Enhancing Building-Integrated Photovoltaics: A Gripper System for Precise Layup of Solar Cell Strings in PV Module Production

Photovoltaic systems have significant potential for generating and utilizing of renewable energy, and research is being conducted to expand the range of applications for photovoltaic modules. One promising solution for activating previously unutilized potential is to extend the yield areas of roofs or open spaces to building facades. However, achieving high utilization of this area requires a high degree of geometric flexibility and a wide variety of PV module shapes, which are currently very limited due to rigid manufacturing processes. To address these challenges, it is essential to enhance the flexibility and optimize the production process. A crucial aspect of this is the safe handling of cell formats of different sizes with consistently high process accuracy. In this article, we present an approach for a modular vacuum gripper that can safely handle solar strings of variable cell size and length. A detailed analysis of the geometric cell parameters was used to precisely adapt the gripper design to the respective specifications. Tests regarding gripper quality validate the safe handling of different formats without cell damage. Investigations into positioning accuracy, on the other hand, reveal unstable and complex string behavior, which currently prevents the accuracy requirements from being met and requires further investigation.