the same. During transport, the string may be damaged.
  • the matrix may be damaged.
  • the cells may be damaged.
  • heat and pressure is applied to the cells, leading to possible damage.
  • the prior art discloses different techniques for monitoring the quality of solar module production, however they are limited to inspect general characteristics of the cell or the solar module, for example, inspecting a solar module for bubbles formed inside it. Such inspection is done by storing used cell characteristics such as image of the cell, number of bus bars, etc., and evaluating an image of the final module compared to these characteristics. [0001] Many such techniques are too complex for reliable operation and are not capable of effectively monitoring quality of individual solar cells during the whole PV module manufacturing process. The features of the conventional quality inspecting techniques, disclose a complex design and bulky structural indices that hinder their performance. However, no such system or technique is available in the commercial market at the present time which is capable of monitoring the quality of individual solar cells over a number of stages during the whole PV module manufacturing process.
  • the present scenario is necessitating the need for a new system which is capable of overcoming disadvantages inherent in conventional solar cell or solar module inspecting technique and providing an effective means to achieve a controlled and optimized PV device production process by monitoring the quality of individual solar cells over a number of stages during the whole PV module manufacturing process.
  • the general purpose of the present invention is to provide an improved combination of convenience and utility, to include the advantages of the prior art, and to overcome the drawbacks inherent in the prior art.
  • the present invention provides an effective means to achieve a controlled and optimized PV device production process by monitoring the quality of individual solar cells over a number of stages during the whole PV module manufacturing process.
  • the present invention provides a method for tracking characteristics of atleast an individual solar cell during a manufacturing process.
  • the method comprises the steps of: making a first measurement of atleast a first characteristic the solar cell; incorporating atleast said solar cell in atleast one of a string and a matrix; making atleast a second measurement of atleast a second characteristic of atleast one of the string and the matrix comprising at least said individual solar cell; comparing the measurements of the first and the second characteristic; and determining changes of atleast said individual solar cell and atleast one of the string and the matrix.
  • the present invention provides a system for monitoring atleast a solar cell in a PV production line.
  • the system comprises: means for holding atleast the solar cell; atleast a first measuring means adapted for measuring atleast a first characteristic of the solar cell; operation means for connecting the solar cell in atleast one of a string and matrix; atleast a second measuring means adapted for measuring atleast a second characteristic of atleast one of the string and the matrix; and means adapted for comparing the characteristics measured by the first measuring means and the second measuring means.
  • FIGS. 1A, IB, 1C, ID illustrate typical solar cells
  • FIG. 2 illustrates a typical string of solar cell
  • FIG. 3 illustrates a typical build up of interconnected strings forming a matrix of solar cells, wherein all solar cells connected in a series;
  • FIG. 4 illustrates a method monitoring atleast a Solar cell in a PV production line, according to an exemplary embodiment of the present invention.
  • FIG. 5 illustrates a system for monitoring atleast a Solar cell in a PV production line, according to an exemplary embodiment of the present invention
  • the terms 'a', 'an', 'atleast' do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item, and the term 'a plurality' denotes the presence of more than one referenced items.
  • the present invention provides an improved system and methods for monitoring the quality of individual solar cells over a number of stages during the whole PV module manufacturing process.
  • the present invention prolongs the life and efficiency of the Solar cell.
  • the system for monitoring Solar cell of the present invention may be mass produced inexpensively and provides user an easy, efficient, secure, cost effective, environment friendly and productive way of monitoring.
  • FIGS. 1A, IB, 1C, ID wherein FIG. 1A illustrate typical solar cells 20.
  • the cell 20 may have a surface 24, a plurality of fingers 15 (also referred to as 'horizontal stripes') and atleast a solar cell bus bar 28 (hereinafter also referred to as 'bus bar' or 'bus bars').
  • the fingers 15 are connected to bus bars 28 which may conduct all electrons from all fingers 15.
  • the bus bar 28 may be made wider to support the large current they have to conduct.
  • electrons may be set free under the influence of light.
  • FIG.2 illustrates a typical string 40 having a plurality cells 20 connected through a plurality of ribbons 48 and atleast a solar cell bus bar 28.
  • the solar cells 20 include crystalline solar cells.
  • FIG. 3 illustrates a build up of interconnected strings 40 forming a matrix 60 of cells 20, wherein all cells 20 are connected in a series through the plurality of ribbons 48 (also called 'wire') and the solar cell bus bar 28 become part of atleast a string 40, according to an exemplary embodiment of the present invention.
  • the cells 20 may be connected in series, in parallel or in any combination thereof. Normally the cells 20 may be connected before they are laminated.
  • the cells 20 of the string 40 may be connected by a plurality of ways including soldering, brazing, induction brazing, laser soldering, ultra-sonic soldering, hot air, infra red, halogen gluing (possibly accelerated by applying energy in the form of heat and or electromagnetic radiation) or any other ways.
  • FIG. 4 illustrates a method 100 for tracking characteristics of atleast an individual solar cell 20 during a manufacturing process, according to an exemplary embodiment of the present invention.
  • the method 100 comprises the steps of: making atleast a first measurement of atleast a first characteristic the solar cell 20 at a step 110; incorporating the solar cell 20 in atleast one of a string 40 and a matrix 60of solar cells 20 at a step 120; making atleast a second measurement of atleast a second characteristic of atleast one of the string 40 and the matrix 60 comprising at least said individual solar cell 20 at a step 130; comparing the measurements of the first and the second characteristic at a step 140; and determining changes of atleast said individual solar cell 20 and atleast one of the string 40 and the matrix 60at a step 150.
  • the first and second characteristic may be the same or different characteristic.
  • the PV device includes atleast any one of an individual waver, a solar cell, a string, a matrices, a solar modules, lay-ups containing solar cells or any combination thereof.
  • the individual PV device typically is a waver or solar cell.
  • the cell is tested atleast before entering in a production line and after exiting the production line.
  • cells may be tested individually and at the end the module may be tested and compared to the individual measurements of the cells.
  • the testing includes atleast any one of an individual Solar cell testing, individual solar cell testing, a group cell testing, a random cell testing or any combination thereof.
  • the individual solar cell testing includes testing of atleast an individual solar cell as such or testing of atleast any one of a string, a matrix, a module, a wavers, a group of solar cells or any combination thereof.
  • the group cell testing includes testing of a plurality of solar cells of atleast any one of the string, the matrix, the module, the group of solar cells or any combination thereof.
  • the group cell testing further includes testing of atleast any one of the string as a whole, the matrix as a whole, the module as a whole, the group as a whole or any combination thereof.
  • the solar cells in atleast the module are tested by monitoring a correlation between measurements of said testing and a quality of the module.
  • the correlation can be estimated by a theoretical model or from measurements in a teach-in phase, or a combination thereof. If a teach-in phase is used any algorithm may be used to distinguish between strings with and without damaged solar cells. Such algorithms may e.g. include statistical data analysis or neutral networks.
  • At least one point of an IV-curve of each PV device is measured.
  • the IV-curve is a plot of an output current of a solar device versus a corresponding output voltage.
  • the IV-curve determines a quality of a solar device by determining an output power of a solar device at every desired voltage by multiplying it with the according current.
  • the IV-curve or points thereof of each individual cell and atleast any one of the string, chains of cells, the matrix, the wavers, the module or any combination thereof is measured and compared to those of the cells. More general the efficiency of the individual cells is compared to that of the complete string or matrix. Normally the maximum power point is used as a measure for the efficiency.
  • the cells in strings are tested by comparing an IV-curve or points thereof of the string to the IV-curve of the individual cells.
  • the cells in modules are tested by comparing an IV-curve or points thereof of the module to the IV-curve of the individual cells.
  • means for electrically contacting are adapted to gain access to atleast any one of the cell, a cell bus bar, a ribbon or any combination thereof.
  • ribbons inside the modules are located using induction coils. The ribbon is like a peace of metal that changes the behaviour of the coil as if it where inserted into it' s position and depth can be measured this way.
  • Atleast a measurement of a first characteristic of atleast any one of the cells, the strings, the matrix, the module or any combination thereof is compared to a second characteristic of atleast any one of the cells, the strings, the matrix, the module or any combination thereof possibly under the use of mathematical operations.
  • the cells or net thereof possibly being treated as an electrical net work and simulated as such using the data from the measurements.
  • the mathematical operations includes atleast any one of averaging, minimum, maximum, correlation, interpolation, extrapolation, image analysis tools or any combination thereof.
  • the IV- curve of multiple cells may be compared to that of the complete module, taking into account the influence of the electrical resistance of the connections between the cells and the transmittance of the used materials.
  • the characteristics the IV-curve, carrier lifetime to recombine, absorption, electrical resistance, electrical capacity, electrical induction, reflection are characteristics of the cells, not the module, or connections between the cells.
  • the characteristics includes atleast any one of an electrical resistance of a connection between the cells, a geometric shape, the IV-curve, a carrier lifetime, absorption, electrical resistance, electrical capacity, electrical induction, reflection or any combination thereof possibly under the use of mathematical operations.
  • the eddy currents may be induced in the cell, that die out.
  • the geometric shape may be measured to detect breakage.
  • the IV-curve may be used to measure the efficiency of the PV device.
  • other materials of the PV device absorb parts of the spectrum, e.g. glass absorbs UV light, therefore at the beginning, the cells may be tested using the spectrum that actually reaches the cells once they may be inside the module, or the correction is made mathematically.
  • the cells may in the initial measurement be placed behind a filter mimicking the materials of the module.
  • the carrier lifetime is the average time it takes for a minority carrier i.e., electron set free under influence of light, to recombine,.
  • the cells or net thereof possibly being treated as an electrical net work and simulated as such using the data from the measurements
  • the means to measuring characteristics of the solar cell includes atleast any one of a contact measurement, a non-contact measurement or any combination thereof.
  • the contact measurements are measurement that needs electrical contact to the cell.
  • the non-contact measurements are measurements that do not contact the cells directly.
  • the contact measurement may be used for electrically contacting atleast any one of the cell, the bus bar, the ribbon or any combination thereof.
  • the contact measurement includes atleast any one of an electroluminescence measurement, an electrical resistance measurement of the cell or of the connection between the cell, an electrical capacity measurement, an electrical induction measurement, a RLC circuit measurement, a thermal heating measurement or any combination thereof.
  • the PV device is coupled to a RLC circuit and its response is measured. The coupling can be done in a capacitive way or by induction. If an image is made of a string e.g. with electroluminescence, the image of the individual cell has to be compared to that part of the image of the string that contains that solar cell.
  • the thermal heating method again power is supplied to the cell and a current start flowing thru it. Besides the electroluminescence effect, the cell is heated up by the current. Where the p-n junction is relatively permeable for electrons, more current may be flow resulting in local heating of the cell.
  • the non-contact measurements includes atleast any one of an electromagnetic radiation measurement, a wavelength measurement, an electrical induction measurement, vibration or ultra sound measurement, a particle beam measurement, applying high frequency electrical fields and measuring the attenuation of this field or any combination thereof.
  • the electromagnetic radiation includes atleast any one of a visible light, an x- ray, an infrared light, etc, or any combination thereof.
  • the electromagnetic radiation is irradiated upon the cells and a reflected or transmitted radiation thereof is captured, for example, reflected or transmitted radiation thereof is captured probably with a camera sensor.
  • a 3D image of the cell is obtained using atleast any one of the time of flight principle, triangulation, stereo vision or by any combination thereof, for example normal (video) images are made.
  • a wavelength is used for non-contact measurements. The wavelength is least absorbed and thus reflected relatively good, for example blue light may be used.
  • a current is induced inside of the cell and its attenuation over time is measured.
  • the PV device is hooked to a RLC circuit and its response is measured.
  • vibration or ultra sound measurement vibration or ultra sound measurement the sound may be applied with contacting of the PV device and the part that is transmitted or reflected is measured. This way, a ID or 2D image of the cell may be obtained.
  • the particle beam may be used to measure a quality of the cell.
  • the particles may be electron, protons etc.
  • Non-contact measurement may also be done by applying a high frequency electrical fields and measuring the attenuation of this field.
  • the cells are sorted according to the first or second measurement.
  • the ells may be sorted so that very good modules high efficiency, long life time expectation, optically pleasing etc, are made or average modules are formed, depending on the requirement. Cells may be sorted in to classes and used or discarded later.
  • FIG. 5 illustrates a system 200 for monitoring atleast a solar cell in a PV production line, according to an exemplary embodiment of the present invention.
  • the system comprises: holding means 210 adapted for holding atleast the solar cell 20; atleast a first measuring means 220 adapted for measuring atleast a first characteristic of the solar cell 20; operation means 230 for connecting the solar cell 20 in atleast one of a string 40 and the matrix 60; atleast a second measuring means 240 adapted for measuring atleast a second characteristic of atleast one of the string 40 and the matrix 60; and means for comparing 250 the characteristics measured by the first measuring means and the second measuring means.
  • means for transporting the PV device are adapted to transport the PV device.
  • a second measuring means 240 are adapted for performing an operation on atleast one of the string 40 and the matrix 60 after the first measuring means 220 for performing the operation on the individual solar cell 20 has performed its operation.
  • a data base is adapted for holding atleast any one of the measured characteristics, a data derived from the measured characteristics or any combination thereof. Also after the end product or PV device has been manufactured, the data can be retained for long term testing.
  • means are adapted for interrupting a production process or for excluding atleast a problematic part from the production process are adapted.
  • the first operation means includes atleast any one of a stringer, a device for forming a matrix of solar cells, may be from these the strings, a device for assembling a lay-up of materials that may be made into a solar module, a laminator capable of encapsulating atleast a solar module and a device for providing the solar module with a contact box or any combination thereof. If the operation means operates on multiple PV devices simultaneously, the operation means is provided with means to ensure that the PV devices are further processed in the correct order or means for indicating the right order are provided. A laminator holds module. Only the one that should be processed exit if freely removable from the laminator. Optical indicators may indicate what module to process next.
  • performing the operation means includes atleast any one of automatic means, manual means or any combination thereof.
  • the transporting means are capable of extending between any of the means.
  • means for identifying solar cells are adapted to identify the solar cells in the solar device. Once the solar cells have been integrated in a solar device such as a string or module, it has to be identified in order to compare the measurements made in a previous stage. This can be done by simply knowing what cell it should be: When making a string, the third cell delivered to the string will be the third cell in the string. Simple logic dictates what cell is where. The same procedure is applicable for the position of strings in matrices and matrices in modules..
  • the cell is recognized by identification means mounted thereto.
  • Identification means may be codes engraved in the cell. This is usually the case.
  • a bas code could be applied to the cell.
  • the structure of the cells can be used, etc.

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  • Condensed Matter Physics & Semiconductors (AREA)
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Abstract

Disclosed are method and system for tracking characteristics of atleast an individual solar cell, during a manufacturing process. The method comprises the steps of: making atleast a first measurement of atleast a first characteristic the solar cell; incorporating atleast said individual solar cell in atleast one of a string and a matrix of solar cells; making atleast a second measurement of atleast a second characteristic of atleast one of the string and the matrix, wherein atleast one of the string and the matrix comprising atleast said individual solar cell; comparing the measurements of the first characteristic and the second characteristic; and determining changes of atleast said individual solar cell and atleast one of the string and the matrix.

Description

SYSTEM AND METHOD FOR MONITORING PV DEVICE
FIELD OF THE INVENTION
[0001] The present invention relates generally to PV device production monitoring, and, more particularly to system and methods for monitoring the quality of individual PV device over a number of stages during the whole PV device manufacturing process in an effective simple, optimised, controlled, cost effective, secure, and environmental friendly manner.
BACKGROUND OF THE INVENTION
[0002] In PV (photovoltaic) production lines, a number of materials are assembled to form solar modules. Such materials may be adhesive sheets as EVA or PVB, solar cells, connected into a matrix, a back sheet to protect the back side of the module and a glass plate to protect the front side while letting light thru to the cells.
[0003] The most fragile component is the solar cell, for example, a thin film, crystalline or any other technology. A solar cell typically experiences a number of operations before it is encapsulated inside the module. These operations include logistics, cell is picked up from the stack, transport to be stringed, making of the string, transport of the string, forming of the matrix, transport of the matrix, making of lay-up, and lamination, etc.
[0004] Logistics: Usually cells are not produced near the PV production line, i.e., after manufacturing, the cells have to be packaged and shipped, frequently halfway around the world. Cell is picked up from the stack: The cells are delivered to the PV manufacturer in stacks. In a stack numerous cell lying on top of each other. Since the surface of the cells is rather smooth and they most of the time has a slight but identical curvature. The cells are rather hard to separate because the resistance due to ambient air prevents that they may be separated easily in the stack direction.
[0005] Transport to be stringed: Once the cell has been picked of the stack, it is transported to the place it is connected to other cells by ribbons in order to form a string. Making of the string: The connection to the cell is normally done by some sort of soldering, i.e., the contact between the ribbon and the solar cell is normally prepared by applying a soldering flux and then that region is heated to form the connection. Normally the ribbons are plated with soldering tin so that no additional tin has to be added to the process. Normally the solar cells have 2 or three bus bars on each side that are connected to the corresponding bus bars on the adjacent cells. This way a string, for example, 9 solar cells, is formed. The soldering heats up the cells, their bus bars and the ribbon that leads to stress in all materials and potential damage to the same. During transport, the string may be damaged.
[0006] Forming of the matrix: Once a string has been created, it has to be joined with for example, 4 other strings, to form a 9 x 5 cell matrix. On way or the other, these string have to be transported and be positioned in the matrix so that the strings may be connected. Since the strings are normally connected outside of the matrix, this contacting does normally not lead to additional stress on the cells. The holding of the cell during contacting may very well damage the cells though.
[0007] During transport the matrix may be damaged. When making the lay-up, the cells may be damaged. During lamination, heat and pressure is applied to the cells, leading to possible damage.
[0008] In order to improve the quality solar module production, it is important to know where, in the production chain, the quality is impaired. Quality is most commonly defined be efficiency: How much power does the module generate under standardized condition. Lifetime of a module also attributes to quality; lifetime of both the module's mechanical properties and its efficiency. Both deteriorate over the years.
[0009] Currently it is only known how good the modules at the end of the manufacturing process are, making it very hard to find out what processes is influencing the quality of the module the most. Not that other materials and or their processing may lead to poor module quality.
[00010] The prior art discloses different techniques for monitoring the quality of solar module production, however they are limited to inspect general characteristics of the cell or the solar module, for example, inspecting a solar module for bubbles formed inside it. Such inspection is done by storing used cell characteristics such as image of the cell, number of bus bars, etc., and evaluating an image of the final module compared to these characteristics. [0001] Many such techniques are too complex for reliable operation and are not capable of effectively monitoring quality of individual solar cells during the whole PV module manufacturing process. The features of the conventional quality inspecting techniques, disclose a complex design and bulky structural indices that hinder their performance. However, no such system or technique is available in the commercial market at the present time which is capable of monitoring the quality of individual solar cells over a number of stages during the whole PV module manufacturing process.
[0002] Therefore, the present scenario is necessitating the need for a new system which is capable of overcoming disadvantages inherent in conventional solar cell or solar module inspecting technique and providing an effective means to achieve a controlled and optimized PV device production process by monitoring the quality of individual solar cells over a number of stages during the whole PV module manufacturing process.
SUMMARY OF THE INVENTION
[0003] In view of the foregoing disadvantages inherent in the prior arts, the general purpose of the present invention is to provide an improved combination of convenience and utility, to include the advantages of the prior art, and to overcome the drawbacks inherent in the prior art.
[0004] In one aspect, the present invention provides an effective means to achieve a controlled and optimized PV device production process by monitoring the quality of individual solar cells over a number of stages during the whole PV module manufacturing process.
[0005] In another aspect, the present invention provides a method for tracking characteristics of atleast an individual solar cell during a manufacturing process. The method comprises the steps of: making a first measurement of atleast a first characteristic the solar cell; incorporating atleast said solar cell in atleast one of a string and a matrix; making atleast a second measurement of atleast a second characteristic of atleast one of the string and the matrix comprising at least said individual solar cell; comparing the measurements of the first and the second characteristic; and determining changes of atleast said individual solar cell and atleast one of the string and the matrix..
[0006] It is further an object of the present invention to know where in the PV production chain the quality is impaired and to improve the quality of solar module production.
[0007] In another aspect, of the present invention provides a system for monitoring atleast a solar cell in a PV production line. The system comprises: means for holding atleast the solar cell; atleast a first measuring means adapted for measuring atleast a first characteristic of the solar cell; operation means for connecting the solar cell in atleast one of a string and matrix; atleast a second measuring means adapted for measuring atleast a second characteristic of atleast one of the string and the matrix; and means adapted for comparing the characteristics measured by the first measuring means and the second measuring means.
[0008] These together with other objects of the invention, along with the various features of novelty that characterize the invention, are pointed out with particularity in the claims annexed hereto and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there are illustrated exemplary embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] For a better understanding of the nature of the present invention, reference should be made in the detailed description taken in conjunction with the accompanying drawings in which:
[00010] FIGS. 1A, IB, 1C, ID illustrate typical solar cells;
[00011] FIG. 2 illustrates a typical string of solar cell;
[00012] FIG. 3 illustrates a typical build up of interconnected strings forming a matrix of solar cells, wherein all solar cells connected in a series; [00013] FIG. 4 illustrates a method monitoring atleast a Solar cell in a PV production line, according to an exemplary embodiment of the present invention; and
[00014] FIG. 5 illustrates a system for monitoring atleast a Solar cell in a PV production line, according to an exemplary embodiment of the present invention;
[00015] Like reference numerals refer to like parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[00016] The exemplary embodiments described herein detail for illustrative purposes are subject to many variations and structure and design. It should be emphasized, however that the present invention is not limited to a particular system and methods for achieving a controlled and optimized Solar cell production process by monitoring the quality of individual solar cells over a number of stages during the whole PV module manufacturing process as shown and described. Rather, the principles of the present invention can be used with a variety of monitoring configurations and structural arrangements. It is understood that various omissions, substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but the present invention is intended to cover the application or implementation without departing from the spirit or scope of the it's claims.
[00017] In the following detail description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without these specific details.
[00018] As used herein, the terms 'a', 'an', 'atleast' do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item, and the term 'a plurality' denotes the presence of more than one referenced items.
[00019] In an exemplary embodiment, the present invention provides an improved system and methods for monitoring the quality of individual solar cells over a number of stages during the whole PV module manufacturing process. The present invention prolongs the life and efficiency of the Solar cell. The system for monitoring Solar cell of the present invention may be mass produced inexpensively and provides user an easy, efficient, secure, cost effective, environment friendly and productive way of monitoring.
[00020] Referring to FIGS. 1A, IB, 1C, ID, wherein FIG. 1A illustrate typical solar cells 20. The cell 20 may have a surface 24, a plurality of fingers 15 (also referred to as 'horizontal stripes') and atleast a solar cell bus bar 28 (hereinafter also referred to as 'bus bar' or 'bus bars'). The fingers 15 are connected to bus bars 28 which may conduct all electrons from all fingers 15. The bus bar 28 may be made wider to support the large current they have to conduct. On the surface 24 of the cell 20, electrons may be set free under the influence of light.
[00021] Referring to FIG. 2 and 3, wherein FIG.2 illustrates a typical string 40 having a plurality cells 20 connected through a plurality of ribbons 48 and atleast a solar cell bus bar 28. The solar cells 20 include crystalline solar cells. FIG. 3 illustrates a build up of interconnected strings 40 forming a matrix 60 of cells 20, wherein all cells 20 are connected in a series through the plurality of ribbons 48 (also called 'wire') and the solar cell bus bar 28 become part of atleast a string 40, according to an exemplary embodiment of the present invention.
[00022] Referring to FIGS. 1A, 2 and 3, wherein cells 20 may be connected to a matrix
60 that normally has two dimensions, for example, 8 x 6 cells. The cells 20 may be connected in series, in parallel or in any combination thereof. Normally the cells 20 may be connected before they are laminated. The cells 20 of the string 40 may be connected by a plurality of ways including soldering, brazing, induction brazing, laser soldering, ultra-sonic soldering, hot air, infra red, halogen gluing (possibly accelerated by applying energy in the form of heat and or electromagnetic radiation) or any other ways.
[00023] Referring to FIG. 4, which illustrates a method 100 for tracking characteristics of atleast an individual solar cell 20 during a manufacturing process, according to an exemplary embodiment of the present invention. The method 100 comprises the steps of: making atleast a first measurement of atleast a first characteristic the solar cell 20 at a step 110; incorporating the solar cell 20 in atleast one of a string 40 and a matrix 60of solar cells 20 at a step 120; making atleast a second measurement of atleast a second characteristic of atleast one of the string 40 and the matrix 60 comprising at least said individual solar cell 20 at a step 130; comparing the measurements of the first and the second characteristic at a step 140; and determining changes of atleast said individual solar cell 20 and atleast one of the string 40 and the matrix 60at a step 150. The first and second characteristic may be the same or different characteristic.
[00024] The PV device includes atleast any one of an individual waver, a solar cell, a string, a matrices, a solar modules, lay-ups containing solar cells or any combination thereof. The individual PV device typically is a waver or solar cell.
[00025] The cell is tested atleast before entering in a production line and after exiting the production line. At an input, cells may be tested individually and at the end the module may be tested and compared to the individual measurements of the cells.
[00026] The testing includes atleast any one of an individual Solar cell testing, individual solar cell testing, a group cell testing, a random cell testing or any combination thereof. The individual solar cell testing includes testing of atleast an individual solar cell as such or testing of atleast any one of a string, a matrix, a module, a wavers, a group of solar cells or any combination thereof. The group cell testing includes testing of a plurality of solar cells of atleast any one of the string, the matrix, the module, the group of solar cells or any combination thereof. The group cell testing further includes testing of atleast any one of the string as a whole, the matrix as a whole, the module as a whole, the group as a whole or any combination thereof. The solar cells in atleast the module are tested by monitoring a correlation between measurements of said testing and a quality of the module. The correlation can be estimated by a theoretical model or from measurements in a teach-in phase, or a combination thereof. If a teach-in phase is used any algorithm may be used to distinguish between strings with and without damaged solar cells. Such algorithms may e.g. include statistical data analysis or neutral networks.
[00027] According to an exemplary embodiment of the present invention, at least one point of an IV-curve of each PV device is measured. The IV-curve is a plot of an output current of a solar device versus a corresponding output voltage. The IV-curve determines a quality of a solar device by determining an output power of a solar device at every desired voltage by multiplying it with the according current. The IV-curve or points thereof of each individual cell and atleast any one of the string, chains of cells, the matrix, the wavers, the module or any combination thereof is measured and compared to those of the cells. More general the efficiency of the individual cells is compared to that of the complete string or matrix. Normally the maximum power point is used as a measure for the efficiency.
[00028] According to an exemplary embodiment of the present invention, the cells in strings are tested by comparing an IV-curve or points thereof of the string to the IV-curve of the individual cells. The cells in modules are tested by comparing an IV-curve or points thereof of the module to the IV-curve of the individual cells.
[00029] According to an exemplary embodiment of the present invention, means for electrically contacting are adapted to gain access to atleast any one of the cell, a cell bus bar, a ribbon or any combination thereof. The atleast any one the cell, the cell bus bar, the ribbon or any combination thereof connected thereto inside the module. In an exemplary embodiment ribbons inside the modules are located using induction coils. The ribbon is like a peace of metal that changes the behaviour of the coil as if it where inserted into it' s position and depth can be measured this way.
[00030] According to an exemplary embodiment of the present invention, once a location of atleast any one of the cell, the bus bar, the ribbon or any combination thereof to be contacted is known [how the location is known?] a hole is drilled of milled to gain electrical access to atleast any one of the cell, the bus bar, the ribbon or any combination thereof. A needle is used to punch thru a back sheet of the solar module to establish a desired contact. The back sheet is repaired and rendered water proof.
[00031] According to an exemplary embodiment of the present invention, atleast a measurement of a first characteristic of atleast any one of the cells, the strings, the matrix, the module or any combination thereof is compared to a second characteristic of atleast any one of the cells, the strings, the matrix, the module or any combination thereof possibly under the use of mathematical operations. The cells or net thereof possibly being treated as an electrical net work and simulated as such using the data from the measurements. The mathematical operations includes atleast any one of averaging, minimum, maximum, correlation, interpolation, extrapolation, image analysis tools or any combination thereof. [00032] According to an exemplary embodiment of the present invention, different characteristics are combined and compared to another characteristic, for example, the IV- curve of multiple cells may be compared to that of the complete module, taking into account the influence of the electrical resistance of the connections between the cells and the transmittance of the used materials. The characteristics the IV-curve, carrier lifetime to recombine, absorption, electrical resistance, electrical capacity, electrical induction, reflection are characteristics of the cells, not the module, or connections between the cells.
[00033] Further, means to measure defects of the characteristics are also adapted. The characteristics are measures and monitored.
[00034] The characteristics includes atleast any one of an electrical resistance of a connection between the cells, a geometric shape, the IV-curve, a carrier lifetime, absorption, electrical resistance, electrical capacity, electrical induction, reflection or any combination thereof possibly under the use of mathematical operations. The eddy currents may be induced in the cell, that die out.
[00035] The geometric shape may be measured to detect breakage. The IV-curve may be used to measure the efficiency of the PV device. As, other materials of the PV device absorb parts of the spectrum, e.g. glass absorbs UV light, therefore at the beginning, the cells may be tested using the spectrum that actually reaches the cells once they may be inside the module, or the correction is made mathematically. The cells may in the initial measurement be placed behind a filter mimicking the materials of the module.
[00036] The carrier lifetime is the average time it takes for a minority carrier i.e., electron set free under influence of light, to recombine,.
[00037] According to an exemplary embodiment of the present invention, the cells or net thereof possibly being treated as an electrical net work and simulated as such using the data from the measurements
[00038] According to an exemplary embodiment of the present invention, the means to measuring characteristics of the solar cell includes atleast any one of a contact measurement, a non-contact measurement or any combination thereof. [00039] The contact measurements are measurement that needs electrical contact to the cell. The non-contact measurements are measurements that do not contact the cells directly.
[00040] The contact measurement may be used for electrically contacting atleast any one of the cell, the bus bar, the ribbon or any combination thereof. The contact measurement includes atleast any one of an electroluminescence measurement, an electrical resistance measurement of the cell or of the connection between the cell, an electrical capacity measurement, an electrical induction measurement, a RLC circuit measurement, a thermal heating measurement or any combination thereof. The PV device is coupled to a RLC circuit and its response is measured. The coupling can be done in a capacitive way or by induction. If an image is made of a string e.g. with electroluminescence, the image of the individual cell has to be compared to that part of the image of the string that contains that solar cell.
[00041] According to the electroluminescence measurement, power is supplied to the solar cell that starts working as a light emitting diode. Moreover, a p-n junction in the cell emits photons under influence of the applied power. Note that theoretically the current may be induced by light as well. Since the current would have to flow the cells have to be grounded. For electroluminescence a power is applied to the cells and the light emitted is recorded. If the cells are inside a module, the glass may stop part of the emitted light. This has to be corrected mathematically.
[00042] According to the thermal heating method, again power is supplied to the cell and a current start flowing thru it. Besides the electroluminescence effect, the cell is heated up by the current. Where the p-n junction is relatively permeable for electrons, more current may be flow resulting in local heating of the cell.
[00043] The non-contact measurements includes atleast any one of an electromagnetic radiation measurement, a wavelength measurement, an electrical induction measurement, vibration or ultra sound measurement, a particle beam measurement, applying high frequency electrical fields and measuring the attenuation of this field or any combination thereof. [00044] The electromagnetic radiation includes atleast any one of a visible light, an x- ray, an infrared light, etc, or any combination thereof. The electromagnetic radiation is irradiated upon the cells and a reflected or transmitted radiation thereof is captured, for example, reflected or transmitted radiation thereof is captured probably with a camera sensor. A 3D image of the cell is obtained using atleast any one of the time of flight principle, triangulation, stereo vision or by any combination thereof, for example normal (video) images are made. A wavelength is used for non-contact measurements. The wavelength is least absorbed and thus reflected relatively good, for example blue light may be used.
[00045] According to electrical induction measurement, a current is induced inside of the cell and its attenuation over time is measured. The PV device is hooked to a RLC circuit and its response is measured. According to the vibration or ultra sound measurement, vibration or ultra sound measurement the sound may be applied with contacting of the PV device and the part that is transmitted or reflected is measured. This way, a ID or 2D image of the cell may be obtained. Further, the particle beam may be used to measure a quality of the cell. The particles may be electron, protons etc.
[00046] Non-contact measurement may also be done by applying a high frequency electrical fields and measuring the attenuation of this field.
[00047] The cells are sorted according to the first or second measurement. The ells may be sorted so that very good modules high efficiency, long life time expectation, optically pleasing etc, are made or average modules are formed, depending on the requirement. Cells may be sorted in to classes and used or discarded later.
[00048] Referring to FIG. 5, which illustrates a system 200 for monitoring atleast a solar cell in a PV production line, according to an exemplary embodiment of the present invention. The system comprises: holding means 210 adapted for holding atleast the solar cell 20; atleast a first measuring means 220 adapted for measuring atleast a first characteristic of the solar cell 20; operation means 230 for connecting the solar cell 20 in atleast one of a string 40 and the matrix 60; atleast a second measuring means 240 adapted for measuring atleast a second characteristic of atleast one of the string 40 and the matrix 60; and means for comparing 250 the characteristics measured by the first measuring means and the second measuring means. [00049] Further, means for transporting the PV device are adapted to transport the PV device. Also, a second measuring means 240 are adapted for performing an operation on atleast one of the string 40 and the matrix 60 after the first measuring means 220 for performing the operation on the individual solar cell 20 has performed its operation.
[00050] According to an exemplary embodiment of the present invention, a data base is adapted for holding atleast any one of the measured characteristics, a data derived from the measured characteristics or any combination thereof. Also after the end product or PV device has been manufactured, the data can be retained for long term testing.
[00051] According to an exemplary embodiment of the present invention, means are adapted for interrupting a production process or for excluding atleast a problematic part from the production process are adapted.
[00052] According to an exemplary embodiment of the present invention, the first operation means includes atleast any one of a stringer, a device for forming a matrix of solar cells, may be from these the strings, a device for assembling a lay-up of materials that may be made into a solar module, a laminator capable of encapsulating atleast a solar module and a device for providing the solar module with a contact box or any combination thereof. If the operation means operates on multiple PV devices simultaneously, the operation means is provided with means to ensure that the PV devices are further processed in the correct order or means for indicating the right order are provided. A laminator holds module. Only the one that should be processed exit if freely removable from the laminator. Optical indicators may indicate what module to process next.
[00053] According to an exemplary embodiment of the present invention, performing the operation means includes atleast any one of automatic means, manual means or any combination thereof. The transporting means are capable of extending between any of the means.
[00054] According to an exemplary embodiment of the present invention, means for identifying solar cells are adapted to identify the solar cells in the solar device. Once the solar cells have been integrated in a solar device such as a string or module, it has to be identified in order to compare the measurements made in a previous stage. This can be done by simply knowing what cell it should be: When making a string, the third cell delivered to the string will be the third cell in the string. Simple logic dictates what cell is where. The same procedure is applicable for the position of strings in matrices and matrices in modules..
[00055] According to an exemplary embodiment of the present invention, the cell is recognized by identification means mounted thereto. Identification means may be codes engraved in the cell. This is usually the case. A bas code could be applied to the cell. For multi crystalline cells the structure of the cells can be used, etc.
[00056] Although a particular exemplary embodiment of the invention has been disclosed in detail for illustrative purposes, it will be recognized to those skilled in the art that variations or modifications of the disclosed invention, including the rearrangement in the configurations of the parts, changes in sizes and dimensions, variances in terms of shape may be possible. Accordingly, the invention is intended to embrace all such alternatives, modifications and variations as may fall within the spirit and scope of the present invention.
[00057] The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions, substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but is intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention.

Claims

We Claim
1. A method for tracking characteristics of atleast an individual solar cell, during a manufacturing process, the method comprising the steps of:
making atleast a first measurement of atleast a first characteristic the solar cell;
incorporating atleast said individual solar cell in atleast one of a string and a matrix of solar cells;
making atleast a second measurement of atleast a second characteristic of atleast one of the string and the matrix, wherein atleast one of the string and the matrix comprising atleast said individual solar cell;
comparing the measurements of the first characteristic and the second characteristic; and
determining changes of atleast said individual solar cell and atleast one of the string and the matrix.
2. The method of one of the previous claims, wherein the cells in atleast the module are tested by monitoring a mathematical relation between measurements of said testing and a quality of the module.
3. The method of one of the claim, 1, wherein atleast one point of an IV-curve of each individual solar cell and atleast one of the string and the matrix is measured.
4. The method of one of the previous claims, wherein characteristics includes atleast any one of an electrical resistance of a connection between the cells, a geometric shape, the IV- curve, carrier lifetime to recombine, absorption, electrical resistance, electrical capacity, electrical induction, reflection or any combination thereof.
5. The method of one of the previous claims, wherein in an initial measurement of the cells are tested using the spectrum that reaches the cells once the cells are inside the module or the correction is made mathematically.
6. The method of one of the previous claims, wherein the measurement includes atleast any one of an electroluminescence measurement, an electrical resistance, an electrical capacity measurement, an electrical induction measurement, a thermal heating measurement, a ultra sound measurement, an electromagnetic radiation measurement, a wavelength measurement, an electrical capacity measurement, an electrical induction measurement, vibration or ultra sound measurement, a particle beam measurement, applying high frequency electrical fields and measuring the attenuation of this field or any combination thereof.
7. The method of one of the previous claims, wherein said individual solar cells, the string, the matrix or any combination thereof are sorted according to the determined change.
8. A system for monitoring atleast a solar cell in a PV production line, the system comprising:
holding means adapted for holding atleast the solar cell;
atleast a first measuring means adapted for measuring atleast a first characteristic of the solar cell;
operation means for connecting the solar cell in atleast one of a string and matrix; atleast a second measuring means adapted for measuring atleast a second characteristic of atleast one of the string and the matrix; and
means for comparing the characteristics measured by the first measuring means and the second measuring means.
9. The system of one of the previous claims, wherein the operation means includes atleast any one of a stringer, a device for forming a matrix of solar cells, a device for assembling a lay-up of materials, a laminator capable of encapsulating atleast a solar module and a device for providing the solar module with a contact box or any combination thereof.
10. A PV production line monitoring system as used in one of the previous claims.
PCT/IB2011/052504 2010-06-09 2011-06-08 System and method for monitoring pv device WO2011154910A2 (en)

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Cited By (3)

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ITBS20120168A1 (en) * 2012-11-30 2014-05-31 Francesco Pezzotti DEVICE DETECTION OF INTERVENTION ON SOLAR PANELS
JP2015021819A (en) * 2013-07-18 2015-02-02 信越化学工業株式会社 Electrode evaluation method and solar battery cell
KR20220091757A (en) * 2020-12-24 2022-07-01 한국에너지기술연구원 Performance measuring method and system for individual solar cell of photovoltaic module

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JP2008066437A (en) * 2006-09-06 2008-03-21 Mitsubishi Heavy Ind Ltd Manufacturing method of solar panel
JP2009141056A (en) * 2007-12-05 2009-06-25 Sharp Corp Method and device for manufacturing solar cell module
JP3142922U (en) * 2008-04-17 2008-07-03 日清紡績株式会社 Conveyor device for solar cell inspection equipment

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ITBS20120168A1 (en) * 2012-11-30 2014-05-31 Francesco Pezzotti DEVICE DETECTION OF INTERVENTION ON SOLAR PANELS
JP2015021819A (en) * 2013-07-18 2015-02-02 信越化学工業株式会社 Electrode evaluation method and solar battery cell
KR20220091757A (en) * 2020-12-24 2022-07-01 한국에너지기술연구원 Performance measuring method and system for individual solar cell of photovoltaic module
KR102537513B1 (en) * 2020-12-24 2023-05-30 한국에너지기술연구원 Performance measuring method and system for individual solar cell of photovoltaic module

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