abstract: In the interest of expediting future pilot line start-ups for solar cell research, the development of Arizona State University's student-led pilot line at the Solar Power Laboratory is discussed extensively within this work. Several experiments and characterization techniques used to formulate and optimize a series of processes for fabricating diffused-junction, screen-printed silicon solar cells are expounded upon. An experiment is conducted in which the thickness of a PECVD deposited anti-reflection coating (ARC) is varied across several samples and modeled as a function of deposition time. Using this statistical model in tandem with reflectance measurements for each sample, the ARC thickness is optimized to increase light trapping in the solar cells. A response surface model (RSM) experiment is conducted in which 3 process parameters are varied on the PECVD tool for the deposition of the ARCs on several samples. A contactless photoconductance decay (PCD) tool is used to measure the dark saturation currents of these samples. A statistical analysis is performed using JMP in which optimum deposition parameters are found. A separate experiment shows an increase in the passivation quality of the a-SiNx:H ARCs deposited on the solar cells made on the line using these optimum parameters. A RSM experiment is used to optimize the printing process for a particular silver paste in a similar fashion, the results of which are confirmed by analyzing the series resistance of subsequent cells fabricated on the line. An in-depth explanation of a more advanced analysis using JMP and PCD measurements on the passivation quality of 3 aluminum back-surface fields (BSF) is given. From this experiment, a comparison of the means is conducted in order to choose the most effective BSF paste for cells fabricated on the line. An experiment is conducted in parallel which confirms the results via Voc measurements. It is shown that in a period of 11 months, the pilot line went from producing a top cell efficiency of 11.5% to 17.6%. Many of these methods used for the development of this pilot line are equally applicable to other cell structures, and can easily be applied to other solar cell pilot lines. / Dissertation/Thesis / M.S. Electrical Engineering 2014

A novel 2SSS (2 Step Solid Selenization) CIGS (Cu, In, Ga, Se) thin film solar cell recipe was developed which can be a replacement to the conventional co-deposition process usually employed for large-scale manufacturing. The co-deposition procedure is faced with multiple problems such as selenium incorporation, effective gallium incorporation in the absorber. It is a 2-step proprietary procedure with better control over growth mechanisms and material utilization for the absorber layer for the CIGS thin film solar cells. It makes use of solid selenium source as preferred by manufacturers. Each step of the 2-step procedure was dealt with separately for stoichiometric analysis and interesting trade-offs between materials such as gallium, indium and selenium was found. Solar cells with this proprietary absorber were fabricated on soda lime glass substrates. Results of the solar cells made with the 2SSS process matched with that of the co-deposition process with the quantum efficiencies near 80% of the co-deposition cells. These experiments are going to serve as the test bed for the pilot line that is intended to be installed at USF's research campus soon. The finished solar cells were characterized. The scanning electron microscope (SEM), energy dispersive spectroscopy (EDS) and X-ray diffraction (XRD) were some of the important tools during the analysis of stoichiometry and structural properties. The device performances were measured with the help of current-voltage (I-V) testing and quantum efficiency (QE) measurements.

Planning and management of logistics and material flow are widely studied and two key factors contributing to company competitiveness. Automation in material flow is recognized in efficient and profitable factories in the context of today’s smart industry, however, the operators are playing a significant role as well. The purpose of the study was to identify which criteria could be used to determine the level of automation in a material flow of the industrial factory. A model was developed to practically support the decision making on the level of automation for the case company that was going to build a pilot line for battery manufacturing. The question for the case company was to decide whether the process should be fully automated, manual, or semi-automated in its trial production to avoid costly reconfigurations when a full production starts. In this study a literature review was conducted in the form of previous research to describe which criteria were important to decide the level of automation. The literature study together with site visiting, interviews, survey and document analysis was used for the formulation of research questions, establishment of methodology and model development. The study has identified different criteria whereas six of them are shared by both literature studies and the case company. Two unique criteria were identified in the case company but not found in the literature: lead time and recruitment. The lead time refers to the time from planning to finished process and the recruitment is about how difficult to recruit people with the right skills. Two theoretical contributions presented in this study: new criteria when deciding on the level of automation and a model that assists in decisions regarding the level of automation in early phases. The model is also a practical contribution to the case company. Finally, some suggestions for further research within the area are presented.