Blog

26
Mar 2024

FACTORY FINDINGS

Glass Scratch and Breakage

This instance of glass scratches was observed when factory personnel mishandled modules, accidentally scraping them against equipment of the production line. Also, glass scratches could potentially originate from the glass manufacturing process. Hence, it is vital to conduct a comprehensive incoming material quality check to identify and address this defect. 

Module glass breakage was recorded during improper forklift handling of pallets. The forklift forks failed to extend completely beneath the module pallet, therefore not reaching the support boards on the opposite side. As a result, the weight load was primarily absorbed by the center boards, causing them to deform and ultimately leading to the breakage of the module glass at the bottom. Forklift handling training is crucial.

Cell Cracks
We identified explosive spots and cracks on the cell due to tin accumulation during lamination. This is caused by a failure to timely clean the flux crystals in the module guide grooves, leading to a blockage in the air amplifier and insufficient cooling time during lamination.

Insufficient Maximum Power
The abnormal low power in the PV module test is attributed to the weak “negative pole” soldering of the junction box. This issue arises from the personnel’s failure to timely clean the head of the soldering machine.

Additionally, the newly replaced soldering head has poor contact, and the lengthy downtime required for soldering head replacement contributes to equipment instability and delays .

PV Module Grid Broken and Weak Soldering in EL Imaging
This defect is attributed to the failure in timely replacing the damaged cooling fan and soldering machine indenter. The delayed replacement of the cooling fan leads to elevated soldering machine temperatures, while the indenter, when not promptly replaced, becomes ineffective in pressing the soldering strip.

Additionally, worn clamping jaws result in the soldering ribbon bending after being pulled. Furthermore, the EL staff lacks training on the standard operation of EL sampling checks.

We also identified additional defects during various stages of the manufacturing process inspections. These include an inadequate calibration of module maximum power test during the final quality control check, back-sheet offset in lamination caused by incomplete coverage of module edges with tapes, soldering tin residue inside the junction box leading to damage, damage to pallet corners during packing, and silicone spillage resulting from abnormal framing, etc.