Periodic Reporting for period 1 - Flex2Energy (Automated Manufacturing Production Line for Integrated Printed Organic Photovoltaics)
Periodo di rendicontazione: 2023-01-01 al 2024-06-30
Flex2Energy (F2E) is a 48-month project with the ambitious goal to manufacture reliable Integrated Photovoltaics (IPVs)
F2E will be realized by 5 objectives:
• Develop and upgrade manufacturing tools for design and aesthetics of OPV products
• Integrate tools, QC, equipment to Machines to build & demonstrate automated PL manufacturing of IPVs
• Manufacturing high efficiency, durable printed IPV products at competitive cost
• Demonstrate and Validate IPVs in energy efficient buildings, automotive and agriculture industries
• Deploy Market Strategy and Bridge the gap between PV and Building sectors
F2E will implement innovative IPV products in three business cases. BIPV products will be installed on a public and heavy industry building façade as energy efficient windows.
Agri-PVs will be installed on the roof of Greenhouses as a shade curtain system making it energy autonomous.
VIPVs will be installed on the roof of commercial vehicles and solar carports to provide energy to electric vehicles
F2E will be realized by 5 objectives:
• Develop and upgrade manufacturing tools for design and aesthetics of OPV products
• Integrate tools, QC, equipment to Machines to build & demonstrate automated PL manufacturing of IPVs
• Manufacturing high efficiency, durable printed IPV products at competitive cost
• Demonstrate and Validate IPVs in energy efficient buildings, automotive and agriculture industries
• Deploy Market Strategy and Bridge the gap between PV and Building sectors
F2E will implement innovative IPV products in three business cases. BIPV products will be installed on a public and heavy industry building façade as energy efficient windows.
Agri-PVs will be installed on the roof of Greenhouses as a shade curtain system making it energy autonomous.
VIPVs will be installed on the roof of commercial vehicles and solar carports to provide energy to electric vehicles
WP1:
• Visit of COA to OET/AUTh for on-site discussion on requirements of the R2R of the PPL
• Final decision on layout for machinery for R2R machine as a straight line (deviates from M12 status)
• Decision to develop new efficient dryers for R2R Machine
• Creation of layout for R2R machine
• Interfaces R2R for data management system DMCP defined
• Specifications of inspection systems aggregated
• Specifications for iPV modules defined
• Specifications for the IPV assembly line
• Specifications for each of the equipment composing the IPV assembly line
WP2:
• Creation of an Excel tracking file to monitor the international legislative framework for the IPVs.
• Population of the tracking file with 160 nationals (Greece, Romania, France, Lithuania), European, and international regulations, directives and standards.
• Decision to perform the certification of the IPVs on a combined basis to ensure reduced time and costs, compliance of the products with the latest version of the design requirements, and “one-stop” testing
• Decision to use standards IEC 61215 and IEC 61730 regarding the design and safety of the products, respectively, for the qualification process
• Creation of the environmental data collection datasheet, which includes all the necessary information regarding the manufacturing process steps, material inputs and outputs, energy and water consumption etc.
• Performance of the initial LCA and LCC screening of the IPV products, both of which are presented in detail in D2.5
WP3:
• Laser scribing tools design and scale up completed according to project requirements
• Laser process tests performed on real samples received from OET for P1, P2, P3 laser scribing
• Laser trimming tools were evaluated through real OPV samples and laser type is identified.
• Necessary changes and upgrades were identified and will be applied in all laser systems
• 4-axis base mechanical design has finished
• Research and orders of commercial materials of the 4-axis base has finished.
• Initial evaluation of the advanced manufacturing tools was conducted.
WP4:
• R2R SE, IPL and REF tools assembly and test, improvements of measurement and analysis speed
• Successful development and upgrade of software for the R2R-SE, R2R-IPL, R2R-REF optical tools
• Precise determination of the optical properties and thickness of materials involved in OPV stack
• Development of methodologies for the accurate acquisition and modelling of the optical properties of OPV nanomaterials
• Definition of the optical properties and reference optical values of the IPV nanomaterials for use as reference
• Creation of the library for optical properties of reference materials
• Successful assembly and calibration of the AOI-Coating/Laser System
• Development of the R2R-AOI Coating and Laser inspection software
WP5:
• Definition of information exchange between the lamination process and DMCP
• Definition of communication protocol and overall architecture for data exchange
• Specifications for the lamination process and equipment
• Initial laminator equipment concept
• Initial lamination process development with low temperature encapsulants
• Raw material selection and supplier identification compatible with specifications
WP6:
• Click&Coat modules defined for partner aggregates (R2R Machine)
• Full layout of R2R machine defined
• Registration alignment strategy discussed with OET
• QR code printing strategy research ongoing
• Prototype dryer defined and ordered
• Test module for web vibration measurement designed and ordered
• Facility requirements further defined
• Several IPV assembly line conceptual designs
• Computer simulation on performance of several IPV assembly line configuration
• Selection and detailed design of final IPV assembly line lay-out fitting OET facilitiesIPV
WP8:
• OET’s visit at ALU’s and ALBA’s facilities for the investigation of the two BIPV demo cases
• Effective collaboration between OET, KIR, and ALU in developing BIPV prototypes
• Successful planning, and construction, of the Mediterranean Greenhouse.
• Established the acquisition of the first car and investigated for the second for demonstration purposes.
WP9:
• The first characteristics of the toolkit aiming at creating workflows that will satisfy any stakeholder, has been established.
• The mapping of the relevant stakeholders has started for the F2E ICN, a cluster of clusters that will be established among the relevant partners of the consortium and with the addition of other members from around the world including other strong existing innovation clusters.
• Meetings with agri-clusters and workshops were organized.
• Communication channels with governmental organizations were established and an inventory of political participation in the events in which F2E participates has been created.
• Associations and clusters were identified, and contact was engaged to help building the so-called 3E (energy, environment, and economics) model which will be a typically linear optimization model.
• Visit of COA to OET/AUTh for on-site discussion on requirements of the R2R of the PPL
• Final decision on layout for machinery for R2R machine as a straight line (deviates from M12 status)
• Decision to develop new efficient dryers for R2R Machine
• Creation of layout for R2R machine
• Interfaces R2R for data management system DMCP defined
• Specifications of inspection systems aggregated
• Specifications for iPV modules defined
• Specifications for the IPV assembly line
• Specifications for each of the equipment composing the IPV assembly line
WP2:
• Creation of an Excel tracking file to monitor the international legislative framework for the IPVs.
• Population of the tracking file with 160 nationals (Greece, Romania, France, Lithuania), European, and international regulations, directives and standards.
• Decision to perform the certification of the IPVs on a combined basis to ensure reduced time and costs, compliance of the products with the latest version of the design requirements, and “one-stop” testing
• Decision to use standards IEC 61215 and IEC 61730 regarding the design and safety of the products, respectively, for the qualification process
• Creation of the environmental data collection datasheet, which includes all the necessary information regarding the manufacturing process steps, material inputs and outputs, energy and water consumption etc.
• Performance of the initial LCA and LCC screening of the IPV products, both of which are presented in detail in D2.5
WP3:
• Laser scribing tools design and scale up completed according to project requirements
• Laser process tests performed on real samples received from OET for P1, P2, P3 laser scribing
• Laser trimming tools were evaluated through real OPV samples and laser type is identified.
• Necessary changes and upgrades were identified and will be applied in all laser systems
• 4-axis base mechanical design has finished
• Research and orders of commercial materials of the 4-axis base has finished.
• Initial evaluation of the advanced manufacturing tools was conducted.
WP4:
• R2R SE, IPL and REF tools assembly and test, improvements of measurement and analysis speed
• Successful development and upgrade of software for the R2R-SE, R2R-IPL, R2R-REF optical tools
• Precise determination of the optical properties and thickness of materials involved in OPV stack
• Development of methodologies for the accurate acquisition and modelling of the optical properties of OPV nanomaterials
• Definition of the optical properties and reference optical values of the IPV nanomaterials for use as reference
• Creation of the library for optical properties of reference materials
• Successful assembly and calibration of the AOI-Coating/Laser System
• Development of the R2R-AOI Coating and Laser inspection software
WP5:
• Definition of information exchange between the lamination process and DMCP
• Definition of communication protocol and overall architecture for data exchange
• Specifications for the lamination process and equipment
• Initial laminator equipment concept
• Initial lamination process development with low temperature encapsulants
• Raw material selection and supplier identification compatible with specifications
WP6:
• Click&Coat modules defined for partner aggregates (R2R Machine)
• Full layout of R2R machine defined
• Registration alignment strategy discussed with OET
• QR code printing strategy research ongoing
• Prototype dryer defined and ordered
• Test module for web vibration measurement designed and ordered
• Facility requirements further defined
• Several IPV assembly line conceptual designs
• Computer simulation on performance of several IPV assembly line configuration
• Selection and detailed design of final IPV assembly line lay-out fitting OET facilitiesIPV
WP8:
• OET’s visit at ALU’s and ALBA’s facilities for the investigation of the two BIPV demo cases
• Effective collaboration between OET, KIR, and ALU in developing BIPV prototypes
• Successful planning, and construction, of the Mediterranean Greenhouse.
• Established the acquisition of the first car and investigated for the second for demonstration purposes.
WP9:
• The first characteristics of the toolkit aiming at creating workflows that will satisfy any stakeholder, has been established.
• The mapping of the relevant stakeholders has started for the F2E ICN, a cluster of clusters that will be established among the relevant partners of the consortium and with the addition of other members from around the world including other strong existing innovation clusters.
• Meetings with agri-clusters and workshops were organized.
• Communication channels with governmental organizations were established and an inventory of political participation in the events in which F2E participates has been created.
• Associations and clusters were identified, and contact was engaged to help building the so-called 3E (energy, environment, and economics) model which will be a typically linear optimization model.