5 组件生产来料检验-英文版

Raw Materials Incoming Inspection

Purpose：Making sure all purchased raw materials be inspected and qualified so at to module production goes smoothly.

Scope：Apply to all incoming raw materials of solar module production. QC dept. takes in charge of this process.

Inspection Reference：Technical Drawings, Inspection Criterion Procedure:

1）First, verify relevant certificates or quality testing report of materials. 2）Inspection Items and methods, etc.

5.1 Solar Cell

1） Inspection Contents and Methods

a）Solar cell manufacturer, cartons and inner packages, solar cell appearance, dimension, thickness, electrical characteristics, solderability, print quality of fingers, bending degree of solar cell, the soldering quality;

b） Inspection Methods: Random sampling inspection by QC (sampling ratio：2‰ of the incoming materials), full inspection for solar cell appearance 2）Apparatus

Single solar cell tester, micrometer, vernier caliper, soldering iron, blades, eraser 3）Material: Welding strip 4） Inspection Method: a）Packages and Appearance ? Good Packages;

? Visual Inspection: No cracks, unfilled corner < 1.5mm2, fragment, color difference,

fingers broken (breaking point<1mm), water mark, displacement of busbar (fall off<1mm), etc.

b） Dimension: as manufacturer’s standard ±0.5mm c） Thickness: Single cell ±20um,whole batch ±40um

d） Electrical Characteristics: Normally tolerance：±3℅ (subject to purchase requirement) e）Solderability: Use suitable welding strip, 60W constant temperature soldering iron, at temperature 320~350 ℃,there is even silver-tin alloy left on the busbar after peeling off the welding strip.

f） Print quality of fingers: Use an eraser to wipe the fingers 20 times, if no fingers fall off, that will be judged with pass.

g） Bending degree of Solar Cell: Firstly as single cell welding method to weld solar cell and then measure the bending degree of solar cell, if solar cell bending ≤ 1.2℅ of cell

length, it will be judged with pass. h） Soldering quality:

Welding single solar cell as workmanship requirements, and then use tensimeter to measure the pulling force between solar cell and welding strip, the pass criterion is when pulling force ＞2.5N, welded parts of strip still cannot be peeled off from solar cell. 5） Notes

a） When opening carton box, solar cell cannot be slashed by blade. b） Not allowed to touch solar cell with bare hands. c） Handle with care

5.2 Welding strip & Ribbon 1） Inspection Method

a）Manufacturer information, specs, models, packaging situation, warranty period, appearance, thickness and evenness, weight, solderability, breaking rate, serpentine bend rate（Panel package）

b） Methods: Random sampling inspection by QC, Full Inspection for Product Appearance 2）Apparatus : Steel ruler, magnifying glass, vice, soldering iron, solar cell micrometer, vernier caliper, platform balance, tensimeter 3）Material: Solar Cell 4） Inspection Method:

a）visual inspection for goods packaging, Warranty Period, Specs/Models and Manufacturer information

b） Appearance: Check appearance to see if there have black spot, uneven tin coat, twist etc. on its surface.

c） Measure the geometry dimension as supplier’s technical standard (width ±0.12mm, thickness ±0.02mm), and measure the weight;

d） Breaking rate test: take 10 pieces welding strip/ribbon with same length , 180°bending each piece count as once and till welding strip break. Welding strip/ribbon shall not be broken within 7 times.

e） Solderability Test: welding strip/ribbon bath in flux and then take out and dry it in the air. after that, do trial soldering. f） Serpentine bending:

Cling the welding strip ( length: 1m) to Steel ruler, select the most far way point from Steel ruler and measure the distance. the max value shall be less than 3.5mm

5.3：EVA film

1） Inspection Content and Method:

a）Manufacturer information, specs/models, packaging method, quality warranty period, appearance, evenness of thickness, Peeling strength between EVA and Glass, Peeling strength between EVA and Backsheet, crosslinking degree, softening point, homogenization; b）Random sampling inspection by QC, and visual inspection by workers.

2）Apparatus: micrometer, tape, knife, tensimeter, Crosslinking Degree Tester, Oven, Electronic Balance, etc

3）Materials: TPT Backsheet, small glass, broken solar cells 4） Testing Method:

a）Verify manufacturer information, specs/models, packaging method, quality warranty period;

b） Check appearance and find out problems of EVA surface as QC inspection criterion. c）Measure geometry dimension as supplier’s technical standard (width ±2mm, thickness ±0.02mm);

c） For the incoming materials from new manufacturer, shall request them to provide lamination parameter

d） Take a piece of EVA sample to make a module without cell, and test the peeling strength among EVA, glass and Backsheet (after cooling)

? EVA and Glass: cut a 1cm width small sample from the backsheet side of module, and

then peel it off from glass with tensimeter to test peeling strength. If peeling strength ＞35N, it will be judged with pass.

? EVA and TPT: cut a piece of EVA-TPT strip, nip one end, and pull the other end with

tensimeter, If pulling strength ＞20N, it will be judged with pass. e） Take EVA sample for Crosslinking Degree experiment: The Crosslinking Degree is normally between 70℅ and 90℅;

f） Test EVA Softening Point: When the laminator heats up, put a piece of EVA sample on the heating plate, observe the softening status of EVA; g） Test the homogenization of EVA;

? Take 10 pieces of EVA films with same dimensions , and measure their weight; Compare

the weight of each EVA film, the difference between the max and min weight shall not exceed 1.5%;

? Take one piece of EVA, and laminate with regular lamination parameters, observe the

EVA appearance after lamination, trim the 2cm width surround the laminated EVA, measure the thickness of the left EVA or observe its appearance. If there was cavity, the homogenization is not good. 5） Notes:

a）For initial use of new equipment, shall first do trial lamination, and start mass production

only after the workmanship and conditions are met;

b）Do not touch EVA surface with bare hands, Keep the product from moisture to ensure its agglutination characteristics and prevent it from causing bubbles; c） Pack and seal EVA materials after sampling inspection;

d） EVA shall not be exposed in air so as to prevent it from moisture and dust; e）Make record for the temperature and humidity during sampling.

5.4 Backsheet

1） Inspection Content and Methods:

a）Manufacturer information, specs/models, packaging method, quality warranty period, evenness of thickness, appearance, the Peeling strength between Backsheet and EVA, the Peeling strength of Backsheet layers;

b）Inspection Method: Random sampling Inspection by QC, visual inspection by workers. 2）Apparatus: micrometer, tape, knife, tensimeter, etc 3）Materials: small glass, EVA, broken solar cells 4） Inspection Content:

a） Manufacturer information, specs/models, packaging method, quality warranty period; b） Check appearance, Backsheet surface (as the QC inspection criterion)

c）Check geometry dimension as Supplier’s technical standard (width ±2mm, thickness ±0.02mm);

d）Take a piece of backsheet to make a solar module sample, and test its Peeling strength with EVA;

e）Take a piece of backsheet sample, and test its internal Peeling strength: Split Backsheet, nip one end, and pull the other end with tensimeter (it is qualified if the pulling force is＞20N)

f）Select 5 points for thickness measurement (random selection)

5.5 Tempered Glass

1） Inspection Content and Methods:

a）Manufacturer information, packaging, appearance, specs/models, dimensions, Waveform status, tempering strength, granularity

b）Inspection Method: Random sampling Inspection by QC, visual inspection by workers.

2）Apparatus: micrometer, tape, steel ball (1040g), cold light lamp

3）Materials: EVA, Backsheet, broken solar cells 4） Inspection method：

a） Verify manufacturer information, specs/models, packaging method;

b） Check appearance, glass surface (if there is mildew, watermark, scratch, stone, etc or not)

c）Check geometry dimension as supplier’s technical standard (length, width, thickness, diagonal);

d）Waveform Status: Measure with 300mm ruler, record the max space between ruler and glass. Waveform: ≤0.2% Thickness

e）Take a sample glass, and test its impact resistance (freely fall a steel ball (1040g) from 1~1.2m directly above glass, when it drops on glass surface, glass won’t be smashed. This test just need perform one time.)

f）Take a sample of EVA, and test its Peeling strength with glass g）Granularity request: ≥40 5.6 Flux

1） Inspection Content and Methods:

a） Manufacturer information, Packaging, Warranty period, PH value, solderability b）Inspection Method: Sampling Test 2）Inspection Tool: PH test paper

3）Materials: Welding strip/Ribbon, Solar cell 4） Inspection Content:

a） Verify manufacturer information, packaging method, Warranty period, PH value

b）Shall request supplier to provide relevant parameter report, and compare with the samples; if it was abnormal, shall check gravity, acid degree value, etc; b） PH value: Test with PH paper (5~6, weak acid)

d）Take a sample of flux and test its solderability (spread flux with cotton bud on welding strip and busbar of cells, and then do trial soldering; The flux is ok if there is no cold soldering.)

5.7 Aluminum Frame

1） Inspection Content and Methods:

a） Specs/Dimensions, surface hardness, thickness of oxidation film, curvature, appearance b）Inspection Methods: Random sampling inspection by QC, visual inspection by workers 2）Apparatus: Tape, webster hardness tester, film thickness gauge, plug gauge, vernier

caliper etc. 3）Inspection methods

a） Verify manufacturer information, Specs/Models, Packaging method;

b） Check appearance, and frame surface (such as: crack, hit, scratch, bubbles, etc.) c） Check the physical dimensions as Technical Drawing;

d）Take a sample of frame and test its hardness (hardness＞12); Can use webster hardness tester to test.

e）Take a sample of frame and test its film thickness (the average thickness of oxidation film＞10um);

f）Check the internal diameter (If it uses screwing hole, test based on designed dimension and the specific dimension of screws, the difference in dimension shall be within the tolerance; If it uses corner bracket, it shall be tested based on designed dimension and the actual dimension of the frames)

g）Check curvature: Put frames on a level table and observe its curvature.

5.8 Junction Box

1） Inspection Content and Methods:

a）Verify manufacturer information, Specs/models, appearance, raw material, stretching resistance, biting force, Unidirectional conductivity of Bypass Diode.

b）Inspection Methods: Random sampling inspection by QC, visual inspection by workers

2）Apparatus: Tension meter, multimeter

3）Materials: Ribbon 4） Inspection method：

a) Verify manufacturer information, Models/Specs: visualization;

b) Check appearance: Visual defects, marks, cable specification (visualization);

c) Check the number of Bypass Diodes, its specifications; Check if the mark inside Junction Box is correct (visualization);

d) Stretching resistance test of connectors: connecting connectors with junction box and then clamp junction box, and clamp connectors with tension meter to exert pulling force. It is qualified if the tension is more than 100N

e) Biting Force of Cables: Put a piece of ribbon into bayonet, pull it with Tension meter (It is qualified if the tension is more than 40N)

f) Biting Force of Diode: Pull the Diode with Tension meter (It is qualified if the tension is more than 20N)

g) Biting Force of Junction Box Cover: continually open the cover 3 times, it is still difficult to open with bare hand and can only be opened by special tool, that means qualified.) h) Unidirectional conductivity of Bypass Diode: Test two times with multimeter, and confirm its unidirectional conductivity.

5.9：Silicon Gel

1） Inspection Content and Methods:

a）Manufacturer information, Specs/Models, Packaging, Warranty period, Material quality, Peeling strength with Backsheet, elongation test, dry-to-touch time.

b）Inspection Methods: Random sampling inspection by QC, visual inspection by workers

2）Apparatus: Glue Gun, Knife, stopwatch, Tension meter

3） Materials: Kinds of backsheets, small glass, frames 4） Inspection Methods:

a）Verify manufacturer information, Specs/Models, Packaging method, Warranty period and Instruction manual;

b）Initial check, the Silicon gel is normally white or cream white, with no irritant smell. It do not allowed to have collapse of paste or solidation phenomenon;

d） Open the closing plug at bottom, watch if there is solidation and cavity;

e）Do elongation experiment: Spread the silicon gel on the surface of glass (record the spreading time, and dry-to-touch time), and do experiment after solidation (record solidation time, the thickness of silicon gel strip, original length, length after elongation≥300%), record the average value;

f）Take a sample to test its bonding strength with Backsheets: Spread silicon gel (3 strips) on each different kind of Backsheet, after solidation, observe their bonding status and test the values. Record the average value.

g）Sampling to do bonding experiment with backsheet: spread silicon gel on 3 different backsheet, after dried, observe bonding condition and record the average value of detected numerical

5.10：Stainless Steel Screw (corner bracket) 1） Inspection Content and Methods:

a）Manufacturer information, models/specs, dimensions, material, matching degree with frames

b） Inspection Methods: Random sampling inspection by QC, visual inspection by workers. 2）Apparatus: vernier caliper, magnet 3）Material: Aluminum alloy frame 4） Inspection Methods:

a) Check manufacturer information, models/specs, appearance

b) Check dimensions: use vernier caliper to measure diameter, length, diameter of screw rear, the width and depth of cross slot conform to the design request (thickness, width and length of corner bracket)

c) Material: use magnet to absorb the screws, if absorbed, they are not well tempered and easily broken during use; if not absorbed, they are qualified (however not proving their qualification in torsion) d) Matching with frames;

? Measure the diameter of frames on-site, and do trial fixing. It is not good if they were

too hard to fix or very easily fix (“too hard”means that the screw would break easily; “very easily”means the fixing strength is not enough);

? Measure the internal diameter of frames on-site, and do trial fixing.(There shall be

size tolerance for frames and corner bracket: If the tolerance of frame is positive, and that of corner bracket is negative, the fixing would be not firm; conversely, the fixing can not to be done.)

5.11 Packaging Carton box

1） Inspection Content and Methods:

a） Manufacturer information, specs, dimensions, bearing test.

b）Inspection Method: QC Random sampling Inspection, Track during packaging process 2）Apparatus: Tape, Calculator, Scale 3）Material: Wooden Board, Weight 4） Inspection Methods:

a) Check the specs: Neutral, Regular, Special b) Check dimensions as drawing

c) The bearing weight test of carton: Place carton on ground horizontally, then put a Wooden Board (size bigger than carton) on the top of carton. Calculate number of layers, total weight of cartons and PV Modules, and observe the result (it is not qualified if the carton is deformed.)

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