Introduction
Manufacturing 4000 roof tiles for Freesuns has been quite the challenge. Some of what we learned during these manufacturing days went into the design of the Nexus tool to support Fraunhofer ISE in their pilot line for PV modules based on the Shingle Matrix Technology for integrated applications.
Involved partners
M10, Fraunhofer ISE
The primary goal was to collaboratively develop and build a machine with the ISE capable of processing a wide variety of matrix sizes. The system was designed to handle either a single large matrix or multiple smaller ones on a maximum working area of 1300×2300 mm.
Furthermore, an automated label applicator was integrated to place labels at freely configurable positions on the matrix without causing any damage. A specialized dispensing unit also enables the machine to apply conductive adhesives, either directly onto the matrices or onto metal foils inserted in their place. A key requirement, particularly for the production of solar roof tiles, was to achieve a high degree of parallelization to significantly increase the system’s overall throughput.
Ultimately, a system featuring a single axis and a multi-tool head was designed, utilizing the materials provided by the Fraunhofer ISE. A labeling unit and a dispenser can be mounted in parallel on this tool head. Through an HMI, recipes for labeling or dispensing can be created directly or loaded from an external source. This flexibility allows the planning process to be shifted to a separate workstation.
Before the project’s conclusion, the system must be fitted with the necessary safety guards before it can be put into final operation. Afterward, it will support the module production at the Fraunhofer ISE with enhanced precision and throughput, replacing several processes that were previously performed manually.
