Welding Applications

 

Ultrasonic welding application of Amorphous PV
 
Intro

Source:www.Ecotopia.com/ASES/Solar2006
 

Renewable Energy

Accompanying with the ever increasing petroleum price day by day, the application rate of the emerging substitute energy sources are increasing gradually as well. At present, the new energy markets include solar energy, wind power, tide and ocean currents, geothermal energy, hydroelectric power and biomass energy etc., especially the solar energy development is prosperous nowadays in the entire emerging energy market.



Source:www.Ecotopia.com/ASES/Solar2006
 

PV--An high growth industry

However, in view of the development tendency of future substitute energy resources, our demands for petroleum will be gradually decreased in approx. 4% very year, while our demands for solar energy resources will be gradually increased in approx. 50% ever year.



Source:www.Ecotopia.com/ASES/Solar2006
 

Awakens!!!

Here, we must pay more attention to the entire global petroleum market tendency. At present the world has the highest demand on petroleum consumption, but the solar energy is a new energy resource which is worthy for us to use it. Therefore, there will be a big increasing demand on solar energy resources in the years to come.



Source:www.Ecotopia.com/ASES/Solar2006
 

In 2010 the global output value of the solar energy and photocell products will be exceeded to US$ 70,000,000,000

According to the current analysis on solar energy markets, the global solar energy power generation output may reach to 2.3GW. It concentrates mainly in the European market, including Germany and Spain etc. countries, but in the American market, its main market is U.S.A. In the Asian markets, Japan is one of the most popular countries developing the solar energy, even South Korea, India and China have actively joined in these emerging energy industry. Thus we can foresee that there are already large demands on solar energies in the markets. In addition, according to the current market analysis made by Morgan Stanley, it is estimated that in 2010 the global output value of the solar energy and photocell products will be exceeded to US$ 70,000,000,000 which is worthy for us to pay a more closer attention to this fact.

   

Production of Amorphous PV

In the fields of manufacturing solar panels, it refers to a kind of semiconductor manufacture, including the coating, forming and cutting of PN semiconductor membranes. In order to induce the current generated by solar panels effectively, at the last stage of completing the solar modules it relies mainly on the ultrasonic welding of the electrodes.

 


Theory of Ultrasonic Welding

 

Ultrasonic metal welding is based esstinally on high-frequency mechanical to friction overlap the same or different metl materials and to press the welding horn with proper pressure down to the parts making friction on the metal surfaces for welding. No welding additive is required.

This is a special welder designed for welding the electrode of Amorphous PV, base on the ultrasonic metal welding principles, to generate high frequency vibration energy so as to weld the solar energy collection plates (glasses) coated with aluminum together with the aluminum foil. Because the welding method does not use any solder flux, therefore, the resistance of the welding area (joint) is very low, thus it will not generate heat during power loading and/or discharge, so that the service life of the end products can be extended remarkably.

 

Old Welding Technology
 

 
The width of welding area (joint) is about 1-2 mm. If we look closer, except for the insufficient width of welding area, the linearity and stability of welding still need to be improved.

 


Improved Welding Technology

According to our analysis on the traditional welding technologies, we find out four main important issues for development, including:

  1. the welding area is not wide enough
    the required welding area is more than 6-8mm
  2. it is impossible to use several welders at the same time to make series connections of the solar panels:
    According to our past experiences, the main reason for being impossible to use several welders at the same time to make series connections of the solar panels is that the ultrasonic oscillation system is larger than the welding horn (sonotrode), as a result, there will be interference to the welding operation. Therefore, we are endeavoring to develop a welding machine with its welding horn larger than its vibration system.
  3. the problem of uneven welding surface
    In the past, a traditional ultrasonic welding equipment uses usually a smooth (non-knurling) welding horn (sonotrode) which might cause deflection phenomenon during the welding process. For this reason, we will use a knurled welding horn to increase the welding reliability.
  4. The mechanical control is not reliable
    Our past experiences in using the traditional welding equipments showed, that the performance and liability of the ultrasonic welding equipment will affect the effects and yield rate of the entire welding process. Therefore, we are endeavoring to develope a new generation of ultrasonic welding equipment with possibility of digital adjustment.
 
Video 1
 

Video 2
 

Patent

Taiwan No: M333977

Japan No: 3139864

China No: 1116788

 

SMRW Ultrasonic Metal Rolling Welding Machine

Work with 35kHz Ultrasonic Generators

 
   
     

 

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