Mass Produce Smart Solar Material That Includes Switches/Processor
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Factory Production Line Makes Smart Solar Material
Every building in the world should be completely covered with solar photovoltaic material, from roof-edge to roof-edge. MA2 engineers must develop a continuous factory process that manufactures solar material that includes solar cells, conductors, switches, processors, and diagnostics.
Smart Solar Lamination
Layers consist of solar cells, conductors, internal printed circuit boards, switches, processors, and metal backing for strength and fire protection. The blue layer is a solar cell that converts sun light to electricity. Total thickness is 1 to 4mm (0.04 to 0.16"). Material is later placed directly onto plywood roofs or onto corrugated steel panels.
Smart Solar Produces Sinewaves
Switches on PCB produce AC and DC voltages at different voltage levels and frequencies, as required by the various components (e.g. ideal power into compressor motor might be 35Hz at 82VAC). The PCB does much of the DC to AC conversion while relying on external filter components for cleanup.
Mount Conductors onto Sheet of Plastic
Stamping machine creates conductors and attaches to sheet of plastic: (1) Conductors (shown in red) are pressed into the mold (green), (2) upper stem (pink) keeps conductors in mold while press (gold) retracts, (3) plastic sheet (orange) with adhesive is placed above mold, and (4) lower stem (violet) presses conductors against plastic.
Design & Build Prototype Production Line
MA2 engineers design and build multiple prototype production lines that fabricate smart solar material. MA2 engineers create sample material and accurately calculate cost. MA2 funds prototype production lines at universities interested in automated solar (e.g. CMU, GIT, UICU, UCB, UMA, MIT).
Solar Mass Production
Henry Ford revolutionized transportation with mass production. We need to do the same with solar. This has not been done previously due to a lack of standards that define how components interconnect. MA2 needs to create these in order to propel solar forward. The solar industry needs to think more like Henry Ford and less like Rolls Royce.