Unveiling the Secrets of Photovoltaic Bases: How Much “Black Technology” is Hidden Within?
The evolution from manufacturing to intelligent manufacturing is driving the transformation and upgrade of the photovoltaic industry. How does a simple solar cell transform from raw materials into high-tech photovoltaic modules? What role does intelligence play in this industry? Recently, a reporter visited the Haining base of Zhejiang Zhongtai New Energy Technology Co., Ltd. (hereafter referred to as “Zhongtai New Energy”) to find out.
Upon entering the component production workshop at the Haining base, dozens of production lines were running at high speed. Automated Guided Vehicles (AGVs) moved swiftly between various processes, and robotic arms were in constant motion, creating a busy yet orderly atmosphere.
Innovation on the Production Line: The Smart Factory’s Great Wisdom
Wearing special shoe covers and hairnets for the cleanroom, the reporter stepped into the component production area. The vast workshop had very few visible workers. “This is our latest intelligent production line, where almost the entire process, from raw material input to finished product, is completed automatically by machines,” explained the base instructor, Mo Mengting. By widely applying advanced numerical control, intelligent production lines, smart logistics, and intelligent inspection systems, Zhongtai New Energy has reached a leading position in the industry in terms of intelligent and flexible manufacturing.
Not only is it “smart,” but it is also “transparent.” In the Zhongtai New Energy Haining base factory, the automated and flexible production lines for components and cells are interconnected in real-time, providing clear visibility of production data. The manufacturing solutions can be adjusted in real-time according to different production needs. Mo mentioned that every photovoltaic module produced by Zhongtai New Energy carries a barcode, allowing customers to scan it and trace the entire lifecycle information, including process parameters, raw materials, and production pathways, ensuring product quality control and transparency.
It is noteworthy that in 2016, Zhongtai New Energy became a pioneer in “Chinese Intelligent Manufacturing” within the photovoltaic sector, establishing the world’s first “intelligent manufacturing + internet” transparent factory, enabling full monitoring and traceability from raw material input to finished product output. Zhongtai New Energy was also the first in the industry to implement AI automatic defect detection for components. By collaborating with Alibaba Cloud, it achieved 100% inspection of critical processes, intelligently identifying over 20 types of product defects with an accuracy rate of 99.7%.
At the Haining base, the intelligent production lines can save up to 75% of labor costs, significantly increasing the production output of photovoltaic modules. “Intelligent production not only enhances product quality and production efficiency but also greatly reduces production costs, strengthening the market competitiveness of enterprises,” stated Lu Chuan, Chairman and President of Zhongtai New Energy. “Through technological innovation, we can drive the photovoltaic industry from ‘manufacturing’ to ‘intelligent manufacturing’ and contribute intelligence to the energy transition.”
Energy Creation and Conservation: The “Open Source and Thrift” of a National-Level Green Factory
On the rooftop of the Zhongtai New Energy Haining base, photovoltaic panels are efficiently absorbing every inch of sunlight. As a “national-level green factory” and a pilot for future factories in Zhejiang Province, the Haining base has carefully constructed a 53-megawatt distributed photovoltaic power generation system based on energy demand within the park, complemented by BIPV parking sheds, photovoltaic corridors, and wind power stations to ensure stable clean electricity supply. On sunny days, the parking sheds can generate between 150 to 170 kilowatt-hours, sufficient to charge five electric vehicles simultaneously.
Utilizing the Internet of Things, big data, and artificial intelligence, Zhongtai New Energy has established an intelligent operation and maintenance system to monitor and manage photovoltaic and wind power equipment in real-time, greatly improving energy utilization without wasting any sunlight. The energy structure layout of the base is cleverly designed: vertical axis wind turbines perfectly align with the rooftop photovoltaic arrays, while PEM electrolyzers facilitate green power conversion. The energy storage station acts like a giant “power bank,” stabilizing energy fluctuations, collectively forming a “wind-solar-hydrogen-storage-charging” intelligent microgrid for multi-energy complementarity demonstration.
This project effectively combines “parking sheds + photovoltaics + energy storage + charging systems + wind power generation systems + microgrid energy management platforms” through systematic configuration of various clean energy sources and intelligent control of park energy efficiency. This approach promotes a bidirectional integration of energy supply and demand through “open source and thrift,” contributing to the construction of low-carbon green parks and exploring new models for energy supply and consumption.
At the intelligent production lines of Zhongtai New Energy’s Haining base, every product is a green “art piece” crafted by technological power, embodying the immense momentum of the transformation and upgrade of the photovoltaic industry in China. The breakthroughs Zhongtai New Energy has achieved in intelligent manufacturing not only reflect the development of the photovoltaic industry but also serve as a model for energy technology innovation within private enterprises in China.
The growth of photovoltaic companies like Zhongtai is supported by the government’s robust backing of the new energy sector. In recent years, to address issues such as intense competition within the photovoltaic industry, the National Energy Administration, in collaboration with the Ministry of Industry and Information Technology and the National Development and Reform Commission, has conducted multiple investigations and discussions, issuing a series of policy measures to guide the healthy development of the photovoltaic sector and support private enterprises in increasing investments in solar, wind, and other new energy fields.
With the favorable policies, private enterprises account for about 60% of the wind turbine manufacturing industry in China, and the majority of photovoltaic equipment manufacturers are also private firms. By the end of 2024, Zhongtai New Energy’s cumulative global shipments are expected to exceed 130 gigawatts, ranking sixth worldwide in component shipments according to InfoLink for the first half of 2024, and has received the “Global Best Performance Component Manufacturer” award from Kiwa PVEL for reliability testing eight times.
“Private enterprises are an essential part of China’s economy and a vital force driving energy technology innovation,” Lu Chuan stated. “In the future, we will continue to increase our investment in technological innovation, promoting the intelligent and digital transformation of the photovoltaic industry, contributing to the high-quality development of China’s energy sector.”
