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Conveyor – Floating Unit

Floating Units are the solution for all processes that require non-contact transportation and precise positioning of flat, fragile objects.
Floating units are used for the structuring process in solar panel production. During the process, the glass substrate hovers above the Floating Unit at a defined distance of a few μm from the carrier plate.

Description

Concept and Design

Floating Units are the solution for all processes that require non-contact transportation and precise positioning of flat, fragile objects.
Floating units are used for the structuring process in solar panel production. During the process, the glass substrate hovers above the Floating Unit at a defined distance of a few μm from the carrier plate.
This is achieved through the precise arrangement of pressure nozzles and vacuum nozzles. The requirements for precise positioning could not be met by simply creating an air cushion by pressure nozzles that work against the ambient pressure. Only the interaction of positive and negative pressure makes it possible to position the glass substrates so precisely that they can be moved within the narrow focus of a stationary laser. The repeatability of flatness within defined positions on moving substrates is very high.
The body of the Floating Unit is made of black anodized aluminum.
Side-by-side placement of several Floating Units is possible. Deviating sizes are available on request.
The air gap at the edges can be individually controlled by a separate air supply. It is set to 45 μm, while the PV functionality is retained.

key Futures

  • Variable sizes possible
  • Non-contact flattening and transport of substrate
  • Substrate thickness 5 mm ± 0.5 mm
  • Air bearing/vacuum chuck
  • Nominal air gap 30 µm
  • Clean room suitable
  • Side-by-side placement is possible

Setup Procedure

Setup Procedure

  • Connect the Floating Unit (FU) to 4 Tip-Tilt-Units (TTUs), which serve as a leveling
  • Set TTUs to the approximate
  • Position FU on the
  • Connect to air supply and
  • Align FU as required, using an auxiliary axis system and/or a digital spirit
  • Continue setting up the 2nd FU:
    Align 2nd FU with reference to 1st FU. Use an auxiliary axis system, a digital spirit level or a steel ruler. For optimum performance, the height offset at the gap between the FUs should be < 5 µm.
  • Continue with the setup of additional FUs as described

Specifications

Specifications

Mechanical Data Unit PA PV
Dimension (length x width x height) mm 153 x 300 x 35 1) 200 x 432.5 x 50 1)
Mass kg 5.6 2) 8.5 2)
Substrate thickness mm   2.5 ± 0.5
Max. acceptable glass flatness µm 70 µm / 200 mm
Nominal air gap µm ≥100 20 – 30
Flatness of air gap over 100 mm µm ± 5
Flatness of air gap over the entire Floating Unit µm ± 6
Repeatability of air gap with moving glass at any reference point on the PV chuck µm   ± 1
Flatness of chuck surface µm   < 10
Air supply at PA zone mbar 50 50
Air supply at PV zone mbar   1300
Vacuum mbar g   – 600
Air consumption Sl/min 15 15
Vacuum consumption Sl/min   25
Clean room suitability   suitable suitable
Material   aluminum, black anodized
MTBF h > 20,000 > 20,000
Requirements on Air Quality Value ISO class
Particle size ≤ 1 µm DIN ISO 8573-1 class 2
Pressure dew point ≤ +3 °C DIN ISO 8573-1 class 4
Oil content ≤ 0.1 mg/m³ DIN ISO 8573-1 class 2

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