As the demand for solar generated energy increases, so does the need for cost effective manufacturing solutions. In response to this demand, Newport offers the SolaryX series thin film laser patterning systems. The systems are installed at three positions along a photovoltaic production line. The three scribe patterning steps are P1, P2 and P3. These next generation systems provide industry leading performance and reliability to minimize dead zone and maximize throughput.
In addition, Newport offers various options for input and output material handling conveyors, bar code writers and bar code readers, which can be quoted upon further discussions. By selecting Newport, you will benefit from our industry leading lasers, optics and precision motion products, as well as our expertise in providing and supporting complex integrated solutions and systems.
The SolaryX II, P1/P2/P3 Laser Scribe Systems is a laser patterning tool for P1/P2/P3 layer scribing of thin film panels. The system automatically loads the glass, aligns via machine vision the glass panel or previous scribe line, indexes the glass through the process area where the glass is scribed with multiple laser beams and unloads the glass after processing is complete.
Each scribe station features:
- A high precision, high speed air bearing motion stage that is capable of speeds over 2.0 m/sec and 2.5G of acceleration used to move the laser scribe ‘cartridge’ under the glass.
- Laser ‘cartridge’ assembly with four laser scribing nozzles at the required pitch setting mounted on the scribe axis. Each pass of the scribe axis under the glass can make up to 4 scribes. Individual beams can be turned on/off through software control to enable scribing with one, two, three or four beams.
- Variable pitch feature via four motorized axes within the optical cartridge to adjust the pitch. Four downstream vision cameras and associated software provide closed-loop control of line pitch spacing.
- Real-time focus adjustment maintains scribe quality when scribing tempered glass, which is wavier than annealed glass. The scribe axis is equipped with dual laser profiling sensors (on either side of scribe nozzles) to sense the glass and adjust the laser beam focus, accordingly.
- High powered laser systems with excellent pulse-to-pulse stability and high repetition rate. The laser system includes a fail safe laser safety shutter, a computer controlled laser power supply, and a re-circulating water chiller.
- Dual edge grippers (one on each side of the glass) grips the glass along the feed direction and moves it through the scribing zone. The grippers are driven by two linear motor axes with linear encoders to ensure high positional accuracy and fast index times.
- Ability to scribe ‘guard’ scribes orthogonal to scribe lines along the glass edge to allow downstream process checks (e.g., isolation).
- Motorized Input and Output slides with bottom vacuum grippers to load and unload glass from the process area. These motorized slides minimize the glass load/unload times to maximize system TAKT time.
- Roller conveyors allow the glass to move freely during loading and unloading and support the glass during processing.
- Four cameras upstream of the laser scribe area vision-process the previously scribed lines and position the glass accurately over the scribe area. Each camera has programmable intensity Tri-color (red, green, and blue) stadium lighting and thru-the-lens lighting. This flexible lighting capability enables processing of the widest range of glass edges, scribe lines and fiducials by maximizing contrast in the image via optimal color mixing. This feature dramatically increases the robustness of the vision recognition system.
- Machine vision processing occurs prior to each glass index to compute scribe line offset and compensate via glass positioning.
- The industrial PC operating under MS Windows® XP Professional provides overall system control and monitors the system laser safety interlocks. The system includes a flat screen monitor and keyboard on a swing-out arm. An Ethernet connector provides for network and customer factory communication.
- The software with a user-friendly graphical interface integrates all system operations related to scribing and logs scribe station performance, which it sends to a factory computer system.
- Motion control of all closed loop axes and all critical IO handling through a high speed servo motion controller.
- An integrated air conditioning unit keeps the inside of the system at a constant temperature to maintain calibration integrity for accurate and consistent scribing.
- The fixed debris and fume extraction head located above the glass in the scribe area is connected to a suction filter unit to pull away debris generated during the process.
- Interfaces to upstream and downstream equipment.
- Class I safety enclosure.