STATE OF THE ART

MANUFACTURING FACILITY

Bluebird Solar panel manufacturing facility that is fully automated and has provided various residential, commercial and industrial solar power plant projects with best quality PV Modules. Bluebird solar constantly strives to deliver solar power solutions that can transform solar energy into power in efficient way. Our products demonstrate innovative technology and match the globally accepted standards of quality, longevity, performance and environmental sustainability.

Our Manufacturing Unit

The process with which panels are manufactured and the way quality is controlled determines the quality of the solar photovoltaic module, which in turn is very crucial to achieve the maximum possible efficiency & output. We use A Grade Solar cells and other raw materials are also procured from Tier one suppliers. The process and quality control also determines the life of the solar panel. Therefore, every item is stringently tested for conformance to specifications by our production team. On other hand our purchase team makes sure about the uniformity of the cell color, its quality, electrical performance and overall finish of other raw materials. We manufacture a wide range of Polycrystalline and Monocrystalline or Mono PERC Solar Panels for your rooftop solar power plants for homes, offices, industrial and large scale utility projects.

Research & Development

Assisting our endeavors are the intensive R&D, innovation and strict conformance to highest standards of product excellence. Our R&D is a strategic process that ensures all our products match the standards of Quality, Longevity, Performance & Environmental Sustainability. Consequently, the products have good price – performance ratio and they are safe, and easy to install and maintain.

FACILITIES AT FACTORY

Tabber Stringer from Eco progetti with an output of 700 cells per hour, patented soldering technology, and additional feature to process cut cells from 40mm

Fully automatic Laminator with Teflon release sheet on top and bottom; Automatic brush cleaning, Automatic pneumatic membrane tensioning and Safety protection.

100% EL Inspection Pre and Post lamination with high resolution Cameras.(250micron/pixel)

Automatic hydraulic framing machine with crimping feature for robust frame locking

100% Power-backup through UPS and generator system from Consul.

In house Laboratory with set up for Hi-Pot Test, Wet Leakage Test, Gel Test, Pull Test, Peel Test, Ground Bound Test, Impact Test, Load Test.

LED based, Patented Flash test technology for Cells and Modules (AAA+ grade Cell Tester & Sun Simulator from Eco progetti) with LED based patented flash test technology for electrical testing for cells and modules at STC.

Screw Type Air-compressor coupled with Refrigerated Air Dryer from ElGi.

100% Visual inspection Pre and Post lamination

Fully automatic conveyorized system for Material Movement.

Solar Panel Manufacturing Process

Cell Testing & Cutting

Solar cells are checked and inspected using advanced optical or imaging sensors to ensure all the components are located correctly and the cells wafers, which are very delicate, are not damaged or cracked. and with the help of a laser machine they cut into different dimension depending on the wattage of Solar Panel. Cutting is skipped where full size cell is required.

2. Tabbing & Stringing

To make a solar cell array the first step is tabbing and stringing. Multiple ribbons are first soldered to the front and back surfaces of individual PV cells (tabbing). After tabbing the stringer subsystem which solders the front side ribbons of a first PV cell to the back side ribbons of the neighboring PV cell to form strings of PV cells wired in series.

3. Lay-up & Bussing

In this process the solar cell strings from the stringer are placed on layup table above EVA-covered glass. A small pieces of adhesive tape is applied the on the cells to hold them in place. This process is called lay-up. Now second layer of EVA sheet, polymer back-sheet is placed on solar cell array. The bus wire is soldered with tab wires .

4. Visual Inspection

Visual inspection of a PV module performed before the module has been subjected to environmental, electrical, or mechanical stress testing in the laboratory. This visual inspection is done by looking at the glass underneath to check the PV module alignment, cell matrix and presence of dust particle or other element on cell.

5. Electroluminescence Testing

Bluebird solar panels are 100% EL tested. Electroluminescence technology allows asset us to clearly identify the defects in the modules that are invisible otherwise like cell damage / microcracks in the inner structures of the solar cells that can cause underperformance or hot spots in the future. This also checks inactive strings, cell breakage and fissures.

6. Lamination

The encapsulation of the solar cells through lamination is a crucial step in solar panel manufacturing. It ensures longevity of the solar cells of the PV Module. During the lamination process, the prepared 5-layer module is placed in the lamination machine and heated to max. 135°C for 20 -25 minutes. The laminate that comes out is completely sealed and is left for 10-15 minutes to cool down till it reaches room temperature.

7. Framing

Solar panel framing refers to the process of attaching protective and strengthening aluminum frames to the PV laminates of a solar panel. The frame that slides around the laminate will be filled with silicon adhesive. Then, the frame will be pressed around the laminate. The holes on the back of a PV frame make it easy to install the panels on a mounting structure.

8. Sun Simulation Testing

Sun SimulatorTest or Flash Test measure the output performance of a solar PV module. During a flash test the PV module is exposed to a short (1ms to 30 ms), bright (100 mW per sq. cm) flash of light whose output spectrum is as close to the spectrum of the sun as possible. Module parameters are measured at standard test conditions (STC). The results of the flash test are compared to the data specifications of the PV module type which are then printed on the label and pasted at the back of solar panel.

9. Fixing Junction Box

An IP68 rated PV junction box is attached to the back of the solar panel with silicon adhesive. It is the output interface of the solar panel. The diodes inside the junction box keeps the power flow going in one direction, and prevent current from feeding back into the panels when there's no sunshine. it is connected to MC4 connectors with the help of 4mm cables.

10. Cleaning & Packing

The module is then wiped to remove any traces of dust, foreign particles or extra sealant. Being high-priced products, we cannot ignore the significance of correct, safe and efficient packaging of the solar panels. So, Bluebird solar panels are then are then stacked in a boxes. Separators are placed between each module and extra protections are added to the four corners of each module stack. In some cases, modules are also packed in individual cartons boxes to be packed into a large master carton box. Palette packing is also done on demand from customer or on basis of order quantity .