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This subcontract report describes how Energy Conversion Devices, Inc., has developed and built 7 generations of roll-to-roll amorphous silicon PV production equipment. In the ECD/United Solar production process, we deposit about a 1-mm-thick, 12-layer coating consisting of a metal/oxide backreflector, a 9-layer a-Si/a-SiGe alloy triple-junction solar cell, and top transparent conductive oxide coating onto 125-mm-thick, 35.5-cm-wide stainless-steel webs in a series of three roll-to-roll deposition machines. In the PV Manufacturing RD and most of the tasks affect operations and consequently need the support of United Solar production and QA/QC managers. In more » the process we have developed a good working relationship between the production personnel, whose mantra is''change nothing,'' and the R&D personnel, who mantra is''change everything.'' « less

Implementation of a Comprehensive On-Line Closed-Loop Diagnostic System for Roll-to-Roll Amorphous Silicon Solar Cell Production: Phase I Annual Report, 23 April 2003--31 August 2003