Optimization of monocrystalline silicon photovoltaic module assembly lines based on simulation model

Area of Science:

• Manufacturing Engineering
• Sustainable Energy Systems
• Industrial Simulation

Background:

• Photovoltaic module assembly lines face challenges in efficiency and cost-effectiveness.
• Optimizing production processes is crucial for meeting growing demand in the solar energy sector.

Purpose of the Study:

• To systematically enhance the efficiency of monocrystalline silicon photovoltaic module assembly lines.
• To develop and apply advanced simulation modeling for identifying and resolving production bottlenecks.

Main Methods:

• Creation of a high-fidelity virtual model of the assembly line, including layout, workflow, and equipment.
• Rigorous simulation of key assembly stages: string welding, stacking, laminating, framing, and testing.
• Analysis of workflow dynamics and resource utilization to propose targeted optimizations.

Main Results:

• Implementation of simulation-driven optimizations led to a >6% increase in daily production output.
• A 5% improvement in the production line balance rate was achieved.
• Significant reductions in manufacturing costs and idle times were observed, alongside maintained product quality.

Conclusions:

• Simulation modeling offers a scalable framework for improving productivity and reducing waste in photovoltaic manufacturing.
• The methodology provides actionable insights for manufacturers to optimize layouts, resource allocation, and adapt to market demands.
• Simulation-driven strategies are critical for cost-effective, high-efficiency production and advancing sustainable manufacturing in the photovoltaic sector.