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Quality Problems of Solar Panel and Preventive Measures
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Quality Problems of Solar Panel and Preventive Measures

Views:18     Author:Site Editor     Publish Time: 2017-12-14      Origin:Site

Quality Problems of Solar Panel and Preventive Measures

(A) snail pattern

1. The appearance of snail pattern is an integrated process. Factors such as the additives in EVA film, the silver paste on the surface of cell, the crack of cell and the catalysis of water in the system all contribute to the formation of snail pattern , But the appearance of snail pattern is not inevitable, but has its occasional trigger. EVA film formulations include crosslinking agents, antioxidants, coupling agents and other additives, of which cross-linking agents generally use peroxide to trigger cross-linking of EVA resin, as peroxide is a relatively high activity of the initiator, If the cross-linking agent after lamination there are more residual, it will trigger the snail grain and accelerate the role.

2.EVA film additives have purity indicators, in general, the purity requirements of more than 99.5%. Impurities in the additive are mainly byproducts in the synthesis and residues of the auxiliaries in the synthesis, which are present in the form of small molecules with high boiling points and can not be excluded from the system by lamination vacuuming. Therefore, if the additives are of low purity , Then these impurities will also affect the stability of EVA film, may cause the snail pattern appears.


Solar panel Impact:

1. Lines are generally accompanied by the emergence of the hidden film cells.

2. The cell surface is oxidized.

Affected the appearance of the components.


Precaution:

1.VA film using additives in line with the purity index.

2. During the installation of the components are light enough to understand.

(B) EVA delamination

1. Unqualified degree of crosslinking (such as low temperature laminator, lamination time is short).

2.EVA, glass, backplane and other raw materials caused by foreign body surface.

3.EVA raw material composition (such as ethylene and vinyl acetate) can not lead to the normal temperature dissolution caused by delamination.

Excessive amount of flux, prolonged exposure to prolonged exposure outside the main gate line delamination.

Component Impact:

1. When the delamination area is small, it will affect the component high power failure. When the delamination area directly lead to failure of the components scrapped.


Precaution:

1. Strict control of laminating machine temperature, time and other important parameters and in accordance with the requirements of regular cross-linking degree experiments, and the degree of cross-linking control within 85% ± 5%.

2. To strengthen the improvement of raw material suppliers and raw materials inspection.

3. Strengthen the process of finished product appearance inspection.

4. Strict control of the amount of flux, as far as possible not more than 0.3mm on both sides of the main gate line.


(C) Silica poor lead to stratified & cell cross hidden crack

1. Unqualified degree of crosslinking, such as laminator temperature is low, resulting in lamination time is short.

2.EVA, glass, backplane and other raw materials caused by foreign body surface.

3 border glue a gap, the rain into the gap after a long time component of the work in the heat lead to delamination edge components

4. Cells or components caused by external force cracking.


Pv modules Impact:

1. Stratification can lead to internal components of the water inside the module caused by short-circuit component scrapped.

2. Cross-crack will cause the debris fragments to battery failure, component power decay directly affect the performance of components.

Precaution:

1. Strict control of laminating machine temperature, time and other important parameters and regularly do the experiment in accordance with the requirements of the degree of crosslinking.

2. To strengthen the improvement of raw material suppliers and raw materials inspection.

3. Strengthen the process of finished product appearance inspection.

4. Assembled plastic strict requirements operating practices, silicone need to be completely sealed.

5. Avoid external impact when lifting components.


(D) Pv modules burn out

Busbar and ribbon contact area is smaller or Weld resistance increases heat caused by the components burned.

Component Impact:

1. There is no impact on the components for a short period of time, and the components will be burned for a long time on the external power generation system and eventually lead to scrap.


Precaution:

1. In the busbar welding and component repair processes need to be strictly in accordance with the requirements of the operation instructions for welding, to avoid welding in the welding area is too small.

2. After welding is completed, you need to visually check whether the welding ok.

3. Strictly control the soldering iron problem within the control (375 ± 15) and welding time 2-3s.

(E) component junction box fire

1. Lead in the card slot has not been caught in the ignition ignition.

Lead and junction box welding spot welding area is too small appear too much resistance caused by fire.

3 lead is too long contact with the junction box plastic parts will cause a long heat heat.


Component Impact:

1. Fire caused a direct result of scrapped components, may be a serious fire.


Precaution:

1 in strict accordance with the sop operation will lead completely inserted into the card slot.

2. Lead wire and junction box solder joint welding area of at least more than 20 square millimeters.

3. Strict control of lead length in line with the drawings, in accordance with the sop operation. Avoid lead wire access to the junction box plastic parts.

(F) battery lobes

1. Welding process caused by improper operation of lobes.

2. Personnel lifting practices incorrectly caused by component lobes.

3. Laminating machine fault component class piece.


Solar panel Impact:

1. The partial failure of the split affects the power attenuation of the module.

2. Monolithic cell power attenuation or complete failure of components power attenuation.


Precaution:

1. Bus welding and rework area in strict accordance with sop practices.

2. Personnel lifting components in strict accordance with the requirements of the process of lifting components.

3. To ensure regular maintenance of the laminator.Every device replacement parts must be strictly done first ok ok after the production.

4.EL test strictly checks, prohibit bad loss.

(G) too much amount of battery flux

1. Welder to adjust the amount of flux injection caused.

2 personnel in the rework too much flux flux caused.


Pv modules Impact:

1. Affect the component main gate line location EVA delamination.

2 components in the power generation system for a long time after the occurrence of lightning dark spots, the impact of reduced component power components reduce the life expectancy or scrapped.


Precaution:

1. Adjust the welding machine flux injection timing check.

2. Rework Area Please use the designated flux pen when replacing the battery, prohibit the use of large brushes brush flux.

(H) Weld, over welding

1. Too much welding temperature or too little flux or too fast speed will lead to Weld.

2. Welding temperature is too high or welding time is too long will lead to over-welding phenomenon.

Component Impact:

1. Weld appears in a short time with the battery delamination ribbon, affecting component power attenuation or failure.

2. Over-welding leads to damage to the internal electrodes of the cells, which directly affect the power attenuation of the components and reduce the life of the components or result in scrapped.


Precaution:

1. Make sure the parameters of welding machine temperature, flux injection quantity and welding time are set, and check regularly.

2. Rework area To ensure that the soldering iron temperature, welding time and the use of the correct flux brush smear flux.

3. Strengthen the EL inspection efforts to avoid missing the next process of poor.

(Ix) welding ribbon offset or warpage fragments after welding

1. The abnormal positioning of the welding machine will cause the ribbon to shift.

2. Cell sheet main grid line offset will cause the welding ribbon and the main gate line offset.

3 over-temperature ribbon bending hardness is too large lead to the cell after welding is bent.


Component Impact:

1. Offset will lead to reduced contact area of the ribbon with the battery, delamination or affect the power attenuation.

2. Over-welding leads to damage to the internal electrodes of the cell, directly affecting the power attenuation of the components and reducing the life of the components or causing scrap.

3. Bending caused by welding cell fragments.

Precaution:

1. Regularly check the welding machine positioning system.

2. To strengthen the raw materials and solar cells with incoming inspection.

(Ten) component toughened glass burst and junction box wire breakage

1. The components were subjected to severe external force collision during handling resulting in glass blasting.

2. Glass raw materials have blew the original material.

3. Lead wire is not placed in accordance with the provisions of the lead lead back pressure is bad.


Component Impact:

1. Glass blasting components directly scrapped.

2. The damaged wires lead to the power failure of the components or the danger of electric leakage.

Precaution:

1. The components should be handled gently during lifting. Avoid external collision.

2. Strengthen the glass raw materials testing.

3. Wire must be strictly in accordance with the requirements of the disk. Avoid scattered components.


(Eleven) bubble generation

1. laminating machine vacuum temperature time is too short, the temperature is set too low or too high will appear bubbles.

2 internal is not clean there will be foreign body bubbles.

3. Get started Insulating strip size is too large or too small will lead to bubbles.


PV modules Impact:

1. Component bubbles can delaminate, causing serious scrap.

Precaution:

1. Laminating machine vacuum time temperature parameters set in strict accordance with the process requirements set. .

2. Welding and lamination process should pay attention to the process 5s clean. ,

3. Insulation strip cutting size strict requirements for cutting and inspection.


(Twelve) hot spots and delamination

1. Photovoltaic modules hot spot refers to the components in the sunlight, due to some of the cells blocked can not work, making the covered part of the heating is much larger than the unoccupied part, causing the temperature is too high to appear dark spots.

2. The formation of photovoltaic components hot spot mainly by the two internal factors, that is, the internal resistance and the battery itself dark current. Hot spot durability test is to determine the ability of solar modules withstand the heating effect of hot spot test. The solar modules are tested in a reasonable amount of time and process to demonstrate that the solar cell can be used for long periods of time under the specified conditions. Hot spot detection can be detected by infrared thermal imager, infrared thermal imager can use thermal imaging technology, the visible heat map shows the measured target temperature and its distribution.

3. Delamination lamination temperature, time and other parameters do not meet the standards.


Solar Panel Impact:

1. Hot spots lead to component power failure or failure of a direct result of burning components.

2. Delamination causes component power to decay or fail to affect component life to scrap components.

Precaution:

1. SOP requirements in strict accordance with the repair operation, and pay attention to rework inspection note 5s.

2. Soldering iron temperature welding time control to be consistent with the standard.

3 regularly check laminating machine parameters are in line with the process to be done at the same time on time to do the degree of crosslinking experiments to ensure that the degree of cross-linking 85% ± 5%.

(13) EVA delamination

1. Unqualified degree of crosslinking (such as low temperature laminator, lamination time is short).

2.EVA, glass, backplane and other raw materials caused by foreign body surface.

3.EVA raw material composition (such as ethylene and vinyl acetate) can not lead to the normal temperature dissolution caused by delamination.

Component Impact:

1. Delamination can lead to internal components of the water component of the internal short circuit caused the failure of components to scrap.


Precaution:

1. Strict control of laminating machine temperature, time and other important parameters and regularly do the experiment in accordance with the requirements of the degree of crosslinking. Make sure the degree of cross-linking meets the requirements of 85% ± 5%.

2. To strengthen the improvement of raw material suppliers and raw materials inspection.

3. Strengthen the process of finished product appearance inspection.

(Fourteen) inefficient

1. Low-grade battery mixed into the high-end components (raw material mixture / or mixing process).


Component Impact:

1. Affect the overall power components become lower, the power of components in a short period of time greater attenuation.

2 inefficient area will have a hot plate will burn components.

Precaution:

1 production line in the cell when the different grades of cells to make a good distinction to avoid mixing, rework area of the cell must also be a good grade logo, to avoid misuse.

2.EL testers should be strictly tested to avoid loss of low-efficiency film.


(Fifteen) silicone air bubbles and cracks

1. Silicone bubbles and crevices are mainly caused by air bubbles or air gun pressure instability in the silica gel raw material.

2. The main reason for the gap is the staff do not standard plastic caused.

Component Impact:

1. There will be cracks in the place of rainwater into the components into the rain when the heat will cause stratification.

Precaution:

1. Please improve the raw material manufacturers, IQC inspection to strengthen the inspection.

2. Personnel plastic practices to be standardized.

3. After playing the glue, the personnel do their own actions, cleaning personnel strictly test.

(XVI) missed the glue

1. Personnel work is not serious, resulting in leakage of plastic.

2. Production line assembly is not standardized, personnel pulled the wrong product flow into the next process.

Component Impact:

1. Did not hit the plastic will enter the rain or moisture caused by the phenomenon of even the electrical components.


Precaution:

1. Strengthen personnel skills training and enhance self-inspection awareness.

2. Production line in strict accordance with the principle of three products placed to avoid misuse.

3. Cleaning components and packaging at the strict inspection, to avoid poor leakage.

(Seventeen) Lead Weld

1. Personnel practices are not norms or not serious, resulting in leak welding.

2. Soldering iron temperature is too low, too high or too short welding caused Weld.


Component Impact:

1. Component power is too low.

2. Poor connection resistance increases, sparking components destroyed.

Precaution:

1. Strict operation of the operator required to perform SOP operations, standardize practices.

2. Timely check the temperature of the soldering iron, standard welding time.

(XVIII) Junction Box Silicone is not cured

1. Silica gel does not meet the process requirements caused by non-curing silicone.

2. A or B glue out of plastic holes to prevent the glue is not caused by curing.


Component Impact:

1. Silicone non-curing glue will flow out from the edge of the gap of the cable box. The leads in the box will be exposed to the air and rain or moisture will cause the fire to cause the components to fire.

Precaution:

1. In strict accordance with the provisions of the hourly confirmation of silicone surface dry action.

2. Timing to confirm whether the silicone matches the process requirements.

3. Cleaning procedures to ensure strict control of silicone 100% cured ok.

(XIX) EVA strips turn yellow

1.EVA strips exposed to the air for a long time, caused by variation.

2.EVA flux, alcohol and other pollution caused by variation.

3. With different manufacturers with the use of EVA chemical reaction.


Solar Panels Impact:

1. Bad appearance customers do not accept.

2. May cause delamination.

Precaution:

1.EVA opened in strict accordance with the process requirements within 12h after use, to avoid prolonged exposure to the air.

2. Pay attention to the 5s cleaning of the material placement area to avoid being contaminated during processing.

3. Avoid using the same manufacturer with the EVA.

(Twenty) component color

1. Component color difference is caused when the raw material coating uneven coating.

2. Welding machine in the cast cell is not in accordance with the color caused by the release.

3. Rework area did not make color distinction to confirm the cause of mixed color.


Component Impact:

1. Affect the overall appearance of the component. Cause a complaint.

Precaution:

1. Feedback to the improvement of raw materials. And to do a strict inspection of the incoming tube.

2. Welding machine in the feeding of strictly required to do the color distinction to avoid mixing.

3. Rework area battery color grade logo, rework and rework to do their own actions, to avoid using the wrong color film.

(Twenty-one) power attenuation classification and detection methods

Photovoltaic module power attenuation refers to the increase with the illumination time, the component output power gradually decreased phenomenon. The power attenuation of photovoltaic modules can be divided into three categories: the first one is the component power attenuation due to destructive factors; the second one is the initial photo-induced attenuation of the components; the third is the aging attenuation of the components. The second category, the third category is


Component Impact:

1. Component output power gradually decreased.

Precaution:

1. To strengthen the unloading of photovoltaic mono solar panel, reverse transport, installation quality control

2. PV module power attenuation test can be completed by the PV module I-V characteristic curve tester.

(Twenty-two) reticular cracking

1, Crack refers to the small cracks in the cell sheet, cell cracking will accelerate the battery cell power decay, affecting the normal life of the components, and cell cracking will be expanded under mechanical load, may lead to open circuit Damage, cracking may also lead to hot spot effect.

2, the crack is generated due to a combination of many reasons, the components force uneven, or shipped


Shenzhen Sungold solar Co., Ltd is located in Bao’an District, Shenzhen City close to Hong Kong, providing a well-developed and convenient transportation.We offer high quality products and sustainable service to our customers, establishing long-term cooperative relationship with them.

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Add:  Wen Tao Industrial Park, Ying Ren Shi, Shi Yan Town, Shen Zhen City, China.
Telephone:  +86-0755-29685821

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