Industrial Training Report

ABSTRACT

Industrial training is an important phase of a student life. A well planned, properly executed
and evaluated industrial training helps a lot in developing professional attitude. It develops an
awareness of industrial approach to problem-solving, based on a broad understanding of process
and mode of operation of organization.
The aim and motivation of this industrial training is to receive discipline, skills, teamwork
and technical knowledge through a proper training environment, which will help me, as a student
in the field of Information Technology, to develop a responsiveness of the self-disciplinary nature
of problems in information and communication technology. During a period of six-week training
at VITHAI SOLAR SALES, I learn from basic construction & components associated with
panel.
As a result, I vital to achieve the minimum requirement of the company, it will help the
company to maintaining the data on SQL server. Throughout this industrial training, I have been
learned new programming language that required for the system, the process of the production
lines and able to implement what I have learnt for the past year as a Diploma in electrical
engineering student in Trinity Polytechnic Pune.

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CONTENT

1. GENERAL INFORMATION

2. PURPOSE OF VISIT

3. WHAT WE LEARN?

4. CONSTRUCTION & MAIN COMPONENETS OF SOLAR PANEL

5. CONCLUSION

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1. GENERAL INFORMATION

A solar panel is a device that converts sunlight into electricity by using photovoltaic (PV)
cells. PV cells are made of materials that produce excited electrons when exposed to light. The
electrons flow through a circuit and produce direct current (DC) electricity, which can be used to
power various devices or be stored in batteries. Solar panels are also known as solar cell
panels, solar electric panels, or PV modules.
Solar panels are usually arranged in groups called arrays or systems. A photovoltaic
system consists of one or more solar panels, an inverter that converts DC electricity to alternating
current (AC) electricity, and sometimes other components such as controllers, meters, and trackers.
Most panels are in solar farms, which supply the electricity grid as can some rooftop solar.
Some advantages of solar panels are that they use a renewable and clean source of energy,
reduce greenhouse gas emissions, and lower electricity bills. Some disadvantages are that they
depend on the availability and intensity of sunlight, require cleaning, and have high initial costs.
Solar panels are widely used for residential, commercial, and industrial purposes, as well as
in space, often together with batteries.

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SOLAR PANELS

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2. PURPOSE OF INDUSTRIAL TRAINING

Our main purpose for this visit is to be familiar with industrial environment and to get
practical knowledge of how we can install solar panels at actual site & use environment
friendly option to traditional power sources. One other purpose is we can decide our 6th
semester project on industrial based.

3. WHAT WE LEARN?

By doing actual site visit we learn many basic things related to on site installation of solar
panels, various parts of solar panels.

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4. CONSTRUCTION & MAIN COMPONENETS OF SOLAR PANEL

In a world that badly needs clean energy options, solar panels have become a bright light.
These simple devices can do something amazing: they can turn sunlight into electricity. This will
change the way we power our homes, businesses, and even whole towns. This in-depth look will
go over the main purpose of solar panels, the science behind how they work, and the huge impact
they can have on making the future healthier and more sustainable for everyone.

➢ Solar Panel Construction

Solar panel technology is advancing rapidly with greater efficiency and lower prices,
resulting in a huge increase in demand. However, despite the massive advancements in
technology, basic solar panel construction hasn’t changed much over the years. Most solar panels
are still made using a series of silicon crystalline cells sandwiched between a front glass plate and
a rear polymer plastic back-sheet supported within an aluminium frame.

➢ How are Solar Cells Made?

Solar panels use photovoltaic cells, or PV cells for short, made from silicon crystalline wafers
similar to the wafers used to make computer processors. The silicon wafers can be either
polycrystalline or monocrystalline and are produced using several different manufacturing
methods. The most efficient type is monocrystalline (mono), manufactured using the well-known
Czochralski process.

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Main Components of a Solar Panel

1. Solar photovoltaic cells

2. Toughened Glass - Typically 3.2mm thick
3. Extruded Aluminium frame
4. Encapsulation - EVA film layers
5. Polymer rear back-sheet
6. Junction box - diodes and connectors

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MAIN COMPONENTS USED IN THE CONSTRUCTION

OF SOLAR PANEL.

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1. Solar PV Cells

Solar photovoltaic cells or PV cells convert sunlight directly into DC electrical energy. The
solar panel's performance is determined by the cell type and characteristics of the silicon used,
with the two main types being monocrystalline and polycrystalline silicon.
The base of the PV cell is a very thin wafer, typically 0.1mm thick, and is made from either
positive p-type silicon or negative n-type silicon. There are many different cell sizes and
configurations available that offer different levels of efficiency and performance, including half-
cut or split cells, multi-busbar (MBB) cells, and, more recently, shingled cells using thin
overlapping wafer strips.
Most residential solar panels contain 60 full-size monocrystalline cells or 120 half-size
cells linked together via busbars in series to generate a voltage between 30-40 volts, depending
on the type of cell used. Larger solar panels used for commercial systems and utility-scale solar
farms contain 72 full-size or 144 half-size cells and, in turn, operate at a higher voltage. The
electrical contacts that interconnect the cells are known as busbars and allow the current to flow
through all the cells in a circuit.

2. Glass

The front glass sheet protects the PV cells from the weather and impact from hail or
airborne debris. The glass is typically high strength tempered glass which is 3.0 to 4.0mm thick
and is designed resist mechanical loads and extreme temperature changes. The IEC minimum

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standard impact test requires solar panels to withstand an impact of hail stones of 1 inch (25 mm)
diameter traveling up to 60 mph (27 m/s). In the event of an accident or severe impact tempered
glass is also much safer than standard glass as it shatters into tiny fragments rather than sharp
jagged sections.

3. Aluminium Frame
The aluminium frame plays a critical role by both protecting the edge of the laminate
section housing the cells and providing a solid structure to mount the solar panel in position. The
extruded aluminium sections are designed to be extremely lightweight, stiff and able to withstand
extreme stress and loading from high wind and external forces.
The aluminium frame can be silver or anodised black and depending on the panel
manufacturer the corner sections can either be screwed, pressed or clamped together providing
different levels of strength and stiffness.

4. EVA Film
EVA stands for ‘ethylene vinyl acetate’, which is a specially designed polymer highly
transparent (plastic) layer used to encapsulate the cells and hold them in position during
manufacture.
The EVA material must be extremely durable and tolerant of extreme temperature and
humidity, it plays an important part in the long term performance by preventing moisture and dirt
ingress.
The lamination on either side of the PV cells provides some shock absorption and helps
protect the cells and interconnecting wires from vibrations and sudden impact from hail stones
and other objects.
A high-quality EVA film with a high degree of what is known as ‘cross-linking’ can be the
difference between a long life and a panel failure due to water ingress. During manufacture, the
cells are first encapsulated with the EVA before being assembled within the glass and back sheet.

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5. Backsheet

The backsheet is the rearmost layer of standard solar panels which acts as a moisture barrier
and final external skin to provide both mechanical protection and electrical insulation. The
backsheet material is made of various polymers or plastics including PP, PET and PVF which
offer different levels of protection, thermal stability and long-term UV resistance.
The backsheet layer is typically white in colour but is also available as clear or black, depending
on the manufacturer and module.

6. Junction Box and Connectors

The junction box is a small weatherproof enclosure located on the rear side of the panel. It
is needed to securely attach the cables required to interconnect the panels. The junction box is
important as it is the central point where the cell groups interconnect and must be protected from
moisture and dirt.

• Bypass Diodes
The junction box also houses the bypass diodes, which are needed to prevent reverse
currents, which can occur when cells are shaded or dirty. Diodes only allow current to flow in
one direction, and a typical 60-cell panel is divided into 3 groups of 20 PV cells, each with a
bypass diode for preventing reverse current.

• Solar MC4 Connectors

Almost all solar panels are connected using special weather-resistant plugs and sockets
called MC4 connectors. The term MC4 stands for multi-contact 4mm diameter connector. Due to
extreme weather conditions, the connectors must be very robust, secure, and UV resistant and
maintain a good connection with minimal resistance at both low and high voltages up to 1000V.

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Solar Panel Assembly and Manufacturing

Solar panels are assembled in advanced manufacturing facilities using automated robotic
equipment and sensors to precisely position the components with extreme accuracy. The
manufacturing plants must be extremely clean and controlled to prevent any contamination during
assembly.
Throughout the manufacturing process, the panels and cells are checked and inspected using
advanced optical/imaging sensors to ensure all the components are located correctly and the cells
wafers, which are very delicate, are not damaged or cracked during the assembly process.
Depending on the manufacturer, the final panel assembly is thoroughly checked using a
number of tests, including electroluminescent (EL) or flash testing, to identify any defects in the
cells which could lead to failure once exposed to sunlight and high temperatures for many years.

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7. CONCLUSION

From this visit, we got the information and practical knowledge about Solar Panels.
We got the knowledge about different components of solar panels.
Solar panels are widely used for residential, commercial, and industrial purposes, as well
as in space, often together with batteries.

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