Chinese PV production equipment provider Wuxi Autowell (ATW) has introduced a 1.3 GW fully integrated intelligent heterojunction (HJT) module encapsulation solution.
The system consists of a turnkey production line built around a proprietary set of zero busbar (0BB) stringers, automated layup equipment, and energy-efficient lamination technology. Rather than relying on fragmented, stand-alone machines, ATW proposes a fully integrated, data-driven manufacturing ecosystem designed to reduce both mechanical complexity and financial risk in HJT module production.
A key focus of the solution is addressing the inherent constraints of HJT cell manufacturing. Unlike TOPCon or PERC technologies, HJT cells are sensitive to elevated temperatures during interconnection processes and therefore require carefully controlled low-temperature soldering technologies. At the same time, industry trends toward thinner wafers—driven by silicon cost reduction—introduce higher risks of micro-cracks and breakage during handling. These combined challenges demand a production environment that minimizes stress on materials while maintaining high throughput.
“To meet these requirements, ATW’s 1.3 GW line is designed around continuous, low-stress automation,” a spokesperson from the company told pv magazine. “A central element of its cost-reduction strategy is the adoption of 0BB technology, which eliminates conventional silver busbars from the cell surface. This significantly reduces silver paste consumption, one of the largest cost contributors in HJT manufacturing, while preserving electrical performance. Material flow across the line is fully automated and coordinated by automated guided vehicles (AGVs), which transport cassettes between stations to ensure uninterrupted production.”
Within this system, several proprietary equipment units form the backbone of the production process. The AM050KF high-speed PV cell soldering stringer acts as a core processing unit, capable of handling cells ranging from full-cell and half-cell to third-cut and quarter-cut formats. It uses an infrared soldering system optimized for low-temperature pastes and operates at a throughput of over 10800 pieces per hour with an alignment accuracy of around 0.1 mm. Complementing this is the AM059BA/BF intelligent PV string layup machine, which precisely arranges cell strings into module layouts. Designed with flexibility in mind, it supports HJT as well as TOPCon and back-contact (BC) architectures, with cycle times reduced to under 41 seconds, according to the manufacturer.
Another key component is the KM256A multi-layer laminator, which provides encapsulation to protect modules from moisture ingress while also improving factory efficiency. Its vertical multi-layer design reportedly reduces floor space requirements by around 33% and cuts energy consumption by approximately 35%, while offering flexible heating options including electric, oil-based, and induction systems. Supporting these main stations are a series of high-speed auxiliary systems, including the AM141FBA loading machine, which achieves 99.9% transfer reliability through AGV-based handling, the AM078B butyl sealant coating system with a 12-second cycle time and automated inspection, and the AM073A/EA jumper soldering and inspection units, which complete interconnection and resistance verification in under 13 seconds.
Beyond the hardware itself, ATW’s approach also reflects a shift in its role from equipment supplier to process partner. The company positions itself as a provider of integrated services combining equipment delivery, process consulting, and operational support. Drawing on production data related to low-temperature pastes and ribbon materials, ATW assists manufacturers during the planning stage in selecting optimal material combinations tailored to specific cell characteristics, helping to reduce trial-and-error during commissioning.
After installation, support continues through ongoing data analysis of interconnection quality, electroluminescence (EL) imaging, and current-voltage (IV) performance. Combined with spare parts logistics and on-site engineering services, this closed-loop support system is designed to minimize downtime and accelerate ramp-up to full production capacity, enabling manufacturers to realize the efficiency and cost advantages of HJT technology more rapidly.
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