Solar panel manufacturing

Solar panel construction is no longer just a progressive choice, but has become a necessity for many businesses, factories, farmers, and even villa homes. In a world where fossil fuel prices are constantly fluctuating and concerns about air pollution are increasing, solar panel construction is recognized as a practical, affordable, and sustainable solution.

But the main question is this. Is solar panel construction as easy as it seems? The short answer is no. This process requires a detailed understanding of solar cells, the quality of tools, environmental conditions, technical connections, and even how to arrange the panels. For example, many people who have attempted to build solar panels on a small scale without specialized training have ended up facing the problem of low efficiency or early failure of the system. On the other hand, those who have acquired the necessary technical knowledge and used quality components have been able to build panels with a long useful life and reliable performance.

For example, in an agricultural project in the hot and dry region of Yazd, a farmer started building solar panels using basic knowledge and cheap equipment, but due to the use of non-standard glass and low-quality cells, the energy production efficiency reached less than 30 percent of the expected amount. In contrast, a greenhouse owner in Fars province, by purchasing standard equipment and adhering to scientific principles, was able to provide 70 percent of the electricity needed for his complex with solar panels he made himself.

In this article, we will examine the stages of building a professional solar panel with a detailed and step-by-step approach. From choosing equipment and raw materials to examining the challenges, costs and key points, we explain everything in simple but specialized language. If you are looking for energy self-sufficiency and reducing dependence on the electricity grid, or if you are planning to enter the solar energy market, this guide is exactly what you need.

Investigating the Costs of Solar Panel Manufacturing Equipment

To start building a solar panel, it is very important to know the exact costs required. Many people think that by simply buying a few solar cells and connecting them to a glass plate, they can produce a usable panel, but the reality is that the professional manufacturing process requires a set of specialized equipment, high-quality raw materials and high precision in the execution of the steps. Costs can be divided into three main categories:

Raw materials and main parts
Solar cells (Photovoltaic Cells): These cells are the heart of the panel and their quality has a direct impact on the final efficiency. The price of cells varies depending on their type (monocrystalline or polycrystalline). For example, monocrystalline cells with higher efficiency are usually more expensive.
Clear tempered glass: Used to protect the cells from impact, dust and UV rays. One square meter of glass with the appropriate thickness costs about 150 to 300 thousand tomans.
EVA sheet (cell protection adhesive): Used for bonding and insulating between layers. Each square meter of EVA sheet costs about 100 to 150 thousand tomans.
Aluminum frame: Which holds the structure and framework of the panel. The price of each meter of aluminum frame is about 100 to 200 thousand tomans.

Electronic and peripheral equipment
Bypass diode, MC4 connector and junction box: These components are used to prevent reverse current and connect safely to the circuit. A complete set of these components usually costs between 350 to 700 thousand tomans.
Special cables for solar panels: It is necessary to use cables with a UV and moisture-resistant coating. Each meter of cable costs about 60 to 120 thousand tomans.

Assembly tools and equipment
Laminator: Used to compress and stabilize the layers of the panel. This equipment is expensive, and alternative methods are usually used in home projects.
Special soldering iron, voltage tester, precision measuring tools, clamps and holders: These tools may seem simple, but without them, it is not possible to build a solar panel of the desired quality.

We will show you how to get the most out of this equipment. The next section is about the points to consider when choosing construction tools, because the final quality of the panel directly depends on these choices.

Tips for Choosing Quality Tools for Solar Panel Construction

One of the most important parts of building a solar panel is choosing tools that will not only get the job done more accurately and quickly, but will also increase the lifespan and efficiency of the final panel. Many people start out by buying cheap or substandard tools to keep costs down, but the result is usually nothing more than rework and reduced panel quality. In this section, we will discuss key tips for choosing quality tools that are important for both small workshops and industrial projects.

Use tools that are specifically designed for working with solar cells. For example, a regular soldering iron cannot produce the uniform and precise heat needed to solder solar cells. Using a special solar panel soldering iron that has temperature control will allow you to make clean and secure connections and minimize the risk of damage to the cells.
Take the accuracy of your measuring tool seriously. Devices such as a precision digital multimeter, solar voltage tester or even a laser thermometer are crucial in the process of testing voltage, current and final quality control. Low-precision tools may cause errors that are not visible on the surface but cause loss of efficiency or failure in the long run.
Pay attention to the brand of the tools. For example, brands such as Weller for soldering irons or Fluke for multimeters have passed their test in the global market. Although they are more expensive, the accuracy, durability and safety of these tools are much higher than other models.
Do not underestimate auxiliary tools: Holding clamps, movable stands, LED magnifiers and even an anti-static pad (ESD Mat) are among the items that are secondary in appearance but play a fundamental role in the quality and comfort of work. For example, using an anti-static pad can prevent sudden discharge of electrical charge. This can seriously damage sensitive cells.

Challenges and Solutions in Solar Panel Construction

Although solar panel construction may seem simple and attractive at first glance, in practice it is accompanied by a series of technical, operational and even economic challenges. Many projects, especially in the early stages, fail or face low efficiency due to unfamiliarity with these challenges. In this section, we will examine the most common problems and suggest solutions for each so that you have the least waste of time and money during the construction process.

1. Poor connections between cells
Problem: Improper connections between cells cause voltage drops, overheating of the panel and even fire in extreme cases. This happens most often when inaccurate soldering irons or poor-quality solder strips are used.
Solution: Use standard tin strips, a temperature-controlled soldering iron and test the panel before final packaging. Also, testing the resistance of the connections with an accurate multimeter before installation can prevent problems.
2. Using poor quality materials
Problem: Poor quality glass, cheap EVA, or second-hand cells will eventually cause the panel to lose its efficiency very quickly or be vulnerable to weather conditions.
Solution: Always buy from reputable suppliers, even if the price is higher. Initial tests on raw material samples can also help ensure their quality. For smaller projects, buying reputable kits from well-known brands can be a safer option.
3. Lack of proper ventilation and heat dissipation
Problem: Panels heat up greatly when absorbing sunlight. If the design is not designed to dissipate heat, the efficiency of the panel will decrease and its lifespan will be shortened.
Solution: Designing the frame with air circulation behind the panel and using heat-reflecting paints on the backsheet will reduce the operating temperature. Also, installing at the right angle and height can help with natural air circulation.
4. Non-standard cell arrangement design
Problem: Many beginners choose the wrong series/parallel patterns when arranging the cells, which causes voltage interference and output power loss.
Solution: Design a simulated circuit on paper before arranging the cells. If you are not familiar with electrical circuit design, use free software such as PVsyst or Tinkercad or consult a technical consultant.
5. The manufactured panel does not match the consumption requirement
Problem: Sometimes people make panels that are either too weak or their output is not compatible with the existing equipment.
Solution: Before starting construction, first estimate the exact consumption of the desired equipment and based on that determine the required output voltage and amperage. Then select the number of cells and the appropriate arrangement according to these parameters.

Example: In a home project in Rasht, a person started building a solar panel for a yard lighting system. Although the cells were of high quality, the panel worked for only two months and then the efficiency dropped sharply. Investigations showed that the metal frame without ventilation space and poor-quality solder strips were the cause of premature failure. In the redesigned version, by creating a gap between the panel and the mounting surface, using standard tin tape and UV-resistant adhesives, the problem was completely solved and the panel continues to work without loss of performance.

Ways to Ensure Success in a Solar Panel Construction Project

Solar panel construction is a complex process that requires precise knowledge, professional tools, and attention to detail at every stage. As we have seen, to achieve high-quality and efficient panels, one should not rely only on experience, but also use modern science and new technologies. Whether in selecting high-quality raw materials and tools, or in designing circuits and how to arrange cells. Every part of this process is directly related to the final performance of the panel.

For those seeking to build solar panels with world-class standards, focusing on science and expertise rather than relying on old experiences and trial and error methods is vital. Using precise tools, studying and familiarizing oneself with scientific processes, and using consultants and experts in the field of solar energy can pave the way for success on this path.

Introducing Shamim Andisheh and ways to contact Shamim Andisheh

Shamim Andisheh continues its activities with the aim of improving the level of knowledge and capability in the field of renewable energy production, especially solar energy. This complex provides practical and theoretical consulting and training by utilizing the latest methods and specialized tools in the field of manufacturing and optimizing solar panels. Relying on up-to-date technical knowledge and a team of experts, Shamim Andisheh can accompany you on the path to manufacturing solar panels with excellent efficiency and quality.

To contact Shamim Andisheh and receive technical advice, more information, or order equipment, you can do so through the following ways:

∴Contact number: 12-44071011(021)

∴Email: shamim@shamimco.com

∴Website: www.shamimco.com

∴Social networks: Contact us via 09394121002.