INTERNSHIP AT

GOLDI SUN PRIVATE LIMITED IN NAVSARI

STUDY OF SOLAR PV MODULE MANUFACTURING

IN GOLDI SUN PRIVATE LIMITED

A INTERNSHIP REPORT

Submitted by

DHIMMAR JAY KIRANBHAI

(220163109006)

In partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING
In
Electrical Engineering Department
Government Enginerring College, Modasa

Gujarat Technological University, Ahmedabad

April, 2025
Solar PV Module Manufacturing in Goldi Sun Team ID : 730705

GOVERNMENT ENGINEERING COLLEGE, MODASA

Shamlaji Road, Aravali District, Modasa, Gujarat – 383315

CERTIFICATE

This is to certify that the project report submitted for the internship entitled the
STUDY OF SOLAR PV MODULE MANUFACTURING AT GOLDI SUN
PRIVATE LIMITED IN NAVSARI has been carried out by DHIMMAR
JAY KIRANBHAI (220163109006) under my guidance in partial fulfillment
for the degree of Bachelor of Engineering in Electrical Engineering, 8th
Semester of Gujarat Technological University, Ahmedabad during the academic
year 2024 – 25.

Sign : ______________ Sign : _____________

Dr. Vipul J. Upadhyay Prof. Trushna P. Shah

Head of Department Internal guide

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GOVERNMENT ENGINEERING COLLEGE, MODASA

Shamlaji Road, Aravali District, Modasa, Gujarat – 383315

DECLARATION

I hereby declare that the internship report submitted along with the internship at
GOLDI SUN PRIVATE LIMITED IN NAVSARI submitted in partial
fulfillment for the degree of Bachelor of Engineering in Electrical Engineering
to Gujarat Technological University, Ahmedabad is a bonafied record of
original project work carried out by me at GOLDI SUN PRIVATE LIMITED
IN NAVSARI under the supervision of Mr. Jinesh Patel and there is no part of
this report has been directly copied from any students report or taken from any
other source without providing due reference.

Name of Student Sign of Student

DHIMMAR JAY KIRANBHAI _________________

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ACKNOWLEDGEMENT

First of all, I would like to express my gratitude to our mentor Mr. Jinesh Patel to
continuously guided me and patiently cleared up all my doubts on the site and enabled me to
complete this Internship/Project report on “Internship At Goldi Sun Private Limited In
Navsari”.

Successful completion of any type of project requires the helps from a number of persons. I
have also enlisted the help of various people to preparation of this report. Now, there is a
little effort to express my deep gratitude to those helpful people.

I convey my sincere gratitude to my Internal Guide Prof. Trushna P. Shah, Assistant

Professor of Electrical Engineering Department at Government Engineering College,
Modasa. Without his kind direction and proper guidance this project would have been not
success. In every phase the project his supervision and guidance shaped this report to be
complete perfectly. And also thanks to our Head of the Department Dr. Vipulkumar J.
Upadhyay for providing valuable guidance through out our project work.

In addition to that, I would like to mention Mr. Jenish Prajapati, Mr. Vaibhav Patel, Miss.
Dhvani Rathod, Mr. Jagdeesh and their staff member who allowed us to use valuable
resources and gave us the necessary guidance and better experience in Solar PV Module.

I also thank my parents, friends and all the family members. It is only with their invaluable
support and encouragement that I have been able to complete this project successfully.

We are grateful to Gujarat Technological University, Ahmedabad (GTU) for offering us a

Internship/Project.

-Dhimmar Jay Kiranbhai

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ABSTRACT

In the current era of technological advancement, internship (industrial training) is becoming

quite important. Training helps to have a first hand experience of the concepts taught in
books. Thus, it forms a bridge connecting theory and practical. Also it helps an individual to
get exposed to the work culture in industries and corporate life. It was a great experience
formed to work on training at Goldi Sun Private Limited In Navsari through which I could
learn how to work in a professional environment. Now I would like to thank the people who
guided me and have been constant source of inspiration throughout the tenure of my
internship. I am sincerely grateful to all staff and engineer who rendered us his valuable
assistance and constant encouragement which made this training actually possible.

In which I try to explain whatever experience and knowledge I have gained during my 12
weeks of Industrial training. Thus, the Project/Internship training has equipped with skill-sets
which are essential from the perspective of employability as well.

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LIST OF FIGURES

FIG 1.1 GOLDI SUN PRIVATE LIMITED .......................................................................... 1

FIG 1.2 GOLDI SUN LOCATION ....................................................................................... 3

FIG 1.3 RESIDENTIAL GRID SYSTEM ............................................................................. 4

FIG 1.4 RESIDENTIAL GRID CONNENCTION ................................................................ 5

FIG 2.1 ELECTRIC HAZARDS SIGNS ............................................................................... 7

FIG 2.2 USE OF FIRE EXTINGUISHERS ACCORDING TO TYPES OF FIRE ................. 8

FIG 3.1 PROCESS OF SOLAR PANEL MANUFACTURING .......................................... 10

FIG 3.2 CONSTRUCTION OF MODULE.......................................................................... 11

FIG 3.3 EVA FILM ............................................................................................................ 12

FIG 3.4 CELL ..................................................................................................................... 13

FIG 3.5 BUS BAR .............................................................................................................. 13

FIG 3.6 FRAME ................................................................................................................. 14

FIG 3.7 BACKSHEET ........................................................................................................ 15

FIG 3.8 JUNCTION BOX................................................................................................... 16

FIG 3.9 CELL CUTTING MACHINE ................................................................................ 17

FIG 3.10 T & S MACHINE ................................................................................................ 18

FIG 3.11 AUTO LAYUP MACHINE ................................................................................. 19

FIG 3.12 GLASS LODER ................................................................................................... 20

FIG 3.13 EVA & BACKSHEET CUTTER MACHINE ...................................................... 21

FIG 3.14 AUTO BUSSING MACHINE .............................................................................. 22

FIG 3.15 EL TESTING MACHINE .................................................................................... 24

FIG 3.16 LAMINATOR...................................................................................................... 26

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FIG 3.17 90O VISUAL QC.................................................................................................. 29

FIG 3.18 AUTO FRAMIMG ............................................................................................... 30

FIG 3.19 CURING LINE .................................................................................................... 31

FIG 3.20 SUN SIMULATOR.............................................................................................. 32

FIG 3.21 POST EL.............................................................................................................. 33

FIG 3.22 FINAL VISUAL QC ............................................................................................ 33

FIG 3.23 AUTO SORTER .................................................................................................. 34

FIG 3.24 PACKING AND DISPATCH .............................................................................. 34

FIG 4.1 CONSTRUCTION OF SOLAR CELL ................................................................... 35

FIG 4.2 TYPES OF PHOTOVOLTAIC SOLAR CELL ...................................................... 36

FIG 4.3 WORKING OF PV CELL ...................................................................................... 37

FIG 4.4 STRING CONNECTION ....................................................................................... 38

FIG 4.5 BATTERY ............................................................................................................. 39

FIG 4.6 POLY CRYSTALLINE CELL ............................................................................... 40

FIG 4.7 DIFFERENCE BETWEEN MONO AND POLY ................................................... 41

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LIST OF TABLES

TABLE 3.1 BUS – BAR DIMENSION............................................................................... 14

TABLE 3.2 CELL CUTTER MACHINE PARAMETER .................................................... 17

TABLE 3.3 T & S MACHINE PARAMETER .................................................................... 19

TABLE 3.4 AUTO LAYUP PARAMETER ........................................................................ 20

TABLE 3.5 GLASS LODER PARAMETER ...................................................................... 21

TABLE 3.6 EVA & BACKSHEET CUTTER PARAMETER ............................................. 22

TABLE 3.7 AUTO BUSSING PARAMETER .................................................................... 23

TABLE 3.8 AUTO TAPPING PARAMETER .................................................................... 24

TABLE 3.9 EL TESTING PARAMETER .......................................................................... 25

TABLE 3.10 LAMINATOR PARAMETER ....................................................................... 27

TABLE 3.11 AUTO TRIMMING PARAMETER ............................................................... 28

TABLE 3.12 90O VISUAL QC PARAMETER ................................................................... 29

TABLE 3.13 AUTO FRAMING PARAMETER ................................................................. 31

TABLE 3.14 CURING LINE PARAMETER ...................................................................... 32

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TABLE OF CONTENTS
Contents

ACKNOWLEDGEMENT ..................................................................................................... v

ABSTRACT ........................................................................................................................ vi

LIST OF FIGURES ............................................................................................................ vii

LIST OF TABLES ............................................................................................................... ix

TABLE OF CONTENTS ...................................................................................................... x

LIST OF ABBREVIATION ............................................................................................... xiii

CH - 1 : INTRODUCTION ................................................................................................... 1

1.1 OVERVIEW OF THE COMPANY ............................................................................. 1

1.2 COMPANY VISION & MISSION .............................................................................. 2

1.3 COMPANY GROWTH STORY.................................................................................. 2

1.4 COMPANY ADDRESS & LOCATION ...................................................................... 3

1.5 PORODUCT BASIC INFORMATION ....................................................................... 4

1.5.1 POWER GENERATION USING SOLAR PV MODULES ................................... 4

CH – 2 : INDUSTRIAL SAFETY ......................................................................................... 6

2.1 EXPLANATION OF GENERAL SAFETY RULES AND SAFETY RULES WHILE

MECHANICAL WORKING: ............................................................................................ 6

2.2 EXPLANATION OF SAFETY RULES WHILE WORKING IN ELECTRIC AND

HIGH VOLTAGE SYSTEM. ............................................................................................ 7

2.3 EXPLANATION OF FIRE SAFETY: ......................................................................... 8

CH – 3 : MANUFACTURING OF SOLAR PANEL ........................................................... 10

3.1 RAW MATERIAL .................................................................................................... 10

3.2 FLOW CHART PROCES .......................................................................................... 10

3.3 CONSTRUCTION OF MODULE ............................................................................. 11

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3.3.1 GLASS................................................................................................................ 11

3.3.2 EVA FILM .......................................................................................................... 12

3.3.3 CELL .................................................................................................................. 12

3.3.4 BUS BAR ........................................................................................................... 13

3.3.5 FRAME .............................................................................................................. 14

3.3.6 BACKSHEET ..................................................................................................... 15

3.3.7 JUNCTION BOX ................................................................................................ 15

3.4 CELL CUTTING MACHINE .................................................................................... 17

3.5 TABBER & STRINGER MACHINE ........................................................................ 18

3.6 AUTO LAYUP .......................................................................................................... 19

3.7 GLASS LODER ........................................................................................................ 20

3.8 EVA & BACKSHEET CUTTER ............................................................................... 21

3.8 AUTO BUSSING ...................................................................................................... 22

3.9 AUTO TAPPING ...................................................................................................... 23

3.10 EL TESTING........................................................................................................... 24

3.11 REWORK................................................................................................................ 25

3.12 POST LAMINTION AREA ..................................................................................... 26

3.13 LAMINATOR ......................................................................................................... 26

3.14 TRIMMING MACHINE ......................................................................................... 27

3.15 90O VISUAL QUALITY CHECK ........................................................................... 28

3.16 AUTO FRAMING ................................................................................................... 30

3.17 CURING LINE ........................................................................................................ 31

3.18 SUN SIMULATOR TESTING ................................................................................ 32

3.19 POST EL ................................................................................................................. 33

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3.20 FINAL VISUAL QUALITY CHECKING ............................................................... 33

3.21 AUTO SORTER ...................................................................................................... 34

3.22 PACKING AND DISPATCH .................................................................................. 34

CH – 4 : HOW SOLAR CELL WORK ? ............................................................................. 35

4.1 SOLAR CELL ........................................................................................................... 35

4.2 CONSTRUCTION OF SOLAR CELL ...................................................................... 35

4.3 TYPES OF PHOTOVOLTAIC SOLAR CELL .......................................................... 36

4.4 WORKING PRINCIPLE OF SOLAR CELL ............................................................. 37

4.5 CONVECTIONAL SOLAR PANEL WITH SERIES CONNECTION ...................... 38

4.5.1 WORKING PRINCIPLE OF STRING MODULE ............................................... 38

4.5.2 BENEFITS OF SWITCHING TO A HALF CUT SOLAR CELL ........................ 39

4.6 DIFFERENT TYPES OF SOLAR CELL ................................................................... 40

4.6.1 POLY CRYSTALLINE CELL ............................................................................ 40

4.6.2 MONOCRYSTALLINE CELL ........................................................................... 41

4.7 DIFFRENCE BETWEEN POLYCRYSTALLINE AND MONOCRYSTALLINE .... 41

CH – 5 : ADVANTAGES, DISADVANTAGES, & FACTORS AFFECTING OF SOLAR

PANELS ............................................................................................................................. 42

5.1 FACTORS THAT AFFECT SOLAR PANELS EFFICIENCY .................................. 42

5.2 ADVANTAGES ........................................................................................................ 42

5.3 DISADVANTAGES .................................................................................................. 42

CH – 6 : CONCLUSION..................................................................................................... 43

REFERENCES ................................................................................................................... 44

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LIST OF ABBREVIATION

Abbreviation Definition
PV Photovoltaic Cell
IPP Independent Power Source
BIS Bureau of Indian Standards
EVA Ethyl Vinyl Acetate
POE Polyolefine Elastomer
EPE Expended Polyethylene
T&S Tabber and Stringer
EL Electro Luminous
JB Junction Box
VQC Visual Quality Check
FQC Final Quality Check
AC Alternating Current
( K,M,G ) W ( Kilo, Mega, Giga ) Watt
( n, m ) m ( Neno, Mili ) Meter
Mpa Mega Pascal
db Decibel
kg Kilo Gram

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CH - 1 : INTRODUCTION

1.1 OVERVIEW OF THE COMPANY

Goldi Solar is India's leading solar panel manufacturer, EPC services provider and
Independent Power Producer (IPP) right from its inception, Goldi growth has never stopped.
in just ten years, we have grown exponentially from 10 MW to 500 MW manufacturing
capacity. Subsequently, we aim to add another 2000 MW, leading to a capacity of 2.5 GW by
the end of financial year 22-23. we also plan to foray into solar cell manufacturing with our
third facility by financial year 23-24. We plan to set up 5 GW in the next four years.

A leading original equipment Manufacturer supplier catering to several international brands

in 20+ countries like USA, UAE, Turkey, Myanmar, Italy, Greece, Germany, France,
Denmark and Croatia. we deliver high-end quality at a competitive price. today, as we
continue to explore global export opportunities, strengthen our production, technological and
marketing capabilities, we intend to further consolidate our leadership position in the Indian
solar industry.

FIG 1.1 GOLDI SUN PRIVATE LIMITED

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1.2 COMPANY VISION & MISSION

VISION

To empower the world with clean, renewable and accessible energy, ensuring a brighter
future for generations ahead.

MISSION

Establish ourselves as the market leader for sustainable solar solutions, driving india to
achieve its net zero target before 2070.

1.3 COMPANY GROWTH STORY

We, at Goldi Solar, envision spearheading India's path to achieving its net-zero targets well
before 2070. By leveraging cutting-edge technology and a robust commitment to
environmental stewardship, Goldi Solar is catalyzing a nationwide shift towards renewable
energy.

Goldi Solar is India’s most quality-conscious solar brand. The company manufactures high-
end photovoltaic modules, provides EPC services, and is an independent power producer
(IPP).

Founded in 2011 and headquartered in Surat, Gujarat, we proudly serve international brands
across 20+ countries, including the USA, UAE, Turkey, Myanmar, and Italy. In just a decade,
we’ve expanded our manufacturing capacity from a modest 10 MW to an impressive 500
MW, reaching a milestone of 2.5 GW by FY22-23, with a state-of-the-art 2 GW plant in
Navsari. Building on this momentum, Goldi Solar is set to scale its module manufacturing
capacity from the current 3 GW to a staggering 14 GW by mid-FY26, with plans to achieve 4
GW in cell manufacturing by FY27.

This expansion is expected to reduce reliance on imports and strengthen India’s solar
infrastructure.

At Goldi, we pair robust machines with German and Japanese engineered manufacturing
facilities, usage of robotics and stringent quality check procedures, with best-in-class raw
materials and a highly skilled workforce. Goldi's solar panels exemplify premium quality,
ensuring decades of longevity. Our rigorous quality inspections and top-tier raw materials
guarantee optimal performance in diverse and challenging climates. With a highly skilled

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workforce, Goldi has earned the prestigious 'Top Performer' Kiwa PVEL ranking for 2024, a
distinction held by only 50 manufacturers worldwide. We are listed under ALMM (Approved
List of Models and Manufacturers) and also have BIS (Bureau of Indian Standards)
certification.

1.4 COMPANY ADDRESS & LOCATION

Survey No. 920/3, Vijalpore Road, Navsari, Gujarat – 396445, India

FIG 1.2 GOLDI SUN LOCATION

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1.5 PORODUCT BASIC INFORMATION

The sun's energy is captured and turned in to useable electricity for everyday consumption in
a solar cell, the heart of a solar electric system that uses the power of the sun to create electric
current at the junction of two substances. Solar cells are the basic unitized to generate power
from solar radiation. In a solar module plant, these solar cells are assembled to make a larger,
usable power generation package called solar panels or solar modules. This is the heart of
photo voltaic (or PV) technology for solar power generation .Power is generated using solar
modules or panels with direct solar insulation and is transferred to individual application
feeders or to the grid after converting to AC.

1.5.1 POWER GENERATION USING SOLAR PV MODULES

The Goldi SUN Solar Modules are certified with IEC61215, IEC61730 by TUV SAAR,
Germany as per Standards by International Electro Technical Commission. The solar
modules are of the following two types Mono Crystal line Solar Modules & Polycrystalline
Solar Modules The solar module is packaged and connected assembly of solar cells. Solar
modules are rated by its DC output power under standard test conditions (STC) and typically
range from 3W to 310 watts Photons in sun light hit the solar pane land are absorbed by semi
conducting materials, such as silicon Electrons (negatively charged) are knocked loose from
the diatoms, allowing them to flow through the material to produce electricity.

FIG 1.3 RESIDENTIAL GRID SYSTEM

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FIG 1.4 RESIDENTIAL GRID CONNENCTION

Due to the special composition of solar cells, the electrons are only allowed to move in a
single direction. The modules manufactured using this high- end technology give you more
energy in terms of KWH compared to conventional modules under identical isolation.

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CH – 2 : INDUSTRIAL SAFETY
Workplace safety is very important for each employee in the industry because all employee &
Worker’s desire to work in a safe and protected atmosphere. Health and safety are the key
factor for all the industries to promote the wellness of both employees and employers. It is a
duty and moral responsibility of the company to look after the employee’s protection.

Industrial safety is a broad area of workplace safety, covering a number of issues and topics,
including :

 General safety (issues and concerns that are common across all industries)
 Site-specific safety issues
 Process and production safety
 Material safety
 Fire safety
 Electrical safety
 Building and structural safety (including temporary installations)
 Environmental safety

Although every workplace and job task carry some safety hazard, industrial
(Company)hazards are often higher risk and have the potential to cause severe injury and
extensive property damage, or devastating environmental harm Given the highly specialized
nature of the work, many of the jobs are carryout by trained and skilled employees. Workers
who sustain lost time injuries can difficult to replace, even temporarily. Because of this,
injuries can have significant effects on a company's production output, shipping schedules,
fulfilment, vendor relationships and customer satisfaction. Good safety practices, then, not
only keep workers safe but also help maintain employee, vendor, and client satisfaction.

2.1 EXPLANATION OF GENERAL SAFETY RULES AND SAFETY

RULES WHILE MECHANICAL WORKING:

 Wear Safety Shoes.

 Wear Safety Helmet while Underbody Working.
 Wear Safety Goggles Protect Eyes from Dust and full chemical.
 Wear Gloves for Better Grip.
 Wear leather gloves while welding.

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 Use Appropriate tools for Specific Purpose.

 Read User Manual For any Power tools use.
 Keep Hands away from rotating and hot parts.
 Don’t Wear any Metal Bracelet and watch While Working with any rotating parts it
maybe harmful.
 Don’t Wear Loose cloths.
 Girls Should be tied hair while working.

2.2 EXPLANATION OF SAFETY RULES WHILE WORKING IN

ELECTRIC AND HIGH VOLTAGE SYSTEM.

FIG 2.1 ELECTRIC HAZARDS SIGNS

 Wear Leather Gloves for Insulation.
 Use Insulated Handles tools and spanner.
 Identify High Voltage Cable.
 Disconnect High Voltage Power Supply.
 Use Specified Measuring instruments and Follow User Manual.
 Identify Types of Circuit Failure.
 Install Properly and tidy electrical Cords.
 Install Warning Signs.
 Follow Work Procedure

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2.3 EXPLANATION OF FIRE SAFETY:

 Wear Proper Fire Safety PPE Kit.

 Install Firing Alarms.
 Maintain Firing Alarms Sensors.
 Don’t Be panic While Fire.
 Use Fire Extinguishers.
 Use Basic Fire Extinguishers System. Like Water Supply, Sand, CO2.Extinguisher
Tank.

FIG 2.2 USE OF FIRE EXTINGUISHERS ACCORDING TO TYPES OF FIRE

 Alert to everyone who are working in Work area.
 Tried to evacuate Highly affected person From Fire.
 Identify types of fire.
 According to Types of Fire Use Fire Extinguishers.
 Don’t Use Water if There is electric fire.
 Always Prepared Floor Plan for Fire evacuation on Each Floor.

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 Don’t Use Lift Or any Electric and Electronic Equipment.

 Ask To Local Fire Brigade for Access Safety.
 Maintain Regular Testing of Fire Extinguishers.

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CH – 3 : MANUFACTURING OF SOLAR PANEL

3.1 RAW MATERIAL

First all raw material imported into the factory after that all incoming test do on Raw material
as per standard sated for testing. All raw material that use to make solar module is listed
below :

 Tempered glass
 Solar cell
 EVA (Ethyl Vinyl Acetate) (2 types)
 Bus bar
 Ribbon
 Backsheet
 Junction box
 RTV (room-temperature-vulcanizing)
 Flux
 Frame

3.2 FLOW CHART PROCES

FIG 3.1 PROCESS OF SOLAR PANEL MANUFACTURING

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3.3 CONSTRUCTION OF MODULE

Construction of module are divided into 6 parts. As shown in figure 2. Glass, Eva Film, Cell,
Frame, Back sheet, Junction box.

FIG 3.2 CONSTRUCTION OF MODULE

3.3.1 GLASS
The front glass sheet protects the PV cells from the weather and impact from hail or airborne
debris. The glass is typically high strength tempered glass which is 3.0 to 4.0mm thick and is
designed resist mechanical loads and extreme temperature changes.

The IEC minimum standard impact test requires solar panels to withstand an impact of hail
stones of 1 inch (25 mm) diameter traveling up to 60 mph (27 m/s). In the event of an
accident or severe impact tempered glass is also much safer than standard glass as it shatters
into tiny fragments rather than sharp jagged sections.

To improve efficiency and performance high transmissive glass is used by most

manufacturers which has a very low iron content and an anti-reflective coating on the rear
side to reduce losses and improve light transmission.

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3.3.2 EVA FILM

EVA stands for ‘ETHYLENE VINYL ACETATE’ which is a specially designed polymer
highly transparent (plastic) layer used to encapsulate the cells and hold them in position
during manufacture. The EVA material must be extremely durable and tolerant of extreme
temperature and humidity, it plays an important part in the long-term performance by
preventing moisture and dirt ingress.

FIG 3.3 EVA FILM

The lamination either side of the PV cells provides some shock absorption and helps protect
the cells and interconnecting wires from vibrations and sudden impact from hail stones and
other objects. A high-quality EVA film with a high degree of what is known as ‘crosslinking’
can be the difference between a long life or a panel failure due to water ingress. During
manufacture the cells are first encapsulated with the EVA before being assembled within the
glass and back sheet.

3.3.3 CELL

Solar photovoltaic cells or PV cells convert sunlight directly into DC electrical energy. The
performance of the solar panel is determined by the cell type and characteristics of the silicon
used, with the two main types being monocrystalline and polycrystalline silicon. The base of
the PV cell is a very thin wafer, typically 0.1mm thick, and is made from either a positive p-
type silicon or negative n-type silicon.

There are many different cell sizes and configurations available which offer different levels
of efficiency and performance including half-cut or split cells, multi-busbar (MBB) cells, and
more recently shingled cells using thin overlapping wafer strips.

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FIG 3.4 CELL

Most residential solar panels contain 60 mono or polycrystalline cells linked together via
busbars in series to generate a voltage between 30-40 volts, depending on the type of cell
used. Larger solar panels used for commercial systems and utility scale solar farms contain
72 or more cells and in turn operate at a higher voltage. The electrical contacts which
interconnect the cells are known as busbars and allow the current to flow through all the cells
in a circuit.

3.3.4 BUS BAR

FIG 3.5 BUS BAR

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Zink + Lead coated copper material are used in bus-bar. I shaped bus-bar used in the Top and
Bottom. L & U shaped bus-bar are use in Middel.

I shaped bus-bar - L shaped bus-bar - U shaped bus-bar -

345mm × 4mm 188mm × 6mm 394mm × 6mm

Length = 345mm Length = 188mm Length = 394mm

Width = 4mm Width = 6mm Width = 6mm

- Banding = 18mm Banding = 18mm

TABLE 3.1 BUS – BAR DIMENSION

3.3.5 FRAME
The aluminum frame plays a critical role by both protecting the edge of the laminate section
housing the cells and providing a solid structure to mount the solar panel in position. The
extruded aluminum sections are designed to be extremely lightweight, stiff and able to
withstand extreme stress and extreme stress and loading from high wind and external forces.

FIG 3.6 FRAME

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The aluminum frame can be silver or anodized black and depending on the panel
manufacturer the corner sections can either be screwed, pressed or clamped together
providing different levels of strength and stiffness.

3.3.6 BACKSHEET
The Backsheet is the rear most layer of common solar panels which as acts as a moisture
barrier and final external skin to provide both mechanical protection and electrical insulation.
The Backsheet material is made of various polymers or plastics including PP, PET and PVF
which offer different levels of protection, thermal stability and long-term UV resistance. The
Backsheet layer is typically white in colour but is also available as clear or black depending
on the manufacturer and module.

FIG 3.7 BACKSHEET

Dual glass panels - Some panels such as bifacial and frameless panels use a rear glass panel
instead of a polymer Backsheet. The rear side glass is more durable and longer lasting than
most Backsheet materials and so some manufacturers offer a 30-year performance warranty
on dual glass panels.

3.3.7 JUNCTION BOX

The junction box is a small weatherproof enclosure located on the rear side of the panel. It is
needed to securely attach the cables required to interconnect the panels. The junction box is

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important as it is the central point where all the cells set interconnect and must be protected
from moisture and dirt.

FIG 3.8 JUNCTION BOX

The junction box also houses the bypass diodes which are needed to prevent back current
which occurs when cells are shaded or dirty. Diodes only allow current to flow in one
direction and a typical 60-cell panel is divided into 3 groups of 20 PV cells, each with a
bypass diode for preventing reverse current. Unfortunately, bypass diodes can fail over time
and may need to be replaced, so the cover of the junction box is usually able to be removed
for servicing, although many modern solar panels now use more advanced long - lasting
diodes and non-serviceable junction boxes.

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3.4 CELL CUTTING MACHINE

Cell cutting is use of cut a cell in half ( 182mm x 91mm ) because the transported cells are
usually are in size of 182mm x 182mm. The process of making solar panel start with cell
cutter machine. The cells are cut by laser. It can process 3600 cells per hour. Cell cutting
machine are working on 360V, 50Hz, 55A, 3-Phase 5 Wire system.

FIG 3.9 CELL CUTTING MACHINE

TECHNICALPARAMETER RELATED PARAMETER

Operation Power AC380V, 3-phase, 5-wire system of 50Hz

Maximum Capacity 3600PCS/Hour

Laser Power 50W

Power 17kW

Laser Wave Length 1068nm

Cooling Method Natural Cooling

Operation Air Pressure 0.5~0.8Mpa

TABLE 3.2 CELL CUTTER MACHINE PARAMETER

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Cell cutting machine have problems like cell crack, cell damage, dimension problems, laser
problem, camera problem etc. The normal problem like cell damage or cell crack can be
solved by operator by changed cell but the major problems have to solved by technician or
engineers.

3.5 TABBER & STRINGER MACHINE

Tabber & Stringers weld solar cells to weirs or ribbon in order to interconnect them
electrically and create cell strings. These strings will be matrixed in the lay-up system
immediately after the stringing process.

FIG 3.10 T & S MACHINE

Tabber Stringer is used to weld solar cells to strings, Solar cell stringer machine adopts IR
soldering method, servo motor driving and industrial ccd positioning & detection for
defective solar cell excluding automatically. The soldering effect, such as cell spacing, cell
numbers of single string, soldering temperatures and etc. It can be adjusted according to
requirements. Solar cell welding machine can be integrated with automatic layup machine to
achieve the composing and locating of solar cell strings on tempered glass.

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TACHICAL PARAMETER RELATED PARAMETER

Operation Power AC 380V, 3-phase, 5-wire system of 50Hz

Maximum Capacity 12000 PCS/Hour

Laser Power 50W

Power 22kW

Size 6000mm x 1350mm x 2100mm

Cooling Methode Natural Cooling

Operation Air Pressure 0.5~0.8Mpa

TABLE 3.3 T & S MACHINE PARAMETER

The problems in this machine are cell crack, ribbon cross, cell damage, ribbon bracket etc.
Small problems are solved by operator and the major problems are solved by technician and
engineers.

3.6 AUTO LAYUP

Auto Layup is use achieve solar string automatic laying on glass EVA, and transporting
module to the next process. In this Machine the vacuum use in order to layup the strings. The
hall process is automatically.

FIG 3.11 AUTO LAYUP MACHINE

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The problems on auto layup machines are Vacuum problem, cell crack, string brake, ribbon
cross, cell damage etc. The solutions are carried out by technician.

TECHNICAL PARAMETER RELATED PARAMETER

Operation Power AC380V 3-phase5-wire system of 50Hz

Maximum Capacity 12 Module/Hour

Power 17kW

Equipment Utilization 97%

Cooling Method Natural Cooling

Operation Air Pressure 0.5~0.8Mpa

TABLE 3.4 AUTO LAYUP PARAMETER

3.7 GLASS LODER

Automatically grab the glass and place it on the conveyor line. the equipment includes 2 glass
storage stations and 1 waste paper storage station. The glass transplant robot moves the glass
to the transfer line, and the pick-up robot merges to separate the separator.

FIG 3.12 GLASS LODER

The overall structure is cantilevered. Grab glass up to 470mm, minimum 150mm; glass tray
height 150mm, 100 glass total height of 320mm.

Problem is sometimes it can’t pick up glass and sometimes it cannot dump the waste paper
storage station. Solution for this problem is normal so it can easily solve by operator.

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TECHNICAL PARAMETER RELATED PARAMETER

Operation Power AC380V, 3-phase, 5-wire system of 50Hz

Maximum Capacity 150PCS/Hour

Equipment Dimension 5120mm x 987mm x 3453mm

Power 4Kw

Max Weight 12kg

Operating Air Pressure 0.6~0.8Mpa

Air Consumption 100L/min

Noise <72db

Working cycle time 20s

TABLE 3.5 GLASS LODER PARAMETER

3.8 EVA & BACKSHEET CUTTER

This machine Eva film cutting laying machine is mainly used for cutting and laying Eva film
or Backsheet into the glass or cell string automatically according to the specified dimension.
Great compatibility, compatible with materials with maximum diameter up to 800mm.
Simple and convenient uploading with auxiliary unit of cutting loading.

FIG 3.13 EVA & BACKSHEET CUTTER MACHINE

Equipped with punch module which is adjustable and adaptable with the function of melting
bonding EVA function to improve the efficiency and convenience of operation. With the

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function of TPT head detection to effectively avoid material waste. The whole machine is
with protecting cover plate, and uploading side is protected by light fence, beautiful and safe.

TECHNICAL PARAMETER RELATED PARAMETER

Operation Power AC380V, 3-phase, 5-wire system of 50Hz

Maximum Capacity 1400kg

Working Cycle 20s

Power 8Kw

Equipment Dimension 5940mm x 2250mm x 1700mm

Operation Air pressure <75db

Air Pressure 0.6~0.8Mpa

TABLE 3.6 EVA & BACKSHEET CUTTER PARAMETER

3.8 AUTO BUSSING

Auto bussing machine adopts the method of separating the cell string form the glass and grab
the cell string in air. Then to interconnected solder the middle and tail busbar of the middle
wire. Carry out secondary layup of cell strings with an accuracy of ±0.3mm. Complete
cutting, bending and soldering of all busbars from head, middle to tail. Electromagnetic
induction soldering, tension after soldering is ≥ 5N/mm.

FIG 3.14 AUTO BUSSING MACHINE

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TECHNICAL PARAMETER RELATED PARAMETER

Operation Power AC380V, 3-phase, 5-wire system of 50Hz

Busbar Thickness 0.2~0.4mm

Working Cycle 20s

Power 25Kw

Equipment Dimension 4874mm x 4690mm x 2500mm

Air pressure 0.5~0.8Mpa

Noise <72db

Air Consumption 2200L/m

TABLE 3.7 AUTO BUSSING PARAMETER

In the problems of this machine are vacuum problem, busbar problem, busbar diameter, cell
damage, string damage etc. All these problems can be solved by operator if the same problem
occur more time than technician is the only one solve problem.

3.9 AUTO TAPPING

It uses for Tapping on the module so the alignment of module cannot distract. Vacuum
adsorption, adhesive surface without contacting with tapes to effectively avoid imprint
residue, cleaning, leakage and other problems. Pneumatic rotary joint with independent
patent, with small Air consumption, simple and stable operation. Can choose different paste
directions within the same module: Horizontal or vertical. Can choose 30 tape points.
Problem arise in auto tapping are vacuum problem, tap problem, alignment problem etc.

TECHNICAL PARAMETER RELATED PARAMETER

Operation power AC380V, 3-phase, 5-wire system of 50Hz

Width of Tap 5-10mm

Working Cycle 20s

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Power 5.5kW

Equipment Dimension 3170mm x 2080mm x 1920mm

Air pressure 0.5~0.8Mpa

Noise <72db

Air Consumption 500L/m

Length of Cutting Tap 20mm

TABLE 3.8 AUTO TAPPING PARAMETER

3.10 EL TESTING

FIG 3.15 EL TESTING MACHINE

Testing of modules using this phenomenon can detect hidden defects in the structure of PV

cell. This phenomenon is called electroluminescence. High resolution ：EL camera 2.3M

pixels *12; AOI camera 12M pixels *12, eight cameras in total. Automatically photo
shooting and photo stitching. NG modules can be automatically recognized through AI
calculation after capturing EL or exterior image. Fast change over between modules of
different specifications within 5 minutes. EL can detect problem like cell crack, cell dead,

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cell damage, microcrack, Ribbon cross, busbar damage, cell to cell gape, string to string gap
etc.

TECHNICAL PARAMETER RELATED PARAMETER

Operation Power AC220V, 3-phase, 5-wire system of 50Hz

Display Screen 55inch 4ktv*2

Working Cycle 20s

Power 2.5kW

Equipment Dimension 2400mm x 3200mm x 2100mm

Air pressure 0.5~0.8Mpa

Noise <72db

Air Consumption 1.6L/min

Temperature 20-30C

False Detection Rate <1%

TABLE 3.9 EL TESTING PARAMETER

3.11 REWORK

Rework is manual process of changing damaged or defect cells, string, busbar etc. In the EL
Testing if the defect detected then the module comes into Rework section in the rework
section defective cells, strings or busbar can be replaced and gap between string to string or
cell to cell can be changed in Rework.

Normally the defects are come to the Rework Sections are cell to cell gap, string to string
gap, cell breck, cell dead, hidden crack, ribbon cross, cell crack etc. In Rework Section
usually 4 to 5 people are working.

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3.12 POST LAMINTION AREA

Post-lamination is area of Machines that use for Post lament the solar module. In
Postlamination area There are Numbers of machines are use like Laminator, Auto Trimming,
90 Degree Visual, Framing, Junction Box, Gluing, Curing Line etc.

3.13 LAMINATOR

Solar panel lamination is crucial to ensure the longevity of the solar cells of a module. As
solar panels are exposed and subject to various climatic impact factors, the encapsulation of
the solar cells through lamination is a crucial step in traditional solar PV module
manufacturing. PV lamination is a proven concept and works as following: In order to
laminate a solar panel, two layers of ethylene-vinyl acetate (EVA) are used in following
sequence : glass / EVA / solar cell strings / EVA / Backsheet. Ready for lamination During
the lamination process.

FIG 3.16 LAMINATOR

The prepared 5-layer module is placed in the lamination machine and heated to max. 135°C
for a period of approx. 22 minutes. The laminate that comes out is completely sealed, and
when produced well, will protect the solar cells for at least 25 years. After the laminate is
cooled down, excessive EVA and TPT will be cut away, and the junction box will be
attached. Finally, the laminate can be framed. This way of laminating is a proven concept, but

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it has disadvantages: a lamination machine is large, expensive, and consumes much

electricity. Moreover, a lamination machine is slow and is often considered as the PV module
production bottleneck for any factory.

TECHNICAL PARAMETER RELATED PARAMETER

Operation Power AC380V, 3-phase, 5-wire system of 50Hz

Cooling Water Not higher than 25oC

Working Cycle 25min

Power 195kW

Meant Dimension 2797mm x 3300mm x 2540mm

Air Pressure 0.7~0.8Mpa

Noise <72db

Air Consumption 1000L/min

Temperature 30-180oC

Total Weigh 49T

Water Pressure 0.2~0.3Mpa

TABLE 3.10 LAMINATOR PARAMETER

3.14 TRIMMING MACHINE

The Trimming Machine is mainly used for trimming the excess part of EVA/TPT from the
edge of PV module after the process of laminating. The Edge Trim Station allows convenient
trimming of EVA and module Backsheet that extends beyond the edge of the glass after
lamination. This station includes a rotatable lift table with high friction pads. A hot-knife is
provided for trimming excess EVA and Backsheet material from the module edges.

The Taping Station has a similar conveyor and includes a manual taping tool used to apply
framing tape to the module edge perimeter. The module is automatically conveyed into the
work station. The operator can move and rotate the module into position for trimming or
taping when the module lift table is raised. High friction pads hold the module securely in

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place during the process. Using a hot knife, the operator trims the excess material from the
edges to prepare the module for framing or alternately uses the taping tool to apply tape to the
module edge.

TECHNICAL PARAMETER RELATED PARAMETER

Operation power AC380V, 3-phase, 5-wire system of 50Hz

Maximum capacity 100PCS/Hour

Working Cycle Time 20s

Power 3kW

Equipment Dimension 3400mm x 2350mm x 1650mm

Operation Air pressure 0.6~0.8Mpa

Air Consumption 500L/min

Noise <72db

Weight 1500kg

TABLE 3.11 AUTO TRIMMING PARAMETER

3.15 90O VISUAL QUALITY CHECK

90-degree visual machine take the module and flip the module to 90-degree angle so module
can be checked by the operator. This Machine purpose is operator can see the defect in solar
module and check the module visually so the defected module cannot be in process. The
defective module can use for testing purposes or if defect is minor so the module can use in
the process.

The machine is ensured safety net and safety grating for Laboure operation, safe and reliable.
Equipped with LED on the front and back side to meet the light requirement and easy for
checking. Simple operation surface, easy and reliable.

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FIG 3.17 90O VISUAL QC

TECHNICAL PARAMETER RELATED PARAMETER

Operation Power AC380V, 3-phase, 5-wire system of 50Hz

Maximum Capacity 50kg

Working Cycle Time 20s

Power 3kW

Equipment Dimension 2900mm x 2100mm x 2600mm

Air Pressure 0.6~0.8Mpa

Air Consumption 170L/Mpa

Noise <72db

TABLE 3.12 90O VISUAL QC PARAMETER

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3.16 AUTO FRAMING

Used to install the aluminum frame and automatically overflow glue. Adopt frames in high
position, and the frame can be placed at the same time during transmission to save cycle
times. Flat operation surface can meet the requirement of squeeze-out the glue. One button
switching between different frames, large suction area could effectively correct the
deformation of the module. Equipped with frame straightening function, avoiding the
problem of material deviation.

FIG 3.18 AUTO FRAMIMG

We have to load the Aluminum frames to machine to work. Sometimes if frame is not load
carefully or specific angle the machine cannot work properly or stop. The glue tank has to be
field so the machine can work properly machine or machine cannot work.in this machine
operator has to be carefully and watch over the machine.

TECHNICAL PARAMETER RELATED PARAMETER

Operation Power AC380V, 3-phase, 5-wire system of 50Hz

Maximum Capacity 50kg

Working Cycle Time 20s

Power 13kW

Equipment Dimension 4500mm x 2900mm x 1600mm

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Air Pressure 0.6~0.8Mpa

Air Consumption 800L/min

Noise <72db

Weight 4600kg

TABLE 3.13 AUTO FRAMING PARAMETER

3.17 CURING LINE

The purpose of the curing line is that it dries the glue and maintain certain Temperature so
Glue can perfectly dry. It takes 4 hours to dry the glue Basically, the curing and drying
structure comprises an outer transparent housing and an interiorly disposed solar energy
collector housing defining a drying area or chamber thereunder. During phases of curing
between said outer transparent housing and said collector housing where solar energy in the
form of heat collected is transferred to the passing air system.

FIG 3.19 CURING LINE

The purpose of the curing line is that it dries the glue and maintain certain Temperature so
Glue can perfectly dry. It takes 4 hours to dry the glue Basically, the curing and drying
structure comprises an outer transparent housing and an interiorly disposed solar energy
collector housing defining a drying area or chamber thereunder. During phases of curing
between said outer transparent housing and said collector housing where solar energy in the
form of heat collected is transferred to the passing air system.

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TECHNICAL PARAMETER RELATED PARAMETER

Operation power AC380V, 3-phase, 5-wire system of 50Hz

Maximum Capacity 50kg

Working Cycle Time 20s

Power 7.5kW

Equipment Dimension 2500mm x 1400mm x 3200mm

Air Pressure 0.6~0.8Mpa

Air Consumption 400L/min

Noise <72db

TABLE 3.14 CURING LINE PARAMETER

3.18 SUN SIMULATOR TESTING

FIG 3.20 SUN SIMULATOR

The sun simulator for solar panel testing not only allows to check modules quality but is also
essential to verify eventual power losses in the finished modules. Xenon lamp is use in sun
simulator machine.Sun simulator measure the I-V characteristics of solar modules and cells
during a single flash of a xenon gas discharge lamp or an LED based system.

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3.19 POST EL

FIG 3.21 POST EL

This machine is used for visual inspection. Like Cell Crack, Open Soldering, Micro-
Crack(Chip), PID Defect, Dead cell, Water Defects. It’s same parameter as well as pre EL.

3.20 FINAL VISUAL QUALITY CHECKING

FIG 3.22 FINAL VISUAL QC

In the machine the module Visual Checking, Cell Crack, Bubble, Ribbon Cross, Framimg
width & length, etc. It’s same parameter as well as 90 o visual QC.

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3.21 AUTO SORTER

FIG 3.23 AUTO SORTER

The automatic module sorting machine sport the machine sports the modules according to
test result. Easy Integration with the MES system the modules are arranged automatically.

3.22 PACKING AND DISPATCH

FIG 3.24 PACKING AND DISPATCH

31 modules are tied together and packed. 1 Box = 31 Modules.

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CH – 4 : HOW SOLAR CELL WORK ?

4.1 SOLAR CELL

A solar cell (also known as a photo-voltaic cell or PV cell) is defined as an electrical device
that converts light energy into electrical energy through the photo voltaic effect. A solar cell
is basically a p-n junction diode. Solar cells are a form of photoelectric cell, defined as a
device whose electrical characteristics – such as current, voltage, or resistance – vary when
exposed to light.

Individual solar cells can be combined to form modules commonly known as solar panels.
The common single junction silicon solar cell can produce a maximum open-circuit voltage
of approximately 0.5 to 0.6 volts.

4.2 CONSTRUCTION OF SOLAR CELL

The majority of solar photovoltaic cells, or PV cells, are made using silicon crystalline
wafers. The wafers can be one of two main types, monocrystalline (mono), or polycrystalline
(poly) also known as multi-crystalline.

FIG 4.1 CONSTRUCTION OF SOLAR CELL

A solar cell is a sandwich of two different layers of silicon that have been specially treated or
doped so they will let electricity flow through them in a particular way. The lower layer is
doped so it has slightly too few electrons. It's called p-type or positive-type silicon (because
electrons are negatively charged and this layer has too few of them). The upper layer is doped
the opposite way to give it slightly too many electrons. It's called n-type or negative-type

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silicon. ( You can read more about semiconductors and doping in our articles on transistors
and integrated circuits. )

When we place a layer of n-type silicon on a layer of p-type silicon, a barrier is created at the
junction of the two materials (the all-important border where the two kinds of silicon meet
up). No electrons can cross the barrier so, even if we connect this silicon sandwich to a
flashlight, no current will flow : the bulb will not light up. But if we shine light onto the
sandwich, something remarkable happens. We can think of the light as a stream of energetic
"light particles" called photons. As photons enter our sandwich, they give up their energy to
the atoms in the silicon. The incoming energy knocks electrons out of the lower, p-type layer
so they jump across the barrier to the n-type layer above and flow out around the circuit. The
more light that shines, the more electrons jump up and the more current flows Most of the
solar cells you'll see on people's roofs today are essentially just silicon sandwiches, specially
treated ("doped") to make them better electrical conductors. Scientists refer to these classic
solar cells as first-generation, largely to differentiate them from two different, more modern
technologies known as second- and third-generation. And also, here 3 type of main solar.

4.3 TYPES OF PHOTOVOLTAIC SOLAR CELL

FIG 4.2 TYPES OF PHOTOVOLTAIC SOLAR CELL

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4.4 WORKING PRINCIPLE OF SOLAR CELL

FIG 4.3 WORKING OF PV CELL

When light reaches the p-n junction, the light photons can easily enter in the junction,
through very thin p-type layer. The light energy, in the form of photons, supplies sufficient
energy to the junction to create a number of electron-hole pairs. The incident light breaks the
thermal equilibrium condition of the junction. The free electrons in the depletion region can
quickly come to the n-type side of the junction.

Similarly, the holes in the depletion can quickly come to the p-type side of the junction.
Once, the newly created free electrons come to the n-type side, cannot further cross the
junction because of barrier potential of the junction.

Similarly, the newly created holes once come to the p-type side cannot further cross the
junction became of same barrier potential of the junction. As the concentration of electrons
becomes higher in one side, i.e. n-type side of the junction and concentration of holes
becomes more in another side, i.e. the p-type side of the junction, the p-n junction will
behave.

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4.5 CONVECTIONAL SOLAR PANEL WITH SERIES CONNECTION

FIG 4.4 STRING CONNECTION

4.5.1 WORKING PRINCIPLE OF STRING MODULE

Bypass diodes are a standard addition to any crystalline PV module. The bypass diodes’
function is to eliminate the hot-spot phenomena which can damage PV cells and even cause
fire if the light hitting the surface of the PV cells in a module is not uniform. The bypass
diodes are usually placed on substrings of the PV module, one diode per up to 20 PV cells.
This configuration eliminates the creation of hot-spots and enables the PV modules to
operatewith high reliability throughout their lifetime. In addition to effectively fulfilling this
function, many people believe the bypass diodes are also effective in reducing power loss
dueto shading in PV installations. This is far from the truth. In this document we will analyze
several everyday scenarios and show how the bypass diodes can actually cause great power
loss.

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FIG 4.5 BATTERY

4.5.2 BENEFITS OF SWITCHING TO A HALF CUT SOLAR CELL

The reduction in power loss increases the fill factor (The ratio of maximum obtainable
Reduced Losses – The resistive losses in a half-cut solar cell is reduced compared tothe
traditional solar cells (Resistive losses are generated during conversion of solar energy into
electrical energy by solar cells).

In the half-cut solar technology, the cell is divided into halves which reduces the current
generating capacity by each cell by half, thus reducing the power loss,

P Loss= I2R

Where, P - Power ( Watt )

I - Current ( Amp )

R - Resistance ( Ohm )

The decrease in the current-carrying capacity results in the reduction of power losses. power
output to the product of open-circuit voltage and short circuit current), thus improving the
output efficiency of the solar panel.

More tolerance for shading : The half-cut solar cells is more resistant to the effect of shade on
the panels than the conventional full solar cell. In conventional full cell solar technology,
solar cells are wired together in a series combination. In this scheme, even if one cell gets
shaded or damaged, the entire row within that particular series wiring stops operating.

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In this technology, two sets of 60 series-connected solar cells each operating at 30V are
connected in parallel (As in parallel the voltage remains constant). This scheme results in
improved shading tolerance, as even if one cell gets shaded or damaged the other part will
still operate at its optimum.

Space requirement: The power generation capacity is increased in half cut solar cells as
compared to conventional solar cells. This enhanced power output results in a reduced
number of solar cells, thus saving the space required for installation. Half-cut solar cell
technology proves to be a good alternative for residential, commercial and industrial
locations with limited space.

4.6 DIFFERENT TYPES OF SOLAR CELL

There are 2 major types of solar panels available on the market today :

Monocrystaline, Polycrystaline

4.6.1 POLY CRYSTALLINE CELL

FIG 4.6 POLY CRYSTALLINE CELL

Poly crystalline silicon (also called: polysilicon, poly crystal, poly-Si or also: multi-Si,mcSi)
are manufactured from cast square ingots, produced by cooling and solidifying molten
silicon. The liquid silicon is poured into blocks which are cut into thin plates.
Thesolidification of the material results into cells that contain many crystals, making the
surface of the poly-Si/ mc-Si cell less perfect than its mono-Si counterpart. Due to these
defects, polycrystalline cells absorb less solar energy, produce consequently less electricity
and are thus less efficient than monocrystalline silicon (mono-Si) cells. Due to their slightly
lower efficiency, poly-Si/ mc-Si cells are conventionally a bit larger, resulting in comparably
larger PV modules, too. This factor has to be considered if space is limited. The standard size

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of poly-Si cells is 6 inch (=15.24 cm). As compared to mono-Si cells, they have a grainy
bluish coating appearance which is a result of the imperfect crystal structure of the cell. On
average, the conversion efficiency of poly-Si cells is between 16% and 19%.

4.6.2 MONOCRYSTALLINE CELL

These solar cells are also referred to as single crystalline cells. They are easily identifiable by
their deep black color and cut edges. Monocrystalline solar cells are also made from a very
pure form of silicon, making them the most efficient material when it comes to the
conversion of sunlight into energy.

Additionally, monocrystalline solar cells are also the most space-efficient form of silicon
solar cell. In fact, they take up the least space of any solar panel technology that is currently
on the market. They also have the great advantage of being the longest lasting solar cell
technology, with their life expectancy currently set at around half a century. As a result of
this, you will find that the majority of manufacturers will offer you warranties of up to 25
years on these solar panels, lasting half of their expected lifetime.

4.7 DIFFRENCE BETWEEN POLYCRYSTALLINE AND

MONOCRYSTALLINE

FIG 4.7 DIFFERENCE BETWEEN MONO AND POLY

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CH – 5 : ADVANTAGES, DISADVANTAGES, & FACTORS

AFFECTING OF SOLAR PANELS

5.1 FACTORS THAT AFFECT SOLAR PANELS EFFICIENCY

There are some factors that should be taken into consideration to guarantee theoptimal
efficiency of the solar panels.

 Energy conversion efficiency

 Solar shadings
 Orientation
 Temperature
 Inclination
 Latitude
 Operation and Monitoring
 Maintenance

5.2 ADVANTAGES

 Solar energy is a renewable energy source and reduces carbon emissions.

 Solar energy can reduce your home’s electricity bill.
 Solar panels have low maintenance costs.
 Solar energy can generate electricity in any climate.
 Technology Development.
 Solar Energy does not pollute.

5.3 DISADVANTAGES

 The high initial costs of installing panels.

 Solar panels have less efficiency on cloudy day.
 Solar panels are dependent on sunlight.
 Solar energy storage is expensive.
 Uses a lot of space.

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CH – 6 : CONCLUSION
On the whole, this internship was useful experience. I have gained new knowledge and skills.
I achieved several of our learning goals related to our study. Solar Energy is a clean, pollution
free renewable source of energy. Development of this source of energy requires an accurate
detailed long-term knowledge of the potential taking into account seasonal variations.
Directly use of solar energy is the only renewable means capable of ultimately supplanting
current global supply from non-renewable sources. It was an eye opener to how a Photo
voltaic Module is manufactured in real. This internship gives the exposes to both Quality and
Manufacturing operations.

This experience not only equips them with technical expertise but also instills a profound
appreciation for the impact of innovation in creating a cleaner, safer, and more efficient
future.

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REFERENCES
WEBSITE

1. http://en.jinchencorp.com
2. https://goldisolar.com
3. https://youtube.com/playlist?list=PLSO_8SOeAq1N0600PCFO97ycfwQ5PPMLm&si
=OllG1CdqRanwNgkZ
4. https://www.sfpe.org/publications/periodicals/sfpeeuropedigital/sfpeeurope21/europei
ssue21feature5

BOOKS

1. Chetan Singh Solanki“Solar Photo voltaic Fundamentals, Technology and

Application”.
2. Solar Electricity Basics: A Green Energy Guide Daniel D. Chiras.

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