Vacuum Tube Lifter for Rational Quality Control in PV Production

20.05.2010

While production processes for solar components are almost entirely automated, the logistics for units that are ready for assembly is often neglected. In this area, vacuum handling technology provides greater economy in the handling of collectors and modules.

The imminent end of subsidies and the radical changes this will bring to the solar heat and photovoltaic industries is forcing manufacturers to make production more efficient. One way to do this is by making individual process steps faster, while another is to eliminate unproductive downtime. While the handling of individual components such as wafers and strings has been fully automated for a long time, the units ready for assembly are often still handled manually. The following application report shows that vacuum technology can not only be used to rationalize automated processes, but also manual handling of solar heat collectors and photovoltaic modules. At Somont GmbH, a vacuum tube lifter is used to do this. The company, based in Freiburg (Germany), specializes in the development, production and sales of high-speed solar cell soldering systems. Somont responded to its customers' growing demands for efficiency and economy by investing in a new generation of machines and systems: "Rapid". The use of high-speed soldering technology was making deficits all the more obvious during the manual final inspection process.

Gentle vacuum-based handling that leaves no marks

While the technically demanding production of solar modules is almost fully automated, for its final quality controls, Somont continues to rely on the expertise of its experienced employees. If a module is recognized as defective, it is manually picked out and placed on a pallet set up for that purpose. Up to now, this was done by removing the 17-kg module from the production system's conveyor line, swiveling it by 90° and putting it down in an upright position. Manual handling of the faulty modules used to lead to an (excessive) physical burden on employees, increasing the risk that they would fall ill or be unable to work. That is why Somont made an effort to introduce a pragmatic handling concept that would be seamlessly integrated in the production process and would not change the material flow, as such. The company opted for a vacuum handling system that consisted of a vacuum tube lifter with a 90° swiveling unit, mounted on a column-mounted slewing crane with a long jib. Their partner for implementing the entire system was J. Schmalz GmbH, the vacuum specialist. Somont was already using vacuum components in its production systems and therefore knew that Schmalz had the necessary knowledge of the industry and processes.

Cost-effective solution from the standard modular components system

From the standard modular components for vacuum tube lifters, the system consultants from Schmalz configured an immediately impressive complete package. They chose a JumboErgo 45 vacuum tube lifter with a PSE pneumatic swiveling unit, a quadruple suction pad and a column-mounted slewing crane specially developed for the Jumbo tube lifter. Although the PSE pneumatic swiveling unit reduces the lifting capacity of the vacuum tube lifter, a maximum load of 30 kg still provides sufficient reserves. The lifting tube provides a stroke length of 1,810 mm through precise evacuation and venting. The vacuum is supplied by a powerful, frequency-controlled SBV blower with a suction capacity of 185 m³/hour, which generates a vacuum of -520 bar. The operating unit, with a handle length of 500 mm and twist-grip operation, allows a pleasant and at the same time ergonomic working position. Two additional buttons on the operator handle can be used to easily control the PSE pneumatic swiveling unit, and thus the swiveling process, into the vertical or horizontal position. During this process, the photovoltaic modules are held by a quadruple suction pad made up of a longitudinal beam that is 1,200 mm long, two crossbeams of a length of 800 mm and four SPU suction plates. The suction plates are made of NBR, the standard material, and are equipped with special suction plate covers protecting the sensitive modules from marks. The quick and easy replacement of the suction plate covers guarantees the tube lifter's top operational readiness. This solution is as simple as it is cost-effective. The blower box for reducing noise pressure levels creates a pleasant, quiet working environment.

More efficiency in quality control

The complete vacuum handling system is attached to a column-mounted slewing crane with a jib length of 4,000 mm and a jib height of 3,000 mm (lower edge of jib). Due to the comparatively large operating range and the maximum swivel angle of 270°, all relevant areas, from the system conveyor belt to the pallet storage space, can be reached without difficulty. The crane jib of the column-mounted slewing crane is equipped with an aluminum crane rail, moves extremely easily and is extraordinarily easy to maneuver. The entire system allows sensitive yet quick handling of the unwieldy modules (1,300 mm x 875 mm x 6 mm) and ensures safety and an ergonomic position at all working heights. This not only increases productivity in the quality control division, but also makes work much easier for the operator. Since this also prevents quick fatigue and health risks, Somont's investment in the vacuum tube lifter quickly paid off.

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