As the solar panel market continues to grow, it’s important for solar manufacturers to prioritize solutions that help them meet demand while keeping costs for the end-user within reason. There is a variety of technology available for various parts of the process, but one in particular continues to play a critical role in production success. How conveyors are leveraged within the factory floor can go a long way in ensuring consistent throughput goals are met and customers are satisfied.
Despite a variety in their design and application, some solar panel manufacturers may think all conveyors are the same. However, it’s crucial to understand the different variations and characteristics to make informed decisions that will directly impact throughput.
One of the most critical aspects to consider is durability. Panel manufacturing can put a strain on all components, especially when panels come out of a laminator, as temperatures can reach 160°C. Manufacturers need to know if the individual components within the conveyor are built to withstand that type of environment. Throughout the line, belts are the most common component that moves panels from station to station, and most are rated to operate for 20,000 hours. In the most efficient conveyors, those belts are only in use during panel transport, versus conveyors that require constant power and movement. When the belts do wear down, where they’re positioned within the conveyor is vital when considering downtime for repairs. If they’re located near the top of the conveyor, where employees can quickly and easily change them, then production can resume faster than if they’re in a hard-to-reach position further within the framing. Additionally, conveyors that don’t require any lubrication help eliminate unnecessary costs and maintenance time compared to those that do.
One of the biggest advancements available to manufacturers regarding conveyance is technology that’s literally at their fingertips. Modern design software is playing a big role in helping design conveyance solutions to meet their exact needs and layout. By utilizing free programs like MTpro, solar manufacturers can have a more hands-on experience compared to selecting components and solutions through a catalog. This is increasing the speed-to-market so that solutions are commissioned faster while also reducing the possibility of purchasing unnecessary components. Still, solar manufacturers must maintain a relationship with the supplier, who can guide them through the purchasing process and advise on exact components that will fit the manufacturer’s needs.
Often, solar panel manufacturers’ throughput goals need to be adjusted or scaled based on market demand. That’s why it’s equally as important to utilize conveyors — and technology in general — that can be adjusted, repositioned or expanded. Lean manufacturing is a top priority for many manufacturers who need to maximize productivity for a given physical space, especially those in brownfield settings where new technology is integrated into an existing space. Modern conveyors can be constructed to change in elevation and even be mounted overhead, all to operate efficiently within a designated space.
All the above benefits add up to a central theme: When utilized in the right way, conveyance can serve as the backbone to efficient solar panel manufacturing. Solar manufacturers can design, purchase and install them faster thanks to modern software. Conveyors utilize power only when they’re needed, which helps extend their usage and potentially reduce costs. When they do need maintenance, conveyors that are constructed with easy-to-reach components can be repaired faster. If market demands shift, many conveyors can be adjusted to meet those needs. As technology and processes continue to evolve, conveyance will continue to play a central role in panel manufacturing, and solar manufacturers that understand their value and customizable design are best positioned to respond to market demands and maintain consistent productivity.
Bill LeAnna is the Sales Product Manager – Transfer Systems at Bosch Rexroth.
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