Digitized Production Lines for Solar Cells and Modules from Europe

The quality and scope of materials and components manufactured in Europe for photovoltaics, such as silicon wafers, solar cells, and modules, are essential for the further development of the industry. It is important to reduce dependence on imports at all stages of production and to create competitive conditions. The focus is on the production of high-quality and efficient solar cells using the latest technologies. Another aspect of manufacturing in Europe is compliance with environmentally friendly production standards. This includes the use of recycled materials, the use of renewable energies in production, and the minimization of waste and emissions.

The EU-funded PILATUS project addresses this issue and aims to strengthen the competitive advantage of the “Made in Europe” factor with digitized pilot lines. The aim is to keep the entire value chain in Europe and comply with the latest environmental standards. The project uses patented tunnel IBC technology to achieve the goal of mass production of solar cells in M10 format (monocrystalline silicon as material, 10 inches in diameter). Tunnel IBC technology reduces losses in the solar cell and increases efficiency. It is a specific type of back-side contacting that allows the entire front of a solar cell to be used for light capture and thus for electricity generation. The project also aims to keep the ecological footprint small by using recycled materials and eco-design practices to facilitate the dismantling of photovoltaic modules and production facilities that comply with environmental standards.

The pilot line for photovoltaic modules is expected to achieve an annual production capacity of at least 170 megawatts, accompanied by a cell capacity of 190 megawatts. By combining inline measurement technology and Industry 4.0 concepts along the entire production chain, the cells and modules are analyzed throughout the manufacturing process so that conclusions can be drawn about possible errors and weak points directly during production. This will ensure that a yield of over 90 percent is achieved at the end of the project and that photovoltaic modules have a service life of over 40 years.

The activities at Fraunhofer CSP are aimed at developing an automated inline metrology system that uses artificial intelligence (AI) during the metrological data chain. Initially, AI will be used to extract features from image data of samples and to correctly recognize and classify features and defects. Further down the chain, AI-based algorithms will be applied to the extracted classification and feature data from the measuring device to find patterns that indicate process errors and can be used as direct feedback for process control. »For this purpose, we will use the high-throughput metrology and classification platform MK4.0 located at Fraunhofer CSP, which will be equipped with IBC inline metrology solutions and sensor technology for statistical cell data analysis and AI image algorithms as part of the project,“ says Dr. Marko Turek, group manager ”Solar Cell Diagnostics and Metrology" at Fraunhofer CSP.

For offline solar cell characterization, the Fraunhofer CSP will detect defect areas on the IBC solar cells in the nanometer range and analyze them using microstructural methods to identify the production steps that cause the defects.

In addition, offline test procedures will be used to ensure the degradation stability of the IBC solar cells using established tests for light-induced degradation and UV degradation. For this purpose, the IBC solar cells will be tested in an LED-based lighting unit with an adjustable light spectrum and then subjected to an electrical performance analysis.