HDX200-P Half Cell Auto Bussing Machine – High-Speed Automatic Busbar Welding for Solar Module Production
The HDX200-P Half Cell Auto Bussing Machine is an advanced automatic busbar welding system engineered for high-throughput solar module production lines. Designed to handle the critical process of welding busbars to cell strings in half-cut and tri-cut module configurations, this machine employs an innovative overhead suspension welding method that separates the cell strings from the glass substrate, lifts them to a precise working height via a gantry crane mechanism, and welds the head, middle, and tail busbars with exceptional accuracy.
This bussing machine supports rolled busbar ribbon feeding with automatic cutting and bending, producing both U-type and L-type leads with upward bending orientation. It is fully compatible with mainstream solar cell formats from 156mm to 230mm, supporting 5 to 30 busbar MBB configurations, making it an ideal solution for PERC, TOPCon, IBC, and other advanced cell technologies. With a cycle time of 18 seconds or less and an overall yield rate exceeding 99%, the HDX200-P delivers the reliability and speed required for modern gigawatt-scale solar panel manufacturing.
Technical Specifications
Performance Parameters
| Parameter | Specification |
|---|
| Cycle Time | ≤18 seconds |
| Utilization Rate | ≥99% |
| Overall Yield Rate | ≥99% (incoming component layout accuracy within ±3mm) |
| Cell Breakage Rate | <0.02% (calculated per cell) |
Compatibility and Dimensions
| Parameter | Specification |
|---|
| Maximum Compatible Module Size | 1650×900 – 2500×1500mm |
| Compatible Cell Size | 156–230mm |
| Compatible Busbar Count | 5–30 busbars (MBB) |
| Standard Configuration | 182mm cell / full grid line compatibility |
| Module Layouts (Half-Cut) | 6×10, 6×11, 6×12, 6×13 half cells ×2 |
| Cell Spacing | -0.5 to 4mm |
| String Spacing | 1–6mm |
| Tri-Cut Upgrade (Paid) | 5×10, 6×10, 5×15, 6×15 tri-cut cells ×2 (210mm) |
Feeding and Positioning System
| Parameter | Specification |
|---|
| Number of Conveyor Belts | 4 |
| Feeding Method | Long-side component feeding |
| Component Conveying | Variable frequency motor + belt drive |
| Maximum Incoming Deviation | Glass center deviation<30mm |
| Vision System | 9 cameras, positioning accuracy<0.2mm, range ±6mm |
| Positioning Mechanism | Electric cylinder / servo module |
| Number of Positioning Points | ≥5 |
| Positioning Method | Mechanical positioning |
Busbar Making System
| Parameter | Specification |
|---|
| Loading Method | Roll feeding with automatic cutting and bending |
| Roll Shaft Hole | 20–25mm |
| Roll Outer Diameter | <210mm |
| Roll Weight Capacity | ≤13kg |
| Compatible Busbar Width | 4mm, 5mm, 6mm, 8mm |
| Compatible Busbar Thickness | 0.18–0.4mm |
| Cutting Accuracy | ≤0.5mm |
| Lead Bending Direction | Vertically upward |
| Lead Angle and Deviation | 90° ± 2–3° |
| Transport Method | Servo motor + vacuum suction |
| Positioning Method | Mechanical positioning + vacuum adsorption |
| Positioning Accuracy | <0.5mm |
| Busbar to Cell Distance | 2–10mm adjustable |
| Busbar Overhang Length Error | ≤2mm |
Welding System
| Parameter | Specification |
|---|
| Welding Method | Electromagnetic induction welding |
| Number of Welding Heads | 18 |
| Welding Head Control | Current control / time control |
| Welding Heating Time | ≤2 seconds |
| Temperature Control Accuracy | ±5°C |
| Welding Tension | ≥2N/mm (busbar to ribbon) |
| Welding Contact Area | ≥80% |
| Weld Scar Size | ≥4×4mm² |
| Solder Appearance | Full and saturated tin fusion |
| Welding Head Lifespan | ≥1 year |
| Welding Head Replacement Time | ≤60 minutes |
| Cooling Method | Forced air cooling |
Control System and Utilities
| Parameter | Specification |
|---|
| Control System | PC + PLC (5% I/O points reserved) |
| Electrical Components | Huichuan (Inovance) |
| Communication Interface | MES compatible |
| Power Supply | Three-phase five-wire 380V/220V, 50/60Hz |
| Power Consumption | Peak 40kW, average approximately 20kW |
| Compressed Air | 0.6–0.8MPa, 2000L/min |
| Machine Dimensions | 4700 × 2200 × 2200mm |
| Alarm System | Tri-color indicator light + buzzer |
Standard Spare Parts Included
| No. | Item | Quantity | Remarks |
|---|
| 1 | Sensor | 2 | OMRON |
| 2 | Vacuum Suction Cup | 10 | Custom made |
| 3 | Electromagnetic Induction Welding Head | 1 | Custom made |
| 4 | Power Driver Board | 1 | Custom made |
| 5 | Relay Base | 1 | – |
| 6 | Relay Body | 1 | – |
Technical Advantages
Electromagnetic Induction Welding TechnologyThe HDX200-P utilizes electromagnetic induction welding rather than conventional contact soldering. This advanced method heats only the busbar and ribbon interface in under 2 seconds, minimizing thermal stress on solar cells while achieving full, saturated solder joints with over 80% contact area coverage. The welding temperature is precisely controlled within ±5°C to ensure consistent quality across every module.
High-Precision 9-Camera Vision AlignmentEquipped with 9 high-resolution cameras, the machine delivers vision-guided positioning accuracy of less than 0.2mm within a ±6mm correction range. This ensures precise busbar placement even when incoming module layouts have slight deviations, directly contributing to the exceptional 99%+ yield rate.
18 Independent Welding Heads with Intelligent ControlThe system features 18 independently controlled welding heads, each with individual current and time control, enabling simultaneous welding of multiple busbar connection points. This parallel processing architecture is fundamental to achieving the rapid ≤18-second cycle time without compromising weld quality.
Versatile Cell and Module CompatibilityStandard configuration supports 182mm cells with full grid line compatibility, accommodating 5 to 30 busbar MBB formats. The machine handles half-cut module layouts from 6×10 to 6×13 configurations. An optional paid upgrade extends compatibility to 210mm tri-cut cell formats (5×10, 6×10, 5×15, 6×15), future-proofing your investment for evolving cell technology trends.
Fully Automatic Busbar PreparationThe integrated busbar making system accepts rolled ribbon stock and performs automatic feeding, precision cutting (≤0.5mm accuracy), and upward bending of U-type and L-type leads at 90° (±2–3°). Compatible busbar widths of 4mm, 5mm, 6mm, and 8mm and thicknesses of 0.18–0.4mm cover all mainstream module designs.
Innovative Overhead Suspension WeldingThe unique overhead crane-based cell string lifting and suspension welding approach physically separates the cell strings from the glass during the welding process. This prevents glass contamination, reduces thermal impact on encapsulant layers, and allows precise access to head, middle, and tail busbar positions for center-lead-out module configurations.
Ultra-Low Cell Breakage RateWith a cell breakage rate of less than 0.02%, the HDX200-P incorporates servo-driven vacuum suction handling and mechanical positioning with vacuum adsorption to ensure gentle yet secure cell string manipulation throughout the entire bussing process.
MES-Ready Communication and Reliable ControlThe PC + PLC control architecture with 5% reserved I/O points provides flexible integration capability. Standard MES communication interfaces enable seamless connection to factory-level manufacturing execution systems for real-time production monitoring, quality tracing, and data-driven process optimization.
Product Applications
Half-Cut Cell Solar Module Production LinesThe HDX200-P is purpose-built for half-cut cell module assembly, handling standard configurations of 6 strings with 10, 11, 12, or 13 half cells per string in dual-segment layouts. It supports the complete range of mainstream module sizes from 1650×900mm to 2500×1500mm, serving both residential and utility-scale panel formats.
Multi-Busbar (MBB) PERC and TOPCon Module ManufacturingFully compatible with 5 to 30 busbar designs, this bussing machine integrates seamlessly into MBB production lines for both PERC and TOPCon cell technologies. The electromagnetic induction welding method is particularly advantageous for high-efficiency cell types where minimal thermal exposure is critical to preserving cell performance.
Tri-Cut Cell Module Production (Upgrade Option)With the optional upgrade package, the machine extends its capabilities to 210mm tri-cut cell formats, supporting 5×10, 6×10, 5×15, and 6×15 configurations. This makes the HDX200-P adaptable to emerging large-format module designs that maximize power density and reduce BOS costs.
Center Lead-Out Module ConfigurationsSpecifically engineered for center lead-out (middle wire exit) module designs, the machine welds head, middle, and tail busbars in a single automated process, supporting the electrical architecture required by modern high-power module designs with optimized current paths.
High-Volume Gigawatt-Scale Solar Panel FactoriesWith its ≤18-second cycle time, ≥99% utilization rate, and ≥99% yield rate, the HDX200-P is designed for integration into fully automated, high-capacity solar panel production lines ranging from 100MW to 1GW+ annual capacity. The machine pairs perfectly with upstream tabber stringers and downstream EL testers and laminators.
Flexible and Upgradable Manufacturing FacilitiesFor manufacturers planning to transition between cell formats, the HDX200-P offers a cost-effective upgrade path. Switching between same-size cells with different grid patterns requires only pad plate replacement, while changing between different cell dimensions (156mm, 158mm, 18Xmm, 210mm) involves welding head and pad plate replacement with hardware adjustments.
Contact Us to Get Your HDX200-P Bussing Machine
Ooitech specializes in providing complete solar panel production line solutions ranging from 5MW to 1GW capacity. As your trusted partner for solar module manufacturing equipment, we deliver not just machinery but comprehensive support including equipment design, delivery, installation, operator training, raw material sourcing, and after-sales service.
Whether you are building a new solar panel factory or upgrading an existing production line with the latest bussing technology, our team of experts is ready to help you select the right configuration of the HDX200-P Half Cell Auto Bussing Machine for your specific production requirements.
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