Assembly cell for the manufacturing of flexible solar modules in building integrated photovoltaics

The current use of photovoltaics is often limited to the utilization of roof surfaces or ground-mounted systems. In particular, building integrated photovoltaics (BIPV) have enormous potential to make energy production more sustainable, because the energy is generated where it is used. However, most of these modules either do not meet the aesthetic requirements of the architects as well as the building owner or are uneconomical, since visually appealing building-integrated PV modules cost several times more than standard modules. In this article, an approach for a (semi) automated assembly line that allows geometry- and material-flexible manufacturing of PV modules is presented. The challenges in automating the flexible manufacturing processes include mainly the handling of limp components and the complexity of geometry variability. Appropriate gripper systems are required to ensure safe and reliable handling of the components. A gripper developed in this article offers the ability to flexibly deposit solar strings. Preliminary tests show that 66% of all conducted trials meet the accuracy requirements.