SUNPOWER Back Contact Cell Welding Machine SL-1000 Overview

       ▶  

The SL-1000 SUNPOWER Back Contact Cell Welding Machine is a fully automatic stringer engineered specifically for welding back contact (IBC/SUNPOWER) solar cell strings. Unlike conventional tabber stringers designed for front-busbar cells, the SL-1000 addresses the unique interconnection challenge of back contact cells where both positive and negative electrodes are located on the rear surface. This machine integrates advanced electromagnetic welding, high-precision CCD vision inspection, and SCARA four-axis robotic positioning to deliver reliable, high-throughput back contact cell string production.

The complete system includes A/B dual cell loading boxes, a loading translational mechanical arm, a cell transmission table, a CCD + four-axis robot detection and positioning system, a welding transmission table, an electromagnetic welding module, welding ribbon material boxes, a welding ribbon transport mechanism, a welding ribbon positioning table, double welding ribbon gluing tables, a welding ribbon placement module, and a fully automatic unloading mechanism with conveyor belt, cell string sucker, clean paper sucker, cell string box, and clean paper box.

Working Principle:The loading translational mechanical arm picks solar cells from the dual cell boxes and places them onto the cell transfer station, while simultaneously collecting interleaving paper into the paper collection box. The transfer station conveys cells to the CCD detection and positioning station. The CCD camera captures coordinate information and sends it to the SCARA four-axis robot, which corrects cell orientation and places each cell precisely onto the welding transfer station. The welding transfer station features multiple independently controlled temperature zones for optimal thermal management during string welding.

Meanwhile, the welding ribbon transport mechanism picks pre-cut solder ribbons from the ribbon material box and delivers them to the positioning table, then transfers them to the ribbon placement table. The ribbon laying mechanism and four-axis robot alternate operations to complete ribbon placement and cell stacking. The assembled ribbon-and-cell array travels from the welding transfer station to the electromagnetic welding station, where the electromagnetic welding module completes soldering. Finished cell strings are transported to the unloading station via conveyor belt, and the unloading mechanism loads strings into the cell string box with clean paper interleaving to prevent scratching.

Technical Parameters

Key Components and Suppliers

Technical Advantages

Electromagnetic Welding Technology

• Non-contact electromagnetic heating provides uniform heat distribution across all solder joints, minimizing thermal stress on delicate back contact cells

• Welding power is fully adjustable to accommodate different ribbon thicknesses and solder paste types

• Dual welding heads increase throughput while maintaining consistent weld quality

• Air cooling and compressed air assisted cooling ensure rapid cycle times and prevent cell overheating

High-Precision CCD + SCARA Robot Positioning

• 800W pixel industrial camera accurately detects cell position, missing corners, and incorrect placement before welding

• SCARA four-axis robot individually corrects up to 4 cells at a time with +/-0.10 mm positioning accuracy

• Closed-loop feedback between CCD vision and robot ensures every cell is placed within +/-0.2 mm tolerance

• Significantly reduces cell breakage rate to 0.2% or less with Class A cells

Flexible Multi-Size Cell Compatibility

• Supports five cell specifications: 125x125 mm, 125x62.5 mm, 125x41.67 mm, 166x166 mm, and 166x41.5 mm

• Adjustable material box accommodates different cell dimensions with simple mechanical adjustment

• Tooling fixture changeover for 166 mm series cells is straightforward and quick

• Maximum string length of 1600 mm covers a wide range of back contact module designs

Fully Automatic Material Handling

• A/B dual cell loading boxes with up to 4 small boxes per station allow continuous production with minimal downtime

• Automatic paper picking and interleaving prevents cell and string surface damage

• Servo-driven loading mechanical arm with high vacuum traceless suction cups ensures gentle, reliable cell handling

• Fully automatic unloading with clean paper insertion protects finished cell strings from scratching

Intelligent Temperature and Process Control

• Multiple independently controlled temperature zones on the welding transfer station enable optimized thermal profiles

• Real-time temperature monitoring with PID control and adjustment maintains stable welding conditions

• Zoned vacuum adsorption system secures cells and ribbons during transport and welding

• Teflon belt conveyor prevents ribbon adhesion and ensures smooth material flow

User-Friendly Software and Operation

• Dedicated software with friendly HMI touchscreen interface for easy parameter editing and process modification

• Centralized numerical control allows all key parameters to be set and saved through the software interface

• Hierarchical password protection separates operation mode and setting mode for safety

• Real-time fault alarm system enables quick diagnosis and minimal production interruption

Applications

Back Contact (IBC / SUNPOWER) Solar Module Production

The SL-1000 is purpose-built for manufacturing solar modules using SUNPOWER-type back contact cells. It is the core stringing equipment in any IBC or back contact solar panel production line, handling the critical step of interconnecting cells where all busbars are on the rear surface.

1/3 Cut and Full-Size Back Contact Cell Stringing

With support for both full-size (125x125 mm, 166x166 mm) and cut cells (125x62.5 mm, 125x41.67 mm, 166x41.5 mm), the SL-1000 serves production lines making standard back contact modules as well as advanced shingled or high-density back contact module designs.

High-Efficiency Premium Solar Panel Manufacturing

Back contact cells deliver higher efficiency and superior aesthetics due to the absence of front-side busbars. The SL-1000 enables manufacturers to produce premium, all-black solar panels targeting residential rooftop, commercial, and BIPV (Building Integrated Photovoltaic) markets.

Pilot Lines and R&D Facilities

With its adjustable welding parameters, flexible cell size compatibility, and detailed process monitoring, the SL-1000 is also well suited for research institutions and pilot production lines developing next-generation back contact cell technologies.

Solar Module Production Line Integration

The SL-1000 integrates seamlessly with upstream and downstream equipment in a complete solar panel production line, including cell laser cutting machines, layup machines, laminators, framing machines, EL testers, IV testers, and sun simulators supplied by Ooitech.

Site Preparation Requirements

Facility Requirements

• Flat ground surface, low-dust environment, away from vibration sources and strong electromagnetic interference

• Equipment footprint: 5390 x 2200 x 1800 mm (L x W x H)

• Equipment weight: 1650 kg

• Transport tools required: forklift and hydraulic tow truck

Environmental Conditions

• Ambient temperature: 20-25 degrees C

• Relative humidity: less than 85% (non-condensation)

• Air cleanliness: not less than 300,000 levels (ISO Class 8)

Power Supply

• Single machine independent power supply, three-phase five-wire (380V/50Hz), capacity 5 kW

• Purified regulated power supply recommended if grid voltage is unstable

• Earth protection terminal connection required

• Leakage protection switch installation required

Compressed Air Supply

• Freeze-dried compressed air, pressure 6-8 Bar, flow rate >=400 L/min

• Dust particles <=0.5 um

• High-pressure air source pipe diameter: 12 mm

Materials to Prepare

• Acetone, alcohol, absorbent cotton, dust-free cloth

• Sample finished and semi-finished back contact battery cells

• Matching special welding ribbons

• Designated full-time equipment operators

Warranty and After-Sales Service

• One year warranty after successful installation or 16 months from Bill of Lading date, whichever comes first

• During warranty period, Ooitech provides timely maintenance services and necessary spare parts free of charge (excluding consumables); spare parts courier cost is the responsibility of the buyer

• If buyer's engineers cannot resolve an issue during the warranty period, Ooitech will dispatch engineers to the buyer's facility; round-trip tickets, local transportation, hotel, and food costs in the buyer's city are paid by the buyer

• Warranty does not cover damage from misuse, abuse, unauthorized modification, or operation inconsistent with the operation manual

• After warranty period, Ooitech continues to provide free online technical support and guidance, with spare parts supplied at favorable prices; on-site service visits after warranty require buyer to cover travel, visa, accommodation, food, and labor costs per Ooitech standards

• Consumable parts are available for purchase at any time

Contact Ooitech for Back Contact Cell Welding Machine

Ooitech, founded in 2013, is a professional turnkey solar energy solution provider with more than 10 years of experience in the PV industry. Our solar panel production line equipment has been exported to Poland, Hungary, Korea, Mexico, Egypt, Algeria, India, Saudi Arabia, Syria, Kazakhstan, and many other countries worldwide.

Our turnkey solutions include:

• 5MW to 1GW solar module production line design, delivery, and commissioning

• Upgrade traditional PV lines to the newest MBB, PERC, TOPCon, IBC, HJT, and back contact production lines

• Factory construction planning and facility layout design

• Raw material sourcing guidance

• Production procedure training and solar power station installation assistance

If you are looking for a reliable SUNPOWER back contact cell welding machine or a complete back contact solar panel production line, contact Ooitech today for professional consultation and a competitive quotation.

Email: [email protected]Phone: +8618571646990WhatsApp: +8615961592660Head Office: Wuhan Yangtze River Center, Wuhan, ChinaWebsite: www.ooitech.comYouTube Channel: www.youtube.com/ooitechMBB Full Automatic Solar Panel Production Line Video: Watch on YouTubeDownload Ooitech Catalogue: Click HereDownload Ooitech Company Profile: Click Here

Subscribe to the Ooitech YouTube channel and stay updated with the latest solar panel manufacturing technology, equipment demonstrations, and factory setup guides.