JP5732332B2 - Solar cell module manufacturing system and manufacturing method thereof - Google Patents

Description

  The present invention relates to a manufacturing system for manufacturing a solar cell module in which a plurality of cells for solar cells are arranged in one direction and a method for manufacturing the solar cell module.

  A solar cell module in which a plurality of cells for solar cells are arranged in one direction is known (see, for example, Patent Document 1). In this solar cell module, the edges of adjacent cells are stacked one above the other. It is joined. Such a solar cell module including a plurality of cells is manufactured as follows, for example.

A plurality of reels around which band-shaped metal members are wound are arranged side by side, and as shown in FIG. 6A, the metal members 80 to 89 are fed out in a plurality of rows from these reels. A power generation layer made of a thin film is formed on the surfaces of the metal members 80 to 89 by a processing apparatus 90 such as a vapor deposition apparatus, a CVD apparatus, or a sputtering apparatus.
And the metal members 80-89 which completed formation of the electric power generation layer are cut | disconnected by the predetermined length L by the cutting device 91 in the state which comprised several rows, and the cell 80a-89a for several sheets of solar cells is carried out. Produced.
Then, as shown in FIG. 6B, the plurality of cells 80a to 89a are placed on the tray 92, and the edges of the cells 80a to 89a are arranged as shown in FIG. 6C. The solar cell modules are arranged in one direction so as to be overlapped and connected to each other.

  In addition, if even one cell having poor battery characteristics is included in such a solar battery module, the bad battery cell adversely affects other cells having good characteristics. It is known that the solar cell module has low performance (poor power generation efficiency).

International Publication No. 2010/023264

As described above, when a thin film (power generation layer) is formed on the metal members 80 to 89 in a plurality of rows by the processing apparatus 90, the film thickness is continuous in the longitudinal direction and greatly changes in each row. However, the film thickness may vary from column to column. For example, among the plurality of rows of metal members 80 to 89, the metal member 80 processed in the end region and the metal member 85 processed in the central region form a film formed by slightly different processing environments. The thickness is also different, and the characteristics as a solar cell may be different.
Therefore, in the plurality of cells 80a to 89a placed on the tray 92 in FIG. 6B, the film thickness varies, and if one module is manufactured from such a plurality of cells 80a to 89a, a cell having low characteristics is obtained. As a result, the battery performance as a whole module is degraded.

  Therefore, it is necessary to inspect the characteristics of each of the plurality of manufactured cells, rank the cells according to the inspection results, collect cells having the same characteristics, and manufacture one module with these cells. . However, such an operation of ranking and the operation of aligning cells thereafter require time and effort and may hinder the improvement of production efficiency.

  Therefore, an object of the present invention is to provide a solar cell module manufacturing system and a manufacturing method thereof, which makes it easy to manufacture one module with a plurality of cells having equivalent characteristics.

The present invention is for manufacturing a solar cell module in which a plurality of elongated solar cells are arranged side by side in one direction orthogonal to the longitudinal direction of the cells so that the long side edges overlap each other. In the manufacturing system, a supply device that supplies a strip-shaped member having a power generation layer that performs photoelectric conversion formed on the surface, and the strip-shaped member that is supplied from the supply device are cut into predetermined lengths one after another to form the cell. A cutting device for manufacturing and sending the cell to the downstream device in the order of cutting, the longitudinal direction of the cell being matched with the feeding direction, and a plurality of the cells toward the one direction orthogonal to the longitudinal direction of the cell as lined, assemble the cell in the order sent from the upstream device, with aligned toward the direction perpendicular to the feed direction of the cell, overlapping the edge portions of the cell when arranging And a location, the cut by the cutting apparatus, the inspection apparatus for inspecting characteristics of the cell before being lined by the assembly device, provided in the middle of the production line between the said supply unit to said assembly device and said that you are.

For example, a belt-shaped metal member obtained by continuously forming a power generation layer that performs photoelectric conversion on a surface thereof by sequentially feeding a belt-shaped metal member in a longitudinal direction to a processing apparatus such as a vapor deposition apparatus, a CVD apparatus, or a sputtering apparatus. In the member, the characteristics (film thickness) of the power generation layer in the longitudinal direction are continuous and do not change greatly. Therefore, according to the present invention, the band-shaped members are successively cut to a predetermined length to produce cells, the cells are sent in the order of cutting, and the cells are arranged in one direction in the order of being sent to the assembly apparatus. These cells produce one solar cell module. For this reason, one solar cell module is constituted by a plurality of cells having the same characteristics.
Therefore, it is possible to easily produce one solar cell module with a plurality of cells having the same characteristics without performing cell ranking according to the characteristics as in the prior art.

In the manufacturing system, an inspection device for inspecting characteristics of the cells before being cut by the cutting device and arranged by the assembly device is provided in the middle of the manufacturing line from the supply device to the assembly device. It has been .
For this reason, in the band-shaped member obtained by continuously forming the power generation layer that performs photoelectric conversion as described above, the characteristics of the power generation layer (film thickness) in the longitudinal direction are continuous and do not change greatly. Even if a cell with exceptionally low characteristics exists, the inspection device can identify the cell. For this reason, it is possible to prevent the solar cell module from being produced while including cells with low characteristics, and it is possible to remove such cells in advance.

In addition, the inspection apparatus has a conveyance path for loading the cell and sending it in the longitudinal direction of the cell, and stops feeding the cell in a state where the leading portion of the cell in the feeding direction protrudes from the conveyance path. It is preferable to include a transport unit that performs the inspection and check the electrical characteristics of the cell by sandwiching the cell with the leading portion protruding from the front and back.
In this case, with the cell placed on the conveyance path, the terminal portion comes into contact with the front and back of the cell, and the electrical characteristics of the cell can be inspected.

In addition, the present invention manufactures a solar cell module in which a plurality of elongated solar cells are arranged in one direction orthogonal to the longitudinal direction of the cells so that the edges on the long side overlap each other. a method, a belt-shaped member to the power generation layer for photoelectric conversion is formed on the surface, the supply device is supplied to the longitudinal direction of the belt-shaped member is cut into a predetermined length by successively cutting device the strip The cells are prepared in the order of cutting, and the cells are sent out with the longitudinal direction of the cells aligned with the feeding direction, so that the plurality of cells are aligned in the one direction perpendicular to the longitudinal direction of the cells, the fed the order, with arranged toward the direction in which the assembly device are perpendicular to the cell in the feed direction of the cell, superimposed edge portions of the cell when arranging, assembling said from the supply device Inspection device provided in the middle of the production line between the up device, characterized in that to check the properties of the cells prior to being aligned by being cut the assembled device by the cutting device.

For example, a belt-shaped metal member obtained by continuously forming a power generation layer that performs photoelectric conversion on a surface thereof by sequentially feeding a belt-shaped metal member in a longitudinal direction to a processing apparatus such as a vapor deposition apparatus, a CVD apparatus, or a sputtering apparatus. In the member, the characteristics (film thickness) of the power generation layer in the longitudinal direction are continuous and do not change greatly. Therefore, according to the present invention, the band-shaped members are successively cut to a predetermined length to produce cells, the cells are sent out in the order of cutting, and the cells are arranged in one direction in the order of feeding. Thus, one solar cell module is manufactured. For this reason, one solar cell module is constituted by a plurality of cells having the same characteristics.
Therefore, it is possible to easily produce one solar cell module with a plurality of cells having the same characteristics without performing cell ranking according to the characteristics as in the prior art.

  According to the present invention, it is possible to easily produce one solar cell module with a plurality of cells having the same characteristics without ranking cells according to the characteristics as in the prior art. It becomes possible.

It is explanatory drawing which shows a part of solar cell module manufactured by the manufacturing system of the solar cell module of this invention. It is a schematic block diagram of the manufacturing system of a solar cell module. It is a top view of an assembly apparatus. It is explanatory drawing explaining the process performed by each apparatus with which the manufacturing system of a solar cell module is equipped. It is explanatory drawing explaining operation | movement of an assembly apparatus. It is explanatory drawing explaining the manufacturing method of the conventional solar cell module.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is an explanatory diagram showing a part of a solar cell module manufactured by the solar cell module manufacturing system of the present invention. First, the configuration of the solar cell module M (hereinafter simply referred to as module M) will be described.

The module M is configured by arranging a plurality of elongated solar cells 7 in one direction, and elongated electrodes 8 are provided on both sides of the plurality of cells 7. One direction in which the cells 7 are arranged is a direction different from the longitudinal direction of the cells 7 (the orthogonal direction in the present embodiment). The adjacent cells 7 and 7 are in a state where the long side edges 7a and 7a are vertically overlapped, and are electrically and structurally connected at the overlapped edges 7a and 7a. . A structure in which a plurality of cells 7 are arranged in one direction in a state where the edges 7a and 7a are overlapped with each other is referred to as a slat structure. In order to connect the cells 7 and 7, in this embodiment, a bonding material (for example, solder paste, silver paste, conductive adhesive, etc.) 5 is interposed between the edges 7a and 7a.
The cell 7 and the electrode 8 arranged in one direction are sandwiched by cover members (not shown) from both sides, and the module M forms an integral sheet. The cover member is made of a film-like resin member that is flexible and transmits sunlight, and is in close contact with the front and back surfaces of the cell 7 and the electrode 8.

  Each cell 7 will be described. A power generation layer 18 that performs photoelectric conversion is provided on an elongated substrate 17 having conductivity, and in this embodiment, a transparent electrode layer 19 that covers the power generation layer 18 is provided. Further, a metal conductive film 20 is formed in a strip shape at the edge of the transparent electrode layer 19. For example, the substrate 17 is made of stainless steel, the transparent electrode layer 19 is made of an ITO film, and the conductive film 20 is made of copper. As the transparent electrode layer 19, ZnO may be used. The conductive film 20 is provided continuously long along the edge 7 a of the cell 7, and the bonding material 5 is scattered on the conductive film 20. Although not shown, a similar conductive film may be formed on the back surface of the substrate 17. In this case, the bonding material 5 is sandwiched between the upper and lower conductive films. Moreover, the joining member 5 may be provided in linear form.

  The manufacturing system for manufacturing such a module M arranges the cells 7 one after another so that the modules M are sequentially longer in one direction (left-right direction in FIG. 1). Seven edge portions 7a and 7a are vertically overlapped, and this overlap is performed in all the cells 7. Then, the edges 7a and 7a are joined together by the joining material 5, and are sandwiched between the cover members, whereby the module M is manufactured. The direction in which the modules M become longer (the one direction) is a direction orthogonal to the longitudinal direction of the cell 7.

And the manufacturing system of this embodiment is provided with the supply apparatus which supplies the strip | belt-shaped member 3 by which various film-forming was carried out on the surface to a downstream apparatus, as shown in FIG. 2, The supply apparatus of this embodiment Is a reel device 11 having a reel 12 around which a belt-shaped member 3 having various films formed thereon is wound (hereinafter, the supply device will be described as the reel device 11).
In addition to the reel device 11, the manufacturing system includes a cutting device 21 that cuts the band-shaped member 3 to produce the cell 7, an application device 31 that supplies the bonding material 5 onto the cell 7, and the cell 7. Are provided with an inspection device 41 for inspecting the battery characteristics and an assembly device 51 having a stage 52 for placing the cells 7 in one direction.
In this manufacturing system, when the reel device 11 is the most upstream device, the cutting device 21, the applying device 31, the inspection device 41, and the assembling device 51 are continuously arranged in that order on the downstream side. These devices constitute one continuous production line. When viewed from the cutting device 21, the applying device 31 is a downstream device, and when viewed from the assembly device 51, the inspection device 41 is an upstream device. In addition, this manufacturing system has a control device (computer) 2 that comprehensively controls the operation timing of each device.

  In addition to the reel 12, the reel device 11 includes a first transport unit 14 that transports the belt-shaped member 3 fed out from the reel 12 to the downstream side. The conveyance part 14 consists of a belt conveyor, and sends the strip | belt-shaped member 3 to the downstream by control of the control apparatus 2. FIG. The reel device 11 further includes a dancer unit 13, and the dancer unit 13 adjusts the balance between the feed amount of the belt-like member 3 fed from the reel 12 and the feed amount of the belt-like member 3 by the transport unit 14.

  The band-shaped member 3 wound around the reel 12 is obtained by forming a power generation layer 18 and a transparent electrode layer 19 on the surface of a band-shaped metal member (see FIG. 1). The power generation layer 18 and the transparent electrode layer 19 are The belt-like member 3 is continuously provided along the longitudinal direction. The power generation layer 18 and the transparent electrode layer 19 are continuously processed by feeding a band-shaped metal member in the longitudinal direction to a processing chamber of a processing apparatus (not shown) such as a vapor deposition apparatus, a CVD apparatus, or a sputtering apparatus. And formed on the surface of the band-shaped metal member. Furthermore, in the present embodiment, the conductive film 20 is continuously provided on the transparent electrode layer 19.

  The cutting device 21 includes a cutting unit 22 that cuts the belt-shaped member 3 fed out from the reel 12 and transported by the first transport unit 14 to a predetermined length one after another, and the cell 7 in the cutting direction in the same direction as the longitudinal direction of the cell 7. It has the 2nd conveyance part 23 sent toward a direction. The 2nd conveyance part 23 consists of a belt conveyor, and sends the cell 7 to the downstream side by control of the control apparatus 2. FIG. The first conveying unit 14 and the second conveying unit 23 send the band-shaped member 3 on the first conveying unit 14 to the second conveying unit 23 for a predetermined length, and the cutting blade of the cutting unit 22 uses the band-shaped member 3. By cutting and repeatedly executing this process, cells 7 having a certain length are obtained one after another. Moreover, the cutting part 22 of this embodiment has a function of forming scribe grooves (not shown) at both ends in the longitudinal direction of the cell 7.

The applying device 31 supplies the bonding material 5 onto the third transport unit 32 that sends the cells 7 in the same direction as the longitudinal direction of the cells 7 in the cut order, and the cells 7 transported by the transport unit 32. And a bonding material supply unit 34 having a nozzle 33. A plurality of nozzles 33 are provided along the conveyance direction of the cells 7 by the conveyance unit 32, and each nozzle 33 discharges the bonding material 5. As described above, the bonding material 5 is supplied onto the conductive film 20 of the cell 7 (see FIG. 1). The conveyance part 32 consists of a belt conveyor, and sends the cell 7 to the downstream side under the control of the control device 2.
By repeating the operation of the applying device 31, the bonding material 5 can be supplied to the cells 7 one after another.

The inspection device 41 is provided in the middle of the production line between the cutting device 21 and the assembly device 51, and after being cut by the cutting device 21 and before being arranged on the stage 52 by the assembly device 51. The characteristics of the cell 7 are inspected.
The inspection device 41 inspects the characteristics (IV characteristics) of the cell 7 as a battery for each cell. That is, a single cell 7 is irradiated with light, and the voltage (current) output thereby is measured. If the output voltage of the cell 7 is equal to or higher than the threshold value, the cell 7 (acceptable cell) is given to the assembly device 51 to be included in the module M. If the output voltage is lower than the threshold value, the cell 7 (failed cell) is not shown. To the discharge section outside the production line.

The inspection device 41 is electrically connected to the fourth transport unit 43 having a transport path 42 for placing one cell 7 and sending the cell 7 in the longitudinal direction thereof, and the cell 7 on the transport path 42. Terminal portions 44 and 45 for inspecting various characteristics. The 4th conveyance part 43 consists of a belt conveyor, and sends the cell 7 to the downstream side by control of the control apparatus 2. FIG. The terminal portions 44 and 45 are arranged on the upper and lower sides (the front side and the back side) with the cell 7 interposed therebetween, and can approach and leave the cell 7 from above and below. The inspection by the inspection apparatus 41 will be described later.
By repeating the operation of the inspection device 41, the cells 7 can be inspected one after another.

  As shown in the plan view of FIG. 3, the assembling apparatus 51 includes a stage 52 for placing the cells 7 side by side and sucking the placed cells 7, and a head portion in the feed direction of the cells 7 to be placed on the stage 52. The holding part 53 which can hold | maintain and the drive part 54 which reciprocates linearly the holding part 53 (head 56 which mounts the holding part 53) along the longitudinal direction extension line of the cell 7 are provided. The cell 7 to be placed on the stage 52 is the pass cell that has been inspected by the inspection device 41. The holding unit 53 and the stage 52 have a structure that holds the cell 7 by suction by air suction.

The drive unit 54 includes a servo motor, and the control device 2 controls the movement amount of the holding unit 53, that is, the feed amount of the cell 7 held by the holding unit 53 based on the rotation speed of the servo motor ( to manage. Each of the transfer units 14, 23, 32, and 43 also has a servo motor, and the amount of cell 7 fed by each of the transfer units 14, 23, 32, and 43 is also based on the rotation speed of the servo motor. The control device 2 controls (manages).
Further, the drive unit 54 also has an actuator that swings the head 56 up and down. The assembling apparatus 51 includes a pressing member 55 that passes over the cell 7 that is attracted to the stage 52 and suppresses the floating portion of the cell 7 toward the stage 52. The holding member 55 is mounted on the same head 56 as the holding portion 53 and moves together with the holding portion 53. The function that the drive unit 54 swings the head 56 up and down and the function of the pressing member 55 will be described later.

  The drive unit 54 advances the holding unit 53 that holds the top portion of the cell 7, and then moves backward to attract the cell 7 onto the stage 52 from the top portion. When one cell 7 is adsorbed on the stage 52, the stage 52 moves one step in a direction orthogonal to the longitudinal direction of the cell 7, and adsorbs the next cell 7 by performing the same operation. . The moving distance of one step of the stage 52 is the width direction dimension (short direction dimension) of the cell 7.

  By repeatedly performing the operation of the assembling apparatus 51, a plurality of cells 7 are arranged in one direction, and the cells 7 are arranged in the one direction in the order sent from the inspection apparatus 41 which is the upstream apparatus. be able to. Then, when the cells 7 are arranged on the stage 52, the edges 7a, 7a of the cells 7 are in a state where they are vertically overlapped.

  The manufacturing method of the solar cell module performed by the manufacturing system provided with the above structure is demonstrated. In FIG. 2, a belt-shaped member 3 having a power generation layer 18, a transparent electrode layer 19, and a conductive film 20 provided on the surface is wound around a reel 12. The belt-like member 3 that is rotated from the reel 12 by rotating the reel 12 is placed on the first transport unit 14 via the dancer unit 13.

  The 1st conveyance part 14 operate | moves synchronizing with the 2nd conveyance part 23, and sends the strip | belt-shaped member 3 downstream by predetermined | prescribed feed amount (refer step S1: FIG. 4 (A)). This feed amount is a value set in the control device 2, and the control device 2 operates the servo motors of the transport units 14 and 23 as much as the feed amount, and temporarily stops the transport of the belt-like member 3. To do. By this step S <b> 1, the leading end S of the band-shaped member 3 becomes a position advanced by a predetermined length L downstream from the cutting blade 24 of the cutting portion 22.

In this state, the cutting part 22 cuts the strip-shaped member 3 to produce a cell having a predetermined length L (step S2). When the cutting is completed, the operation of the second transport unit 23 is resumed, and the cell 7 is sent downstream by a predetermined feed amount (step S3: see FIG. 4B). This feed amount is a value set in the control device 2, and the control device 2 activates the servo motor of the transport unit 23 corresponding to the feed amount, and temporarily stops the transport of the cell 7. By this step S 3, the tip S of the cell 7 is positioned at the leading point (downstream point) P 1 of the transport path 25 of the transport unit 23, and the cutting device 21 sends the cell 7 to the next applying device 31. It will be in a standby state.
In addition, the control device 2 repeatedly executes the steps S1 to S3, so that the band-like member 3 is successively cut into a predetermined length L to produce a cell 7, and the cell 7 is changed to the cell 7 in the order of cutting. Can be sent to the applying device 31 in the same direction as the longitudinal direction.

  From the state where the tip S of the cell 7 is waiting at the leading point P1 of the transport path 25 (the state shown in FIG. 4B), the second transport unit 23 and the third transport unit 32 operate in synchronization. Then, the cell 7 is sent downstream by a predetermined feed amount (step S11: see FIG. 4C). This feed amount is a value set in the control device 2, and the control device 2 operates the servo motors of the transport units 23 and 32 corresponding to the feed amount, and temporarily stops the transport of the cell 7. . By this step S11, the tip S of the cell 7 is positioned at the leading point (downstream point) P2 of the transport path 35 of the transport unit 32, and the applying device 31 sends the cell 7 to the next inspection device 41. It will be in the standby state. In this step S11, the bonding material 5 (see FIG. 1) is supplied to the cell 7. By repeating this step S11, the bonding material 5 is supplied for each cell 7 sent one after another.

  In this step S11, at the position P3 where the tip S of the cell 7 reaches the leading point P2, the transport unit 32 slows down the feeding speed of the cell 7, and during this time, the bonding material is supplied from the nozzle 33 of the applying device 31. 5 is supplied onto the cell 7. A plurality of nozzles 33 are provided at the same interval as the interval between the leading point P2 and the front position P3, and the feeding material 5 is simultaneously supplied from these nozzles 33 so that the feeding speed of the cell 7 is reduced. Thus, the bonding material 5 can be placed on all the regions.

  From the state where the tip S of the cell 7 is waiting at the leading point P2 of the transport path 35 (see FIG. 4C), the third transport unit 32 and the fourth transport unit 43 operate in synchronization. Then, the cell 7 is sent downstream by a predetermined feed amount (step S21: see FIG. 4D). The feed amount is a value set in the control device 2, and the control device 2 operates the servo motors of the transport units 32 and 43 as much as the feed amount, and temporarily stops the transport of the cell 7. . By this step S21, the tip S of the cell 7 reaches the position P4 that has passed the conveyance path 42 of the conveyance unit 43 to the downstream side, the inspection by the inspection device 41 is executed, and after the inspection is completed, the inspection device 41 A standby state for sending the cell 7 to the next assembling apparatus 51 is entered.

In step S <b> 21, as described above, the transport unit 43 stops the feeding of the cell 7 in a state where the leading portion of the cell 7 in the feeding direction protrudes from the transport path 42 to the assembly device 51 side. This leading portion in the feed direction is referred to as a protruding portion 10.
Then, in this state, the terminal portions 44 and 45 of the inspection device 41 move closer to the protruding portion 10 of the cell 7, contact the protruding portion 10 with the protruding portion 10 sandwiched from the front and back, and inspect the electrical characteristics of the cell 7. I do.

  Here, as described with reference to FIG. 1, in each cell 7, a power generation layer 18 that performs photoelectric conversion, a transparent electrode layer 19, and a conductive film 20 are provided on a conductive metal substrate 17. Therefore, a battery is configured for each cell 7. The direction in which the current generated when the power generation layer 18 receives light is the front and back direction (thickness direction) of the cell 7. That is, the cell 7 is a battery that generates a potential difference between the front side and the back side by receiving light from the front side. Therefore, in the inspection apparatus 41, the cell 7 is irradiated with light, and the terminal portions 44 and 45 are brought into contact with the protruding portion 10 (see FIG. 4D) of the cell 7 so as to be in contact with the cell 7 from the front and back. It becomes possible to measure the characteristics (output voltage) of the battery.

  One terminal portion 45 that contacts the surface side of the cell 7 contacts the conductive film 20, and the other terminal portion 44 contacts the substrate 17. Since the electrical resistance of the conductive film 20 made of copper is smaller than that of the transparent electrode layer 19 made of ITO, a test result with higher accuracy can be obtained by bringing the terminal portion 45 into contact with the conductive film 20. The substrate 17 of the cell 7 is a metal member made of, for example, stainless steel and has high electrical conductivity. The other terminal portion 44 is provided at a position facing the one terminal portion 45, and the terminal portion 44 is connected to the substrate 17. Can be contacted.

  As described above, the inspection apparatus 41 can inspect the electrical characteristics of the cell 7 with the portion excluding the protruding portion 10 placed on the conveyance path 42. Then, by repeatedly executing the above step S21, the characteristic inspection is performed for each cell 7 sent one after another.

When this inspection is completed, the holding part 53 of the assembling apparatus 51 sucks and holds the back surface of the protruding part 10 of the cell 7 without operating the transport part 43 (step S31: FIG. 5). (See (A)).
When the holding unit 53 holds the cell 7, the driving unit 54 and the conveying unit 43 of the assembling apparatus 51 operate in synchronization with each other, and the cell 7 is sent downstream by a predetermined feed amount (step S32: see FIG. 5B). ). This feed amount is a value set in the control device 2, and the control device 2 operates the servo motors of the transport unit 43 and the drive unit 54 to correspond to the feed amount to transport (hold) the cell 7. The forward movement of the portion 53 is temporarily stopped.

  As described above, the drive unit 54 also includes an actuator (not shown) that swings the holding unit 53 (head 56) up and down. As shown in FIG. The head 7b of the cell 7 is adsorbed to the stage 52 by air. Then, the holding (suction) of the cell 7 by the holding unit 53 is released, and the driving unit 54 moves the holding unit 53 backward (FIG. 5D). Thereby, the cell 7 is sucked and held on the stage 52 (step S33). When the holding portion 53 moves backward, the pressing member 55 passes over the cell 7 attracted to the stage 52 and suppresses the raised portion of the cell 7 to the stage 52 side. When the cell 7 is adsorbed on the stage 52 over the entire length, the holding unit 53 swings upward and waits for the inspection of the next cell 7 to be completed by the inspection device 41 (step S34).

Then, as described above (see FIG. 3), the stage 52 moves one step in the direction orthogonal to the longitudinal direction of the cell 7 and waits for the next cell 7 to be sucked (step S35).
By repeatedly executing the above steps S31 to S35, the cells 7 to be sent one after another can be arranged in a slat structure. That is, the assembling apparatus 51 arranges the cells 7 in the one direction so that the plurality of cells 7 are arranged in one direction, and arranges the edges 7a and 7a of the cells 7 when arranging them. Can be overlapped.

  As shown in the above step S31 (FIG. 5A), the cell 7 is newly assembled because the leading portion (the protruding portion 10) of the cell 7 protrudes from the transfer path 42 in the transfer direction. The holding unit 53 can suck the back surface of the cell 7 without sending it to the device 51 side. In addition, since the leading portion (the protruding portion 10) of the cell 7 protrudes from the conveyance path 42, the terminal portions 44 and 45 can perform the inspection with the cell 7 sandwiched from the front and back.

  As described above, since the leading portion of the cell 7 protrudes from the conveyance path 42, it is not necessary to newly send the cell 7 in order to move the cell 7 from the inspection process to the assembly process, thereby shortening the time. Is possible. And the holding | maintenance part 53 does not damage the said electric power generation layer 18 side by adsorb | sucking the back surface of the cell 7, ie, the surface on the opposite side to the surface in which the electric power generation layer 18 is formed. Further, the characteristics can be inspected while the cell 7 is still mounted on a part of the production line (conveying unit 43). From the production of the cell 7 by the cutting device 21 to the assembly to the slat structure by the assembly device 51. Can be performed continuously.

According to the manufacturing system and the manufacturing method using the manufacturing system according to the above-described embodiment, even if the cells are not ranked according to the characteristics as in the conventional case, the characteristics are easily obtained. One module M can be manufactured by the plurality of cells 7.
That is, for example, a band-shaped metal member obtained by continuously forming a power generation layer 18 or the like on a surface thereof by sequentially feeding a band-shaped metal member in a longitudinal direction to a processing apparatus such as a vapor deposition apparatus, a CVD apparatus, or a sputtering apparatus. In the member 3, generally, the characteristics (film thickness) of the power generation layer 18 are continuous in the longitudinal direction and do not change greatly. Therefore, the band-shaped member 3 is cut into a predetermined length one after another by the cutting device 21 to produce the cell 7, and the cell 7 is sent out in the cut order, and is sent to the assembling device 51 via the applying device 31 and the inspection device 41. The cells 7 are arranged in one direction in the order in which the cells 7 are arranged, and a solar cell module having one slat structure is manufactured by the cells 7, so that this one solar cell module has a plurality of cells having the same characteristics. 7.

  In addition, as described above, in the band-shaped member 3 in which the power generation layer 18 is continuously formed on the surface, the characteristics of the power generation layer 18 (film thickness) are continuous in the longitudinal direction and do not change greatly. In the present embodiment, the inspection device 41 can identify the cell 7 even if the cell 7 having low characteristics exists. For this reason, the cell 7 with low characteristics is excluded from the slat structure. Therefore, after the module including such a cell having low characteristics is manufactured, the entire module is inspected. As a result, it is possible to prevent the module from being judged to be defective and being wasted.

  Furthermore, in this embodiment, since the cutting device 21, the applying device 31, and the inspection device 41 are linearly provided in the middle of the production line from the reel device 11 to the assembly device 51, the strip member 3 The cells 7 can be produced one after another, the bonding material 5 can be supplied to the cells 7, the cells 7 can be inspected, and the cells 7 can be continuously arranged in one direction. And it becomes possible to manufacture a solar cell module efficiently by joining cells with the joining material 5, and providing the said cover member.

  Further, in FIG. 2, a case has been described in which the conveyance unit 23 and the conveyance unit 32 adjacent to each other on the production line, the conveyance unit 32 and the conveyance unit 43 adjacent to each other, and the conveyance unit 43 and the drive unit 54 that operate adjacent to each other operate in synchronization. However, the transport units 14, 23, 32, 43 and the drive unit 54 operate in synchronization under the control of the control device 2. For example, when the driving unit 54 and the conveyance unit 43 send the cell 7 in synchronization, the conveyance unit 32 operates in synchronization with the conveyance unit 43 and can send the cell 7.

  In addition, the feed amounts of the cells 7 by the transport units 23, 32, 42 and the drive unit 54 can all be the same, and the control device 2 individually sets the feed amounts by the transport units 23, 32, 42 and the drive unit 54. There is no need to control. For this reason, for example, a sensor for detecting the cell 7 is provided in each of the transport paths of the transport units 23, 32, and 42, and the control device 2 starts the feed amount and the feed of the cell 7 based on the detection signal from the sensor. There is no need to control the stop, and a simple program control is sufficient. In the present embodiment, a sensor for detecting the cell 7 is provided in order to confirm that the cell 7 has reached a predetermined position (for example, the leading point P1).

  In addition, from the start of the conveyance of the band-shaped member 3 by the first conveyance unit 14 and the second conveyance unit 23, the band-shaped member 3 is fed out for a predetermined length, and is cut once in a state where the feeding is stopped. The time until the tip S reaches the tip point P1 (see FIG. 4B) (the time of the cutting step), from the start of transport of the cell 7 where the tip S is positioned at the tip point P1, the third transport unit 32 The time until the tip S of the cell 7 reaches the tip point P2 (see FIG. 4 (c)) is completed, and the tip S is located at the tip point P2. From the start of the transfer of the cell 7 to the completion of the inspection of the cell 7 on the fourth transfer unit 43 (inspection process time), and from the start of the transfer of the cell 7 by the holding unit 53, on the stage 52 of the cell 7 The time to complete adsorption (assembly process time) By comparison, the longest time of the feed step. Therefore, although these processes are performed simultaneously, the cutting process, the inspection process, and the assembly process can be completed within the time of the supply process.

Further, in the present embodiment, since the holding unit 53 holds the leading portion of the cell 7 in the assembling apparatus 51, as described with reference to FIG. Each transport unit is controlled to start and stop the cell 7.
That is, by managing the position with respect to the tip S of the cell 7 and making the feed amount by each transport unit constant, if the respective transport units are operated in synchronization with the feed amount, the tip S of the cell 7 is It is aligned with the leading point of the conveyance path, the leading edge S can reach a predetermined position (the position P4) of the assembling apparatus 51, and the holding part 53 can hold the leading part of the cell 7 continuously. It becomes possible.

In addition, since the position is managed with reference to the tip S of the cell 7, even if the length of the cell 7 is changed, it is not necessary to change the feed amount by each transport unit. That is, even if the length of the cell 7 is changed, it is not necessary to change the program of the control device 2 regarding the operation of sending the cell 7 in the longitudinal direction.
In addition, since the width of the conveyance path of the image conveyance unit is sufficiently larger than the width of the cell 7 (dimension in the short direction), it is possible to cope with a change in the width of the cell 7. In this case, it is necessary to change the movement amount of the stage 52 in one step.
Thus, even if the longitudinal dimension and the width dimension of the cell 7 are changed, according to the manufacturing system of this embodiment, it is easy to cope with it. It should be noted that such cell size changes are often required based on module size changes.

Although not shown, the manufacturing system may further include a device for joining the cells 7 and 7 with the joining material 5 and a device for covering the cover member. These devices are disposed downstream of the assembly device 51. Installed.
In addition, the manufacturing system of the present invention is not limited to the illustrated form, and may be in another form within the scope of the present invention. For example, in the above-described embodiment, the case where the supply device that supplies the belt-shaped member 3 having the power generation layer that performs photoelectric conversion formed on the surface is the reel device 11 has been described. Or the manufacturing apparatus which directly forms the strip | belt-shaped members 3, such as a sputtering device, may be sufficient. In other words, the belt-like member 3 continuously formed by this manufacturing apparatus may be supplied directly to the downstream apparatus without being wound around the reel 12. In this case, one module M can be easily formed by a plurality of cells 7 having the same characteristics, without omitting the step of winding the reel 12 and ranking the cells according to the characteristics. Can be produced.

  3: Band-shaped member 7: Cell 7a: Edge portion 10: Overhang portion (leading portion) 11: Reel device (supply device) 12: Reel 18: Power generation layer 31: Giving device 41: Inspection device 42: Conveying path 43: Fourth Conveying part (conveying part) 44, 45: Terminal part 51: Assembly device M: Solar cell module

Claims (3)

A manufacturing system for manufacturing a solar cell module in which a plurality of elongated solar cells are arranged side by side in one direction orthogonal to the longitudinal direction of the cells so that edges on the long sides thereof overlap each other. And
A supply device for supplying a belt-like member having a power generation layer for performing photoelectric conversion formed on the surface;
The strip members supplied from the supply device are cut into predetermined lengths one after another to produce the cells, and the cells are sent to the downstream device in the order of cutting, with the longitudinal direction of the cells aligned with the feed direction. A cutting device;
The cells are arranged in the one direction orthogonal to the feeding direction of the cells in the order of feeding from the upstream device so that the plurality of cells are arranged in the one direction orthogonal to the longitudinal direction of the cells. In addition, an assembly device that overlaps the edges of the cells when arranging,
Equipped with a,
An inspection device for inspecting the characteristics of the cells before being cut by the cutting device and arranged by the assembly device is provided in the middle of a production line between the supply device and the assembly device. Manufacturing system for solar cell modules. The inspection apparatus has a conveyance path for loading the cell and feeding it in the longitudinal direction of the cell, and conveyance that stops the feeding of the cell in a state where the leading portion of the cell in the feeding direction protrudes from the conveyance path And
Manufacturing system of the solar cell module according to claim 1 having a terminal portion for inspecting electrical characteristics of the contact to the cell across the cell in a state in which the head portion is protruded from the front and back. A method for producing a solar cell module comprising a plurality of elongate solar cells arranged side by side in a direction perpendicular to the longitudinal direction of the cells , with the edges on the long sides overlapping each other.
A supply device supplies a belt-like member having a power generation layer for photoelectric conversion formed on the surface thereof in the longitudinal direction of the belt-like member,
The band-shaped member is cut into a predetermined length by a cutting device one after another to produce the cell,
Send out the cells in the cut order with the longitudinal direction of the cells aligned with the feed direction ,
The assembly apparatus arranges the cells in the one direction orthogonal to the feeding direction of the cells in the order of feeding , so that the plurality of cells are arranged in the one direction orthogonal to the longitudinal direction of the cells. When aligning, the edges of the cells are overlapped ,
An inspection device provided in the middle of a production line from the supply device to the assembly device inspects characteristics of the cells before being cut by the cutting device and arranged by the assembly device. Manufacturing method of solar cell module.

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