Rayzon Solar pioneering quality control in the PV industry

The company leads the booming solar PV industry, prioritising quality and resilience in challenging conditions.

Rayzon Solar is at the forefront of the swiftly expanding solar PV sector. Global efforts to reduce emissions and combat climate change underpin the industry’s growth, driving the urgent need for cleaner energy sources. As solar power takes centre stage in national grids, ensuring the enduring effectiveness of solar panels is pivotal for energy security. Rayzon Solar recognises that the performance of solar panels hinges on their long-term quality and resilience, particularly in the face of adverse conditions. Solar panels face unique challenges in regions like India with hot and humid climates due to the synergistic effects of UV rays, temperature, and humidity. Consequently, the company prioritises meticulous quality control practices to address these concerns. As pioneers in adopting advanced technologies like TOPCon and extending warranty periods to 30 years, maintaining stringent quality control during module manufacturing is the company’s guiding principle.

Rayzon Solar’s commitment to quality spans various stages – from Incoming Quality Control(IQC) to In-process Quality Control (IPQC) and culminating in Final Quality Control (FQC). While CoCs from raw material manufacturers offer insights, the company’s verifications are essential. Rayzon Solar stalwarts meticulously inspect critical parameters such as solar glass transmittance, encapsulant volume resistivity, and back sheet stress resistance. The foundation of a reliable solar panel lies in its glass, providing mechanical stability and safeguarding against external elements. The company’s rigorous testing includes the Ball drop and Fragmentation test to ensure glass quality that can withstand the rigours of 30 years.

As far as bifacial glass is concerned, IPQC is very important in the import and inward process since bifacial glass is thin in nature and light as compared to 3.2mm Glass. Encapsulants are central to solar panels, bonding components, and preventing Potential Induced Degradation (PID). To counter PID risks, Rayzon Solar specially procure PID-resistant solar cells, subjecting them, along with encapsulant and back sheets, to in-house climatic chamber tests. Also, for each encapsulant, the volume resistivity of the encapsulant is checked on a sampling basis to minimise leakage current flow in the modules (which also helps prevent PID).

The bond between the encapsulant, glass, and back sheet is evaluated rigorously using automated peel testers. It’s further scrutinised with Pressure Cooker Tests to ensure lasting adhesion. GelContent tests are integral, gauging the cross-linking of EVA encapsulant, which is vital for high-temperature stability. Back sheets contribute to insulation and environmental protection. A multi-layered approach demands stringent tests to prevent hydro-thermal degradation.

UV resistance and Pressure Cooker Tests confirm back sheet reliability, guarding against potential issues. The reliability of the junction box, housing terminals, and bypass diodes is validated through extensive PCT and BypassDiode Thermal tests, with the commitment to quality, which is reflected in the decision to extend the latter to 98 hours, as per NREL’s recommendation. Rayzon Solar’s dedication to quality is unwavering throughout the manufacturing process. The company upholds stringent quality checks from tabber-stringer and layup to lamination. 

Electroluminescence (EL) testing is a vital tool for uncovering hidden defects. Modules undergo rigorous testing using sun simulators and Hi-pot tests, followed by comprehensive accelerated tests to ensure real-world resilience.

At Rayzon Solar, quality management is not just a process; it’s the bedrock. The company’s constant vigilance over raw material and product quality cements the commitment to delivering unmatched reliability and longevity solar panels, aligning seamlessly with the industry’s growth trajectory and the changing energy landscape.