Trina Solar has recently built three Vertex Super Factories in the Chinese cities of Yiwu, Suqian and Yancheng. By the end of 2020, the company will see its 210mm-module production capacity already exceeding 22GW, a figure which will exceed 50GW during 2021.
The Vertex factory in Yiwu was completed and cutover in just 112 days and, at the end of July, the first 4GW phase of module production commenced, with the groundbreaking ceremony for the second phase of 4GW held on the same day. This is the world’s first factory to produce innovative and ultra-high-power products based on 210mm silicon wafers, cells and modules.
The Suqian factory has a capacity of 12GW, with both first and second phases already in operation and a third progressing rapidly, with production scheduled to commence during the first quarter of 2021. Further overseas Vertex factories are in the planning stage.
The Vertex Super Factories are based on cutting-edge technologies and manufacturing techniques that are the most advanced in China’s photovoltaic industry.
In terms of technology, the Vertex series modules incorporate several state-of-the-art technologies such as non-destructive cutting, high-density interconnection and MBB, which are ahead of similar products in terms of power, efficiency and reliability.
Low-voltage, high-string-power design
Vertex 600W+ and 550W series modules adopt an innovative design with low voltage and high string power. This design can effectively reduce the number of strings and corresponding mechanical connections required, such as racking structure, DC cables and junction boxes. Other electrical connections can also be saved, resulting in lower system costs for customers. At the same time, the auto bussing machine equipment has integrated special high-precision placement and automated functionality.
Multi-busbar technology with precision in millimeters
Trina Solar was the first company in China to develop and achieve the industrialization of Multi-busbar technology (MBB). MBB modules use precise positioning and welding solutions to achieve millimeter-level precision. Round ribbons are applied to enhance the secondary optical utilization of the ribbon area. The power, therefore, can be increased by more than 5W compared with 5BB modules, so that the conversion efficiency of Vertex modules can be boosted by as much as 0.3%.
The excellent performance of the company’s 210 mm modules – high efficiency, high power, high reliability, and significant reduction in BOS and LCOE costs – is made possible by a combination of innovative technologies, reflecting Trina Solar’s 23 years of technological and innovative advancement.
High Level of Automation and Productivity Efficiency
Trina Solar produces its Vertex modules with completely automated equipment. The company’s brand-new welding machine can operate at a speed of approximately 4,000 pieces per hour – currently the fastest in the industry – and its laminator is also extremely advanced in terms of power saving and production speed. The Vertex Super Factory can directly detect product defects through automatic visual inspection equipment using artificial intelligence technology, effectively improving inspection efficiency and product yield.
Compared with traditional workshops, Trina Solar’s fully automated workshop can reduce staff size by around 25% per GW. This results in a significant cut in labour costs in comparison with current 166mm or 158mm-module factories.
Sharing Data with Customers for Smart Manufacturing in the 600W+ era
“We already have a complete set of smart factory solutions and manufacturing data centers,” said Yang Xiaojun, General Manager of the Yiwu factory. “Data can help in different areas, such as monitoring the status of all production facilities, order tracking and customer order completion. It can be shared internally and with the company’s remote customers in real-time. For customers, they can view the production process and key parameters of the product anytime, anywhere.”
As one of the initiators of the 600W+ Photovoltaic Open Innovation Ecological Alliance, Trina Solar stands at the forefront of the new photovoltaic era. With super factories and cutting-edge innovation, the company underlines its commitment to its customers, while simultaneously driving the sustainable growth of the photovoltaic industry, leading it into a green future.