PROCESS FOR IMPROVING THE PRODUCTION OF PHOTOVOLTAIC PRODUCTS

• US 20120136470A1
• Filed: 05/21/2010
• Published: 05/31/2012
• Est. Priority Date: 05/22/2009
• Status: Abandoned Application

• Current Assignee: Aurora Solar Technologies, Inc.
• Original Assignee: Aurora Solar Technologies, Inc.
• Inventors: Heaven, E. Michael, Deans, Gordon
• Application Number:
  US13/321,813
• Publication Number:
  US 20120136470A1
• Time in Patent Office: Days
• US Class Current: 700/110
• CPC Class Codes: G05B 19/41875 characterised by quality surveillance of production
• CPC Class Codes: G05B 2219/32182 If state of tool, product deviates from standard, adjust system, feedback
• CPC Class Codes: G05B 2219/32191 Real time statistical process monitoring
• CPC Class Codes: G05B 2219/32194 Quality prediction
• CPC Class Codes: G05B 2219/32195 Feedforward quality control
• CPC Class Codes: G05B 2219/32196 Store audit, history of inspection, control and workpiece data into database
• CPC Class Codes: G05B 2219/32198 Feedforward inspection data for calibration, manufacturing next stage
• CPC Class Codes: G05B 2219/32201 Build statistical model of past normal proces, compare with actual process
• CPC Class Codes: G05B 2219/32212 If parameter out of tolerance reject product
• CPC Class Codes: G05B 2219/32218 Sort workpieces as function of quality data
• CPC Class Codes: H01L 31/18 Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
• CPC Class Codes: Y02P 90/80 Management or planning

Abstract

Methods and apparatuses for manufacturing photovoltaic products include an assessment of each product in a production line for suitability, and assigning a grade based either on assessment of the product at that step, comparison to statistical analysis of assessment results of previous products at that step or comparison of previous assessment results of past steps compared to statistical analysis of cumulative assessment results of past products at those steps. Products can be associated into groups for processing as a group based on the grades and downstream equipment can be adjusted based on the grade of the group to bring the group within determined tolerances.

Claims

1. A method of manufacturing photovoltaic products in a manufacturing production line of a series of production steps, comprising, at each of a plurality of intermediate production steps of the production line:

(a) assessing each photovoltaic product for suitability based on predetermined criteria for a preferred product, to obtain assessment results for the product at each production step;

(b) storing the assessment results for that product by production step, in a memory;

(c) assigning a grade to each photovoltaic product, based on either;

(i) the assessment results for that product at that step;

(ii) a comparison of the assessment results for that product at that step to statistical analysis of assessment results of previously processed photovoltaic products at that step;

or

(iii) a comparison of cumulative historical assessment results for the product at past production steps to a statistical analysis of historical cumulative assessment results of previously processed photovoltaic products over the same production steps;

at each such production step, the grade identifying whether the product is within or outside of predetermined tolerances, representing deviations from the predetermined criteria, for photovoltaic products at such step; and

(d) storing the grade for that product at such production step, in a memory.

2. The method of claim 1 further comprising:

(e) associating all of the products in the production line at a particular step, having the same stored grade, together in a group for further processing as a group.

3. The method of claim 2 further comprising:

(f) for groups having grades indicative of products outside of the predetermined tolerances, adjusting the downstream production equipment of the production line to process each such group of products with the same grade so as to bring the group within the predetermined tolerances; and

(g) processing the group together using the downstream production equipment as adjusted at step (f), to bring the products of the group within the predetermined tolerances.

4. The method of claim 2 wherein steps (a) to (d) are performed at every intermediate production step of the production line to obtain a grade for each product at every production step of the production line and wherein step (e) is performed at each one of those steps.

5. The method of claim 3 wherein the grade assignable to a product at a production step is associated with information for adjusting the downstream production equipment at step (f) so as to bring the group associated with the grade within the predetermined tolerances and wherein the downstream production equipment is adjusted accordingly for processing of that group.

6. The method of claim 2 wherein if groups at a step are identified as outside of the predetermined tolerances, process changes are made upstream of the step to production equipment to bring future products produced within the predetermined tolerances.

7. The method of claim 2 wherein groups identified as outside of the predetermined tolerances at a step are prioritised for further processing after groups at that step which are within the predetermined tolerances.

8. The method of claim 7 wherein groups at a step are prioritised for further processing based on the grade of the group, with groups of grades having more significant deviations from the predetermined tolerances positioned for processing behind groups with grades representing lesser deviations from the predetermined tolerances.

9. A method of controlling a series of production steps in a manufacturing production line for the manufacture of photovoltaic products, comprising the steps of:

(a) at predetermined production steps, receiving grading information associated with a photovoltaic product in the production line at that step,

(b) using the grading information to allocate a grade to the product, the grade indicative of whether the product is within predetermined tolerances for that step;

(c) comparing, by a processor, said grade to a plurality of grades of other previously processed photovoltaic products in a knowledge base stored in a memory, to identify a similar grade, the similar grade being a grade associated with previous products having similar grading information, wherein said knowledge base further comprises information as to the outcome of the grade at further process steps in the line and wherein said knowledge base further comprises production line adjustment information which bring the similar grade products to an acceptable tolerance;

(d) based on the outcome information of the similar grade, determining a predicted outcome of the photovoltaic product at one or more further processing steps in the production line; and

(e) if the predicted outcome is outside of the predetermined tolerance at a further processing step, providing the production line adjustment information for that step to adjust the production line to process the product.

10. The method of claim 9 wherein at step (e):

(a) if the predicted outcome is outside of the predetermined tolerance at a further processing step, storing the product in a product group of products with the same or similar grades until a predetermined number of products are stored and;

(b) providing the production line adjustment information for that step to adjust the production line prior to processing the products as a group; and

(c) inserting the product group after the adjustments are made and processing them as a group to achieve the desired performance tolerances.

11. The method of claim 9 wherein the grading information is based on either:

(a) the assessment results for that product at that step;

(b) statistical analysis of assessment results of previously processed photovoltaic products at that step;

or

(c) a comparison of cumulative historical assessment results for the product throughout its past production steps in comparison to a statistical analysis of historical cumulative assessment results of previously processed photovoltaic products over the same production steps.

12. A method of controlling a series of production steps in a manufacturing production line for the manufacture of photovoltaic products, comprising the steps of:

(a) logging past assessments of a plurality of photovoltaic products at predetermined production steps in a knowledge base stored in a memory, each assessment determined by past processing of photovoltaic products;

(b) logging past courses of action taken at the production steps in response to said past assessments, and associated outcomes, in said knowledge base;

(c) characterizing at least one of said associated outcomes as a positive outcome;

(d) receiving a real-time assessment of a photovoltaic product at a production step;

(e) comparing, by a processor, said real-time assessment to said past assessments to determine a predicted assessment for said product; and

(f) providing one of said courses of action associated with said positive outcome as the course of action to take in further processing of the product.

13. The method of claim 12 wherein at the comparison step, the real-time assessment is compared to said past assessments at that step.

14. The method of claim 12 wherein at the comparison step, the real-time assessment is associated with past assessments of the product at the production step and a predetermined number of past production steps compared to said past assessments at that step and the predetermined number of past production steps.

15. The method of claim 12 further comprising:

(g) receiving the outcome of the photovoltaic product after the further processing;

(h) determining whether the outcome is a positive outcome; and

(i) if the outcome is a positive outcome, logging the real time assessment and the course of action of the photovoltaic product in said knowledge base as a part of the past assessments, past courses of action, and associated outcomes.

16. The method of claim 12 further comprising:

(a) at step (a), logging past damage assessments of the plurality of photovoltaic products at predetermined production steps in a knowledge base stored in a memory, each damage assessment determined by past processing of photovoltaic products;

(b) at step (b), assigning a damage severity threshold based on the damage assessments of past photovoltaic products that cause impairment of the manufacturing production line at a production step, stored in said knowledge base;

(c) at step (d), receiving a real time damage assessment of a photovoltaic product at the production step;

(d) comparing, by a processor, said real-time damage assessment to said damage severity threshold to determine whether said product is at risk of impairing the manufacturing production line; and

(e) if such product is determined to be at risk of impairing the manufacturing production line, providing removal instructions for removing said product from the production line before the next production step.

17. The method of claim 16 wherein together with said removal instructions providing instructions to replace the product to be removed with instructions to replace the product with another product at that production step determined by its damage severity threshold to not be at risk of impairing the manufacturing production line at that production step.

18. An apparatus comprising a processing device;

a computer readable medium tangibly embodying a computer program product for manufacturing photovoltaic products, the computer program product comprises instructions for causing a processor to;

(a) assess each photovoltaic product for suitability based on predetermined criteria for a preferred product, to obtain assessment results for the product at each production step;

(b) store the assessment results for that product by production step, in a memory;

(c) assign a grade to each photovoltaic product, based on either;

(i) the assessment results for that product at that step;

(ii) a comparison of the assessment results for that product at that step to statistical analysis of assessment results of previously processed photovoltaic products at that step;

or

(iii) a comparison of cumulative historical assessment results for the product at past production steps to a statistical analysis of historical cumulative assessment results of previously processed photovoltaic products over the same production steps;

at each such production step, the grade identifying whether the product is within or outside of predetermined tolerances, representing deviations from the predetermined criteria, for photovoltaic products at such step; and

(d) store the grade for that product at such production step, in a memory.

19. An apparatus for manufacturing photovoltaic products comprising:

(a) circuitry for assessing each photovoltaic product for suitability based on predetermined criteria for a preferred product, to obtain assessment results for the product at each production step;

(b) circuitry for storing the assessment results for that product by production step, in a memory;

(c) circuitry for assigning a grade to each photovoltaic product, based on either;

(i) the assessment results for that product at that step;

(ii) a comparison of the assessment results for that product at that step to statistical analysis of assessment results of previously processed photovoltaic products at that step;

or

(iii) a comparison of cumulative historical assessment results for the product at past production steps to a statistical analysis of historical cumulative assessment results of previously processed photovoltaic products over the same production steps;

at each such production step, the grade identifying whether the product is within or outside of predetermined tolerances, representing deviations from the predetermined criteria, for photovoltaic products at such step; and

(d) circuitry for storing the grade for that product at such production step, in a memory.

20. The apparatus of claim 19 further comprising:

(e) circuitry for receiving the outcome of the photovoltaic product after the further processing;

(f) circuitry for determining whether the outcome is a positive outcome; and

(g) circuitry logging the real time assessment and the course of action of the photovoltaic product in said knowledge base as a part of the past assessments and associated past courses of action, if the outcome is a positive outcome.

21. A computer system comprising a memory having stored therein a photovoltaic products manufacturing control application for a manufacturing production line of a series of production steps;

and a processor coupled to the memory, wherein the execution of said manufacturing control application generates a method comprising;

(a) assessing each photovoltaic product for suitability based on predetermined criteria for a preferred product, to obtain assessment results for the product at each production step;

(b) storing the assessment results for that product by production step, in a memory;

(c) assigning a grade to each photovoltaic product, based on either;

(i) the assessment results for that product at that step;

(ii) a comparison of the assessment results for that product at that step to statistical analysis of assessment results of previously processed photovoltaic products at that step;

or

(iii) a comparison of cumulative historical assessment results for the product at past production steps to a statistical analysis of historical cumulative assessment results of previously processed photovoltaic products over the same production steps;

at each such production step, the grade identifying whether the product is within or outside of predetermined tolerances, representing deviations from the predetermined criteria, for photovoltaic products at such step; and

(d) storing the grade for that product at such production step, in a memory.

22. The system of claim 21 wherein the execution of the application further generates a method comprising:

(e) associating all of the products in the production line at a particular step, having the same stored grade, together in a group for further processing as a group.