11工藝部三級文件bp客戶產(chǎn)線sop hrm pe solar六分

1、江陰海潤太陽能電力Module PCPforBPSolar編號：HRM-PE-161版本：A/0編制人/日期：/2011.03.31審核人/日期：/2011.04.02批準人/日期：謝烜/2011.04.072011-04-08 發(fā)布2011-04-08 實施江陰海潤太陽能電力發(fā)布文 件 制 修/ 訂表制/修訂日期制/修訂后版本號制/修訂內(nèi)容制/修訂人審核人2011/03/31A/0根據(jù)客戶要求制定相關工藝制程計劃Module PCP for BP SolarHRM-PE-161A/01目的設置最低在線系統(tǒng)，確保組件的質(zhì)量，這個程序必須使用符合 BOM 中的材料做成組件。2范圍該三個部分組成，

2、分別焊接、層壓以及 I-V 測試，適合 BP 組件生產(chǎn)的制程計劃，其中焊接電池片正面焊接、電池片背面串接以及接線盒焊接。3相關文件。單焊作業(yè)串焊作業(yè)HRM-PE-081HRM-PE-082接線盒焊接作業(yè)指導書HRM-PE-151焊接強度試驗規(guī)范和工藝質(zhì)量計劃HRM-QA-003層壓作業(yè)HRM-PE-086Spire 測試儀作業(yè)HRM-PE-090標板使用規(guī)范HRM-QA-0014定義4.1PCP：process control plan，制程計劃4.24.3交聯(lián)度：原理膠膜經(jīng)加熱固化后形成交聯(lián)，采用二甲苯溶劑萃取樣品中未交聯(lián)部分，從而測得交聯(lián)度。剝離強度：以 180方向，寬度截取 1cm，將

3、EVA 與背板，EVA 與分離4.4MRB：Material Review Board 材料審核會議，是所有檢驗工作站發(fā)現(xiàn)1 / 19異樣狀態(tài)暫時不能確定是否為缺陷的一種處理辦法。Module PCP for BP SolarHRM-PE-161A/05職責5.15.25.35.4生產(chǎn)部：嚴格按照工藝計劃表，對生產(chǎn)異常狀況進行及時反饋質(zhì)量部：對以及進行抽樣檢驗、判定工藝部：校準以及調(diào)試，生產(chǎn)異常處理；部：負責維護保養(yǎng)、維修、調(diào)試。6環(huán)境6.16.2焊接區(qū)溫度測試區(qū)溫度范圍為 255，濕度范圍為 255，濕度范圍為 20%-70%；范圍為 20%-70%。7職業(yè)健康7.17.2焊接時，員工必須佩

4、戴以及手套；層壓組件出料抬料過程時必須佩戴高溫勞保手套；7.3測試過程中必須使用護目鏡；8管理內(nèi)容8.1 焊接工藝計劃表2 / 19ModulePCPforBPSolarHRM-PE-161A/03 / 19Process No.(序號)Product / Process Characteristic（/ 過程特性）Specification and Tolerance（執(zhí)行標準）Evaluation） / Control Method(評估/)Sample Size & Frequency（采樣和頻率）Who Measures（測試）Where Recorded（）Decision Rule

5、 / Reaction Plan（判定規(guī)則/反應計劃）1Mechanical Properties of Interconnect Ribbon（互聯(lián)條機械性能）Elongation15%（延伸率15%）Pull test/ caliper and measure two parts by using ruler（. 使用游標卡尺進行抗拉強度測試，使用直接測量比較兩次長度差異）Only check when Inco（只在來料檢驗）IPQC（巡檢員）Inco material testreport（HRM-QA-007-R01來料檢驗報告）If failure, Call purchasing

6、 department and informr.(若不合格，通知采購并通知供應商)2Solder Iron condition (Manual Solder)(烙鐵頭狀況)Clean, Straight solder tip and smoothness（表面平整光滑干凈）visual inspection（目視）no more than 12pcs cells（不多于 12 片）Operator（操作工）N/AIf failure, Call process engineer（若不合格，通知工藝工程師）3Solder Iron Temperature (Manual Solder for t

7、abbing)（單焊烙鐵頭溫度）340360 Thermometer（測溫儀）Sampling Every 4 hours(每 4 小時測試溫度)Line leader（組長）Soldering iron temperature record（HRM-PE-082-R01 烙鐵溫度表）If failure, Call process engineer（若不合格，通知工藝工程師）Sampling Every 4 hours(每 4 小時測試溫度)QC（巡檢員）Soldering iron temperature record（HRM-PE-082-R01 烙鐵溫度表）If failure, Ca

8、ll process engineer（若不合格，通知工藝工）Heating plate Temperature（加熱臺面溫度）60C 10CThermometer（測溫儀）Per shift（每班）QC（巡檢員）If failure, Call process engineer（若不合格，通知工藝工）ModulePCPforBPSolarHRM-PE-161A/04 / 194Visual Quality of front Solder Joint (Manual Solder)（單焊焊接情況）Continuous soldering（拉焊）Visual inspection of cold

9、 soldering, tin residue, cracked cell. (目視檢查是否有虛焊，錫渣，裂片)100%Operator（操作工）N/ARepair the cold soldering joint（返工焊接起點）5Minimum distance for front solder in both sides to cell border（焊接起始位）Minimum 4 gridlines to borders for both 125mm and 156mm， the distance is about 8mm （125mm 和 156mm 規(guī)格的電池片均從第 4 根柵線起焊

10、，距離大約是 8mm）visual inspection（目視）100%Operator（操作工）N/ARepair the cold soldering joint（返工焊接起點）6Pull strength of cell front solder joints (ManualSolder)（電池片正面焊接拉力）5 points per cell bus bar 2.5N for test at 180 ed please see HRM-QA-003 (每條主柵測試 5 個點，測試拉力為2.5N,參照HRM-QA-003)Force gauge and pull test apparat

11、us（拉力計）Minimum 1 cell tested inthe line every shift AND at least 1 cell every 3 days per operatorfor fully manual operation.（每班每條線至少一片電池片以及每三天每個員工至少一片電池片）QC（巡檢）Peel strength record（HRM-QA-003-R01焊接拉力測試表）For 4 passing joints, confirm with retest, if failure again, check the cell, flux, ribbon, solder

12、ing temperature then retest, If failure again, stop soldering machine and call process engineer.For 3 passing joints, confirm with retest, if failure again, check the cell,flux,ribbon,soldering iron temperature and call process engineer and stop the soldering machine. For equal or less than 2 passin

13、g joints,ModulePCPforBPSolarHRM-PE-161A/05 / 19stop the soldering machine and issue recertification operator, all modules need to perform EL test（. 連續(xù)測試 4 點確定合格，如再次失敗，檢查電池片、互聯(lián)條、匯流條、焊接溫度，然后重新測試。再次失敗，就停止焊臺，然后叫工藝工。對于 3 測試通過的連接點，再重新測試，如失敗，檢查電池片、互聯(lián)條、匯流條、焊接溫度，然后重新測試。再次失敗，就停止焊臺， 然后通知工藝工。少于等于 2 個連接點通過測試，則停止

14、焊接機器，重新培訓操作 員，所有組件都要進行 EL 測試。7Solder Iron condition (Manual Solder)(烙鐵頭狀況)Clean, Straight solder tip and smoothness 表面平整，干凈visual inspection（目視）no more than 12pcs cells（不多于 12 片）Operator操作工N/AClean and re-tin the tip. Replace tip if bent or broken（清潔或者重新上錫，如果彎曲或者損壞更換烙鐵頭）8Solder Iron Temperature (Man

15、ual Solder for stringing)（串焊焊接溫度）360-380Thermometer（測溫儀）Every four hours per shift(每班)Line leader（線長）Soldering iron temperature record（HRM-PE-082-R01烙鐵溫度表）If failure, Call process engineer（不合格通知工藝工）ModulePCPforBPSolarHRM-PE-161A/06 / 19Sampling Every 4 hours（ 每 4 小時抽測）QC（巡檢員）Soldering iron temperatu

16、re record（HRM-PE-082-R01烙鐵溫度表）If failure, Call process engineer若失敗，不合格通知工藝工程師9Visual Quality of back Solder Joint (Manual Solder)（串焊情況）Continuous soldering（拉焊）visual inspection（目視）100%Operator操作工N/ARepair the cold soldering joint（返修）10Minimum distance for backside solder in both sides to cell border

17、（背面焊帶到電池片邊緣的最小距離）Minimum 10mm at the beginning border and between 10mm and 16mm to the end of border（頭部大于10mm，尾部在 10mm到 16mm 之間）visual inspection, with scale mark on the string template（目視,在串焊模板上標注刻度）100%Operator操作工N/ARepair the cold soldering joint（返修）11Pull strength of cell back solder joints (Man

18、ualSolder)（串焊焊接拉力）test 4 points per cell bus bar2.5N for test at 180ed please see HRM-QA-003（主柵測試 4 個點，拉力方向為 180，測試拉力2.5N,參照HRM-QA-003）Force gauge and pull test apparatus（拉力計）Minimum 1 cell tested in the line every shift AND at least 1 cell every 3 days per operator for fully manual operation.（每班每條線

19、至少一片電池片以及每三天每個員工至少一片電池片）QC巡檢員Peel strength record（HRM-PE-188-R01剝離強度表）For 3 passing joints, confirm with retest, if failure again, check the cell, flux, ribbon, soldering temperature then retest, If failure again, stop soldering machine and call process engineer.For 2 passing joints, confirm with re

20、test, if failure again, check the cell,flux,ribbon,soldering iron temperature and call processModulePCPforBPSolarHRM-PE-161A/07 / 19engineer and stop the soldering machine. For equal orless than 1 passing joints ,stop the soldering machine and retrain operator, all modules needto perform EL test. 對于

21、 3 個通過測試的連接點，如不合 格，檢查電池片、互聯(lián)條、匯流條、焊接溫度，然后重新測試，若再次失敗，停止焊接， 通知工藝工。對于 2 個通過測試的連接點，再重新測 試，如失敗，檢查電池片、互聯(lián)條、匯流條、焊接溫度，然后重新測試。再次失敗，就停止焊臺，然后通知工藝工程 師。少于等于 1 個連接點通過測試，則停止焊接機器，重新培訓操作員，所有組件都要進行 EL 測試。12Visual Quality of ribbon solder joints to module bus bars (diodor wide ribbon; ManualSolder) （層壓件外觀檢查）Per GQ5201A（

22、根據(jù) G15201A ）Visual inspection of module bus bars（目視）100%OperatorN/ARepair the cold soldering joint（返修）ModulePCPforBPSolarHRM-PE-161A/07.2 層壓工藝計劃表8 / 1913Visual Quality of junction box solder joints(接線盒焊點檢查)Overlap：:width is 5mm(100%overlap；（length is more than 4mm( More than 80% overlap).（過焊，寬度 5mm

23、要100%焊上，長度最少4mm）Visual inspection of module bus bars（目視主柵線）100%Operator操作工N/Are-solder joints（重新焊接）14Junction box Operator Certification（接線盒焊接員工上崗證）100% certified operators perform junction box solder.70%Extractor and lab balance with 0.1mg accuracy（萃取，使用進度為 0.1g 的實驗室秤）Each laminator per month每臺層壓機每

24、月一次QC檢驗員EVA gel content test report（HRM-QA-005-R01EVA 交聯(lián)度測試報告）If failure, convene MRB.（若不合格，啟動MRB）12EVA adhesion to glass intension（EVA 與的剝離強度）33N/cm (3366 g/cm) Remark: There is back sheet on EVA side. (90方向，大于33N/cm，EVA 背面有背板）Force gauge and pull test apparatus（拉力計）Each laminator per month每臺層壓機每月一

25、次Process engineer 工藝工程師EVA peel strength test report（EVA 剝離強度測試報告）If failure, convene MRB At a minimum: Technology, Quality and Operations（若不合格，啟動MRB召集技術、質(zhì)量和生產(chǎn)同時）13EVAadhesion to back sheet(EVA 與背板的剝離強度)16.5N/cm(1683g/cm，90)（大于 16.5N/cm，90 方向）Force gauge and pull test apparatus（拉力計）Each laminator pe

26、r month(每臺層壓機每月一次)Process engineer 工藝工程師EVA peel strength test report（EVA 剝離強度測試表）If failure, convene MRB At a minimum: Technology, Quality and Operations（若不合格，啟動 MRB召集技術、質(zhì)量和生產(chǎn)同時）14Bus bar distance（匯流條的間距）the bus bar distance of +and - 10mm（匯流條的間距大于10mm）layup template（層疊模板）100% (）Operator（操作工）N/Arew

27、ork (返工)Module PCP for BP SolarHRM-PE-161A/08.3功率測試工藝計劃12 / 19Process No.(序號)Product / Process Characteristic（/ 過程特性）Specification and Tolerance（執(zhí)行標準）Evaluation/ Control Method(評估/）Sample Size & Frequency（采樣和頻率）Who Measures（測試）Where Recorded（）Decision Rule / Reaction Plan（判定規(guī)則/反應計劃）1Recipe title and

28、 part number（組件類型的名稱）Per build plan or equivalentMESBeginning of shift ANDproduct change over（開班或者組件切換）Automatic（自動）recorded in MES（在 MES 系統(tǒng)內(nèi)）Quarmodules MRB (Review & disposition) by Operations & Quality（組件，啟動 MRB，根據(jù)操作以及質(zhì)量檢驗標準處置）2Replace module connection cables（更換測試連接線）Wire diameter must be min. 1

29、2 AWG / 4mm（電纜線必須至少是 4 平方毫米的線纜）Per PM Plan Allowed tay replacement date due to machine idle days（根據(jù) PM 計劃， 如果機器以推遲）Weekly（每周）Maintenance Tech（技術員）PM Data Base（預防維護）Per PM Plan（根據(jù) PM 計劃）3Software checks e.g. RCCorr PeakRatio FFScaleTOffset Number of data points per IV curve（對 FFScale Toffest， 以及測試點的檢

30、查）Sic /Voc/ Pmax variation less than 1%（Isc /Voc/ Pmax 的偏差在1%以內(nèi)）Visual（目視）When calibrate the flash tester and after maintenance（檔校準測試以及維護后的校準)Process Engineer（工藝工）Calibrate recordHRM-PE-161（標板校準表）Ensure parameters are as expected.If not: Review, assess and decide necessary actions by Engineering（如果超

31、出范圍，由工程部給出行動計劃）ModulePCPforBPSolarHRM-PE-161A/013 / 194MCCC for Spire Multi pulse testers (for single pulse Spire testers not required) Monitor Cell Voltage for Berger(MCCC1,MCCC2)+ /- 1%Visual（目視）When calibrate the flash tester and after maintenance.（當校準測試以及維護后的校準)Process Engineer（工藝工）Calibrate rec

32、ordHRM-PE-161（標板校準表）Ensure parameters are as expected.If not: Review, assess and decide necessary actions by Engineering（如果超出范圍，由工程部給出行動計劃）5TMin Tmax（環(huán)境溫度）25 +/- 5 CVisual（目視）daily Check（每天）Operator（操作工）temperature record（HRM-PE-182-R01溫濕度表）Ensure parameters are as expected. If not: Review, assess a

33、nd decide necessary actions by Engineering（如果超出范圍，由工程部給出行動計劃）6Spatial (Light) Uniformity（光強的均勻性）5% maxminimum 96 measurements（至少 96 個點）Every 3 months and when lamps changed（每三或者更換燈管）Process Technician 工藝技術Uniformity test record（HRM-PD-014-R01Uniformity test表）Adjust machine as needed or contact equip

34、ment vendor（調(diào)整均勻性或者廠商）7Repeatability測試重復性1% Max（最大 1%）Minimum of 20 measurements 至少 20 次重復測試Every 3 months 每三Process Technician 工藝技術Sun Simulator Repeatability record(HRM-PD-015 Sun simulator Repeatability 記錄表)Adjust machine as needed or contact equipment vendor 調(diào)整重復性或者廠商ModulePCPforBPSolarHRM-PE-16

35、1A/014 / 198Temperature Measurement Accuracy（溫度傳感器精度）+ /- 1Cthermometer（熱電偶）Every 6 month and when load & measurement board is changed每六 以及更換測試電路板后）Maintenance Technician（技術員）PM Data Base（預防維護）Adjust the offset as needed（調(diào)整溫度補償）9Secondary reference module verification (vs. primary reference module)S

36、ee IEC 60904-6（二級標準組件的驗證）Short circuit variation 1% (短路電流小于1%)use primary reference module and EL tester（使用以及標準組件驗證并做 EL 測試）Every 3 months ORShows signs of damage每三或者出現(xiàn)壞的跡象Quality engineer（質(zhì)量工）verification record二級標板標定證書Recalibrate the check module when the short circuit degradation more than1% comp

37、ared with the original Isc and the degradation more than 5%, replace check module.重新標定二級組件如果短路電流超過 1%，如果跟最初的短路電流相差超過 5%，更換10Monitor daily production data for trends, anomalies, etc.監(jiān)測每天的數(shù)據(jù)趨勢圖， 以及異常等Per product Spec.根據(jù)規(guī)格Data analysis每天分析every day and each month summaryQC/ Product Engineer（巡檢和工）excel chart（Excel表）MRB (Review & disposition) by Engineering, Quality,Operations由工程，質(zhì)量，生產(chǎn)啟動MRB11Verification of glass - If app