Sunway’s Nantong production base meets the growing demand for PV module production lines. It covers an area of 120,000 sqm and is equipped with the most advanced equipment and technology to produce high-quality modules to serve our customers better.
Sunway Solar has built a 400MW high-efficiency solar module production line, and all products are certified by TÜV Rheinland, TÜV SUD, UL, SGS, CQC, and CE.
Solar Cell Sorting
1. Appearance: Whether there are lobes, missing corners, broken grid, etc.;
2. Color: Classification of batteries with similar colors.
Solar Cell Welding
Weld the welding strip and the main grid line of the battery piece together;
Weld the front battery of the battery piece to the back electrode of the other battery piece to form a battery string.
Assembling
1. Tempered Glass
2. EVA (buffer, seismic, heat insulation, moisture-proof)
3. Solar Cell String
4. Backplane (insulation, water resistance, aging resistance)
4 samples are laminated together
Middle Test
Detect whether there are hidden cracks, black chips, dark chips, Broken grid, broken plate, low efficiency plate, over – cutting, positive and negative electrode connection and other problems
Lamination
Vacuum, heat, melt EVA,
Glue the battery, glass, and back plate together
Packing
Package delivery.
From incoming LFP cell grading to End-of-Line (EOL) full-load cycling, every battery module and system undergoes strict automated assembly and full MES barcode traceability.
Incoming Tier-1 prismatic LFP cells undergo automated Open Circuit Voltage (OCV), Internal Resistance (IR), and capacity testing. Cells are grouped into ultra-tight tolerance batches to eliminate capacity barrel effects.
Cell surfaces are plasma-treated to remove microscopic contaminants before structural adhesive application. Automated stacking machines insert aerogel thermal barriers between cells and bind modules under controlled preload force.
3D vision-guided laser welding joins aluminum/copper busbars to cell poles with minimal heat-affected zones. In-line CCD optical inspection and post-weld pull testing verify low contact resistance and structural integrity.
Installation of FPC/wire voltage sampling harnesses, multi-point NTC temperature sensors, and the Battery Management Unit (BMU). Dielectric withstand (Hi-Pot) and insulation resistance tests are executed immediately.
Battery modules, liquid cooling plates (or air ducts), and aerosol fire suppression units are integrated into the enclosure. Differential pressure decay testing validates both cooling loop integrity and IP65/IP67 ingress protection.
Every completed pack undergoes full charge-discharge cycling to verify deliverable capacity, thermal rise, and dynamic cell balance. End-of-Line (EOL) testing validates CAN/RS485 communication and BMS protection triggers.
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