Case Study 1: BIPV Module

In this project, the company was manufacturing BIPV modules featuring a wide variety of sizes, ranging from 300 x 300 mm to 3 x 6 m, produced in very small batches, with a broad range of string configurations within the module to align with different building architectures. To meet these specific requirements, the toolmaker developed a special tabber and stringer capable of adjusting the cell-to-cell gap from 1 mm to 150 mm and building different string geometries within the module. Additionally, the special layup tool, adapted to both small and large modules with varying glass sizes, allows for strings to be placed at 0°, 45°, or 90°. Otaño further added that the incorporation of advanced software into the line minimized module changeover time and enabled specific EL tests for large-size modules.

Case Study 2: Light & Flexible Module

The second case study involved manufacturing light and flexible PV modules with tailored encapsulation and backsheets, combined with a glassless design. This design, which omits the junction box (JB), required a specific lamination process, noted Otaño. Due to the glassless and flexible design, the company redesigned the entire production line, implementing a carrier concept to handle the modules. At the end-of-line stations, including edge trimming, hipot testing, and other testing areas, robotic systems were used to transfer modules between stations. Otaño mentioned that the special edge trimming tool utilized a CNC-like trimming system.

Case Study 3: Light & Rigid Module

The next project involved the production of lightweight and rigid PV modules with a glassless design, using a special rigid honeycomb backsheet, designed for AgriPV applications. As the rigid backsheet serves as the carrier for the module in a sunny side-up position, the company conceptualized the entire line, including the stringer, autobussing, and laminator, to work in the opposite direction of the normal orientation.

Additionally, the company has provided customized production tools for other applications such as space applications, hybrid PV + thermal modules, and vehicle-integrated photovoltaic (VIPV) modules.

Laboratory Application

In addition to special application PV module production tools, the company also offers a multitool stringer adaptable to the needs of different upcoming cell technologies, including welding, ECA application, back contact (BC), shingling, flat ribbon, round wire, a wide range of cell sizes, and multi-busbars. Moreover, it offers a personalized laminator with features like membrane or membrane-less technology, multi-step or multi-stack lamination process, and more.

Conclusion

Otaño concluded his presentation by highlighting the potential of niche applications, projected to reach the GW-scale within the next 10 years. He emphasized that the special application production tool market is not only driven by €/Wp but also by other factors.