The Drive & Control Company

Automation Solutions for the Solar Industry

Our Goal: To Be World Market Leader in Providing Benefits to Customers

Worldwide benchmark for drive, control and motionElectric drives and controls, in- dustrial and mobile hydraulics, linear and assembly technology, pneumatics: only Rexroth offers all drive and control technologies, both specialized and integrated. Our infrastructure with around 33,000 employees in over 80 countries around the world is designed always with partnership and customer proximity in mind. As a company Bosch Rexroth can look back on over 200 years of tradition. As a wholly-owned sub- sidiary of Robert Bosch GmbH we are part of a globally-operating technology group. All this is both our drive and our commitment. And it’s unique – like Bosch Rexroth. The Drive & Control Company.

With our broad portfolio of products and services we are geared to responding swiftly and flexibly to all your require-ments – starting from devel-opment and production, right through to sales and service. Our products, our proximity to our customers worldwide, combined with our high level of consulting expertise, will give you that decisive com-petitive advantage at the same time minimizing your technical and financial outlay, yet offering the highest level of quality.

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The solar industry is evolving from a niche sector to a volume market world-wide. The result is increasing competition in terms of technology and price. Rexroth’s transport and handling systems make it possible to automate production lines using today’s technology that’s not just state-of-the-art, but already designed to handle future innovation and growth.

Systematic Growth

Wafer-based solar modules or cells in thin film technology? Increased demand in Asia or in South America? How are energy prices developing in Europe? After decades in the doldrums, the solar industry is experiencing a boom hitherto undreamed of. Sales revenues are climbing, the pace of technological innovation is accelerating and production methods are being continuously refined to consume less material and to minimize rejects.

Rapid growth leads to a process of continuous change, which makes the planning of production facil- ities more difficult. To keep costs down, it is necessary to automate processes as much as possible, which in turn carries its own risks when technical development is taken into account. Systems can rarely be used for many years without upgrade or innovation. The transport and handling systems employed must therefore be flexible enough that work stations can be added or replaced without compromising the fast and delicate handling of the cells and panels. Even if production capacity has to be extended, solutions that are flexible and globally available have the competitive edge over custom-made solutions.

As a provider of all relevant technologies for drive and control systems, Rexroth has the cross-technological knowledge to provide the right answers to the wide-ranging challenges encountered in the production of photovoltaic systems. Using Rexroth transport and handling systems means that you can innovate and standardize at the same time. Best-in-class technology ensures that our solutions are not only as good as custom solutions, but also just as cost-effective as standard components thanks to Rexroth’s broad, coordinated portfolio.

Rexroth develops custom auto-mation solutions in cooperation with the manufacturers of production systems for photo-voltaic modules. Global presence guarantees world-wide support and short delivery times. In this way high quality systems ready for integration are developed in the right place and with appropriate sizing. And as the business continues to expand, existing components can be reconfigured and re-used further. This is the basis for planned, systematic growth.

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Automation all Along the Line

Whether in vacuum or in fluids, whether laminating on a large scale or doing pinpoint assembly, whether delicate wafers or complete glass panels – Rexroth can offer the right transport and handling system for every task.

Its modular construction in- creases efficiency because the solutions can keep pace with progress in production methods.

Wafer production

Stringing

Lay-up

Cell production

Cleaning

Quality control

Rexroth systems allow you to innovate and standardize at the same time. Beginning-to-end automation solutions make it possible to combine highly specialized modules such as the Rexroth Wafer Lift for gentle handling of silicon wafers with flexible, modular transport and handling systems. This flexibility lends a long term economic perspective to production lines, even in the face of the high rate of innovation in the photovoltaic industry.

Each processing step places different demands on the technology, making a defined combination of different pro- cedures necessary. As a specialist in drive, control and motion, Rexroth has the cross-technological know-how necessary to solve demanding automation problems. The Rexroth portfolio spans the entire production process for solar panels. Our capabilities start with the silicon wafer or the thin-film module and run

all the way to final inspection, including packaging of the finished module. For each individual processing step there are efficient individual systems such as the innovative transport system TSsolar, developed specifically to meet the requirements of the solar industry. Using intelligent control systems, many units can function together as a whole to guarantee reproducible product quality and to ensure high output from the system.

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Lay-up Transport

Laminating

Flashing

Framing

Systems and solutions such as camoLINE or the aluminum structural framing system, avail-able worldwide, are a guarantee for a long service life. A complete system solution can be extended and adapted step-by-step without the individual modules becoming unusable – a likely scenario with a custom solution. Standard connections and intelligent interfaces like Easy-2-Combine make production lines flexible over long periods.

All processing steps must be carried out free of vibrations on a long term basis so that the photo-electrically active layer is not damaged during transport along the production line. The name Rexroth is synonymous with reliable and low-maintenance components that meet the highest standards of quality. Our inverted tooth chain drives function safely with long service lives in high-temperature processes.

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Linear technology:When the subject is precise motion, Rexroth offers reliable and vibration-free solutions, which make special applications possible, such as the Wafer Lift. Also when it’s about the precise handling of complete solar modules, linear motion systems promote automation.(Page 6/8)

Assembly technology:The handling of sensitive solar panels requires technology with a gentle touch. The flexible transport system TSsolar and the camoLINE Cartesian Motion building system are both precise and individually configurable. (Page 8/10)

Pneumatics:The power of air makes contact-free transport possible in cleaning stations and promotes the auto-mation of production processes. (Page 8/9)

Electrical control and drive technology:Innovative control systems are the basis for successful automation. Rexroth’s NYCe 4000 and Indra-Motion for Handling are ideally suited to meeting the needs of the solar industry. The intelligent transport system LMS provides contact-free, careful transport of product, even in a vacuum. (Page 7/10/13)

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The handling of ever thinner silicon wafers requires extremely precise and vibra-tion-free machines. Rexroth’s Wafer Lift uses know-how from wafer manufacturing and automation to insert the brittle wafers safely into the production tools.

Gentle Lift for Razor-Thin Wafers

At 180 to 300 micrometers, a sili-con wafer in a solar cell is much thinner than a hair. Handling the wafers is correspondingly delicate, as they have to be moved absolutely free of vibration to avoid damage or breaking.

The Rexroth Wafer Lift offers particularly gentle and smooth motion. Users have at their disposal a complete, tried and tested sub-assembly, which may be easily integrated into larger production tools.

The Wafer Lift handles wafers outside the tool with extreme care. A variety of high-precision Rexroth components from diverse areas of technology operate in combination to ensure absolutely vibration-free and shock-free transport under all operating conditions.

For example, too much play in the linear axis can lead to slippage and its resulting vibration. Conse-quently, components that are free of backlash are used. A Ball Rail® guide combined with a ball screw assembly of tolerance class five provides linear motion with low frictional resistance. The Wafer Lift system is thus guaranteed to perform seven million working cycles without relubrication. An ingenious combination of preload

in the ball screw drive assembly and the arrangement of the components inhibits undesired vibrations. This is an essential prerequisite for high yield of good product during production.

A precise, maintenance-free servomotor is used for the drive. It is controlled by means of a compact Rexroth IndraDrive Cs servocontroller.

Precise motion through ball screw drive assembly

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Floating in a Vacuum Gentle Lift for Razor-Thin Wafers

In the production of solar cells, a combination of the highest possible precision and a short work cycle is desired. Rexroth’s intelligent transport system LMS meets this requirement using a magnetic field to produce contact-free motion of special product-holders. Through the use of hall sensors, the coils achieve very high repeat accuracy. Because the entire electronics are outside the processing chamber, they do not need to be encapsulated. This makes efficient inline produc-tion possible with a very compact vacuum chamber.

By combining multiple coils, the intelligent transport system LMS is suitable for long production lines, if this is necessary. Multiple product-holder slides can be transported independently of one another, so that the LMS can execute even complex motion patterns without difficulty.

To facilitate efficient automation, the Rexroth NYCe 4000 motion-control system is available, which is optimized for use in the solar and semiconductor fields. Move-ment profiles ensure processes are gentle on material while at the same time ensuring extremely exact positioning.

Like on a magnetic levitation track, product glides contact- free through a vacuum chamber on the LMS intelligent transport system. The method makes work possible under cleanroom conditions with precise control and high process speed.

Very precise positioning and careful handling are made possible by the Rexroth NYCe 4000 motion-control system.

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Efficient and Flexible Production

After the solar cells have been manufactured, they must be combined to form a complete panel. So-called stringing is a task suitable for camoLINE, the modular building block kit for handling systems. A high degree of standardization, coupled with a comprehensive product range, forms the basis for solutions that are both individual and expandable. They permit the construction of tailor-made handling systems that are in no way inferior to custom-built solutions in terms of capability and precision.

camoLINE offers the user perfectly matched linear motion systems, motors and pneumatic mini slides, rotary modules and grippers. They can be combined into rigid 2- and 3-axis systems using the innovative Easy-2-Combine con-nection technology with centering rings for easy assembly with high accuracy.

Through the focussed automation of processing stages using Rexroth intelligent control systems, a homo- geneous overall process amenable to planning can be built up.

Easy-2-Combine makes it possible to combine electromechanical and pneumatic axes in one work station without difficulty. Linear modules from the Compact series are avail- able with a ball screw drive for very accurate positioning or with a toothed belt drive for high-speed positioning. Compatible with these alternatives are Rexroth’s IndraDyn servomotors, combining compact design and excellent dy- namics. On the pneumatics side there is also a wide range of high- performance components, such as the rodless pneumatic cylinder CKP. With NCT we have a non-contacting gripper available that can transfer sensitive solar cells in a particularly careful way.

The form fitting connections mean that there is no need for complex alignment of the different elements. Additional adapters are not ne- cessary. Experience in practice indicates that the assembly is more that 30% faster than it would be with individually manufactured components.

The camoLINE system makes the assembly of high per-form ance handling systems easier than ever before. Typical work stations, such as those used for stringing individual solar cells together to form a complete panel, can be constructed easily.

camoLINE – the easiest path to your particular handling system: From a wide range of compatible components come individualsolutions.

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A Clean Solution

Cleaning is a particularly challeng-ing aspect of the manufacturing process. Water and chemicals can corrode the components. Rexroth therefore offers a line of corrosion-resistant electrical and pneumatic components meeting the highest protection class IP69K.

The pneumatic valve block system CL03 (Clean Line), for example, is resistant to high temperatures, fluids, and most chemicals. At the same time, the easy-to-clean casing inhibits dirt build-up and will withstand high-pressure wash-down. The CL03 is fitted directly into the system, and does not need a separate switch cabinet. Addi-tional tubes and cables for current and compressed air supply are not needed. The Rexroth pneumatic cylinders ICS (ISO Clean Stainless)

Cleaning the glass substrate requires technology that is precise and resistant to fluids of all types. Robust components from Rexroth fulfill both these requirements economically.

are also resistant to all kinds of fluids, even aggressive acids. These round stainless steel cylinders are available with a variety of mount-ing options. Depending on the ambient conditions, users can choose between the robust stan-dard version ICS-D2, made of cor - rosion-resistant V2A-grade steel, or the acid-resistant V4A version. The latter offers exceptional cor - rosion protection, assuring long life in wet environments.

Technologies from Rexroth have been performing success- fully for many years in the food industry, where utmost reliability and easy cleaning are critical. Whether exposed to salt water, disinfectants, chemical cleaning agents or high temperatures, pneumatic cylinders and valves from Rexroth stand up to the toughest demands. These proven features are invaluable when it comes to solar panel cleaning.

Round cylinder ICS

The CL03 valve terminal system with easy-to-clean casings is

washable and resistant to aggressive cleaning agents.

Solar modules make extreme demands on material transport both within and between the individual processing stations. The large glass panels must be transported free of vibration, must not be bent and are extremely sensitive to conta-mination. Rexroth developed the intelligent transfer system TSsolar specifically to meet the requirements in the photovoltaic industry.

The assembly of the preworked solar panels requires a variety of processing steps, such as the soldering of connections or the application of the EVA-film or laminating the rear side. Here it is necessary to transport the large, sensitive panels carefully from one processing station to the next. Vibrations or uneven support can result in damage to the optically active layer.

With TSsolar, Rexroth has developed a transfer system that moves modules of any width vibration-free and that flexibly adjusts to a wide range of requirements. The basis for TSsolar is the tried and proven transfer technology incorporated in TS2plus, which includes a large number of standard components to facilitate the rapid and economic construction of individual solutions. TSsolar includes a number of special features designed to address the demanding requirements in the solar industry. For example, a low-abrasion, low-wear, toothed belt is used that additionally forms a closed surface. The fabric-backed belts are arranged in parallel tracks and through ESD-inhibiting

design are anti-static like all of TSsolar. Because every section of the line can consist of an arbitrary number of tracks, the transfer system is suitable for processing panels of any size. A typical segment is two to three meters long, 0.6 to 1.5 meters wide and consists of two to four toothed belt tracks.

Each module has a drive of its own that, thanks to the frequency converter, carefully brakes or accelerates the solar panel. Thus, the workpiece glides gently to its processing point or automatically waits on the current segment, if the next segment is still occupied by another module. The subdivision of a longer transport way into shorter segments under auto-nomous, intelligent control enables secure, continuous processing. Every TSsolar-segment contributes to the objective that there be no sudden movements resulting from congestion on the production line.

The pre-assembled transfer tracks are ready for installation and can be reconfigured without great effort. They can also be combined with the modules from Rexroth’s

Transfer with Intelligent Drives

Every segment in TSsolar is equipped with its own drive, allowing large panels to move safely and without jostling.

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manual production system and aluminum profile construction system. This means that there are no complications if systems are to be subsequently extended or converted. Special modules such as the lift/transfer unit ensure that the modules are gently transferred from the longitudinal tracks to the transverse tracks. In this way TSsolar is readily adaptable to space limitations. Because the unsealed glass panels are exceedingly sensitive to contamination during production, all components in the TSsolar range are suitable for use in Class 6 clean rooms in accordance with EN ISO 14644-1.

The anti-static design also con- tributes to protection. During manufacture, photovoltaic modules are heated – the panels, at up to 160 °C, are handled by means of a special, high-temperature solar- transport.

TSsolar facilitates the standardized volume production of photovoltaic systems. The modular construction, together with each line segment having its own drive, is the prerequisite for high throughput at a reproducible quality standard. For more advanced automation, programmable logic controllers (PLC) are available from Rexroth. The IndraLogic series combines scalability with standardized open interfaces.

It supports the full extent of the IEC 61131-3 language and thus enables sophisticated motion-logic solutions. There is a comprehensive development tool compatible with PLCs available for the programming of individual processes.

The large selection of standard components guarantees an individual

construction is possible.

Heat-Resistant

Laminating is used to protect the sensitive inner workings of the solar panels from environmental factors. During the melting of the weatherproof plastic composite film, care must be taken to ensure a uniform temperature distribution in order to prevent the formation of folds and blisters. A continuous working process is necessary here.

The temperature loading places severe demands on the transport system. Inverted chain drives from Rexroth excel in temperatures up to 400 °C. Through the use of high-quality material, inverted chain drives from Rexroth are insensitive to radiant heat, have a long service life and can ensure the smooth passage of the panels. A roller drive with Biflex inverted chain permits, through optimized meshing, the transport of product without relative motion, which could otherwise damage the surface of the glass.

During production inverted chain drives carry the solar glass panels safely and quickly through a vacuum deposition facility, even if high temperatures are involved. The continuous process increases the yield from the production line.

Inverted chain drives operate very precisely and require little maintenance, even under extreme conditions.

Flexible and tough: Inverted chains from Rexroth.

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Automation without Compromises

During final inspection, the functional capability of solar panels is tested by so-called flashing. Not only are manufacturing faults detected in this way but also the panels are classified into perform-ance categories and packaged correspondingly. For the automation of the process, Rexroth offers a powerful control system in the form of IndraMotion for Handling. It simplifies the engineering, maxi- mizes the flexibility and increases the productivity of the individual work stations. IndraMotion for Handling can coordinate even very complex motion profiles and is well-suited for sophisticated motion-control tasks.

Quality control consists of a number of steps, where man and machine often operate in close proximity. For this reason, Rexroth has offered servo drives with “Safety on Board” since 1999. Up to 20 integrated safety functions ensure the safety of the employees. The built-in safety solutions make sure that the drives stop exactly and, if necessary, also maintain position without power. Even under load, collapse of vertical axes is prevented. The stop categories 0 to 2 defined in EN 60204-1 are completely supported. To guarantee that safety functions are always operational, the system performs cyclical testing of the brakes.

Many manual operations can be partly or completely automated using intelligent control systems. Quality is improved and throughput increased. Integrated safety functions ensure the safety of employees.

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We are There Where You Need Us

As global demand increases so does the global requirement for production facilities for photo-voltaic systems. As a company with a global presence, Rexroth offers comprehensive local support.

The worldwide sales and service network of Bosch Rexroth AG provides excellent coverage. We are represented in over 80 countries with branch offices and production sites. Thus our customers have access to the complete range of Rexroth know-how anywhere in the world.

Our staff not only speak your language but also have the necessary knowledge of local conditions. This is important for the successful execution of projects in countries with different standards and regu- lations. Local experience facilitates project planning, commissioning, training and technical service.

Rexroth products satisfy inter-national standards and are available worldwide in reliable quality and quantity. Availability of new best-in-class products and spare parts is thus assured.

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More Than Just Products

Solutions in automation do not come ready-to-wear; they have to fit like a tailor-made suit. Our worldwide technical service will assist during all phases of a project, from planning through to daily operations.

Faster and easier: This applies to automation just as much as in daily cooperation. With Rexroth-Service even complex problems can be solved easily. Whatever the continent or the technology, your single contact person will get the right technical specialists around the table to start a rapid, reliable reaction to the challenges you face.

Our technical service will assist you during all phases of a project from planning through to after-sales service. Regardless of whether it concerns commissioning, field service, teleservice or retrofit – we aim to satisfy our customers by providing in-depth advice, sector-specific service packages, fixed agreements and reasonable prices.

Rexroth operates worldwide according to the same procedures and standards. Manufacturers and operators of facilities for the production of solar cells and photovoltaic systems can profit from international cooperation with one partner for all automation requirements. Your specifications and quality requirements will be uniformly adhered to worldwide.

Such reliability applies to the total life cycle of the products and services. Our omnipresent service network guarantees a reliably rapid response. Rexroth’s understanding of technical service is considerably more than just the delivery of spare parts. In agreement with the respective user, Rexroth service personnel operate at the customer’s plant. Condition monitoring and remote maintenance concepts, or innovative services for all drive and control technologies, raise system availability, and enhance the planning of maintenance cycles.

Bosch Rexroth AGMarktplatz 397816 Lohr, GermanyPhone: +49(0)9352/18-4103Fax: +49(0)9352/18-4100sales@boschrexroth.dewww.boschrexroth.com

Printed in Germany RE 09938/12.08