KUKA Systems at the SNEC PV Expo 2010 in ShanghaiWith product innovations and expansion of the spectrum of products and services for the photovoltaic sector, the internationally active KUKA Systems Group is gearing up for the growth market of alternative energies in the Asian region. The company will be at the SNEC PV Expo 2010 (www.snec.org.cn) again this year, showcasing its newly developed products and innovative solutions for manufacturing wafers and photovoltaic modules. KUKA Advanced Wire Saw Machine – AWSMTo meet the continuously increasing demand of the semiconductor and photovoltaic industry for high-quality wafers and high technical availability of the production machinery, KUKA Systems can offer a portfolio of Advanced Wire Saw Machines (AWSM) in a variety of dimensions:The models of the 3800 and 4800 series are characterized by innovative technical features and numerous advantages, such as the wide range of hard materials that can be processed, e.g. silicon ingots for the photovoltaic and semiconductor industry, glass, ceramics, etc. The robust technology of these machines, in which numerous standard components are installed, has been service-proven over many years yet remains future-oriented, resulting in machines that are maintenance-friendly and cost-effective. KUKA AWSMs can use different wire types for the sawing process. This is in line with the trend towards ever finer saw wires and the fact that diamond wire is becoming ever more popular. The integrated capstan wire tensioning device also optimizes and controls the wire tension, thereby significantly increasing the service life of the principal mechanical components. This reduces downtime and maintenance time of the saw and optimizes the spare parts requirements, with a major influence on the operating costs. The optimized ingot loading offers ergonomic advantages, as does an optionally available swiveling unit that enables suspended unloading. Worldwide, KUKA Systems offers not only AWS machines and individual components, such as circular cross-cut saws and automated square-sawing machines, but also the services for which the Augsburg-based automation specialist is particularly well known: the complete engineering and implementation of fully customized wafer lines for automated production. Production support services, such as on-site commissioning and training, maintenance and teleservicing options, which can also be covered by the local subsidiaries in Europe, Brazil, China, India and USA, ensuring customer proximity, round out the customer-oriented range of products and services.KUKA Advanced Cell Stringer – ACS 600Another new product is the KUKA ACS 600 process tool – the Advanced Cell Stringer. With an output of 750 cells per hour, the KUKA ACS processes both polycrystalline and monocrystalline cells, from 160 µ to 220 µ in thickness, with two or three bus bars. The alignment accuracy range is less than ±0.2 mm, while the breakage rate of the cells is less than 0.5%.Early monitoring of cells for quality and possible cracks or breakage is of decisive importance for the entire module production process and, already at this stage, prevents costly rejects later in production.The key to the automatic string manufacturing process is the patented soldering technology, KUKA SoftTempProfile. In a preliminary stage, the cells are pre-tempered from both sides in order to achieve the best possible, reliable soldered connections with the patented temperature profile in the ensuing in-frared soldering process. The cell string is subsequently cooled in a three-stage process that is continuously monitored. The load on the cells caused by the thermal induction is thus reduced and physical expansion of the cells and bars is prevented. The cells are positioned quickly and precisely by a KUKA KR 5 Scara with a vacuum suction gripper. A single handling process for the gripping of the cell, measurement and visual inspection under a stationary camera, solder application and positioning of the cells on the high-tech vacuum conveyor also reduces the load on the cells and minimizes potential sources of damage to the solar cells.The KUKA ACS 600 is also available as the KUKA ACS 600/2 dual stringer with an hourly throughput of 1500 cells and integrated layup and string inspection.