TABBER & STRINGER: THE KEY TO PRECISE, FAST AND RELIABLE SOLAR ASSEMBLY

In solar-module manufacturing, precision in solar-cell interconnection defines final performance. Mondragon Assembly’s PV Tabber & Stringer machines are essential for achieving automated solar assembly lines that combine speed, process control, and maximum reliability.

How a PV Tabber & Stringer Works in Solar Module Manufacturing

The Tabber & Stringer joins solar cells by soldering or conductive adhesive, creating the electrical “strings” that form the heart of a photovoltaic module.
This automated process ensures uniform and precise interconnection — essential for optimizing energy efficiency and durability.

Thanks to its adaptable and modular design, Mondragon Assembly’s machines adjust to different materials and cell technologies (such as TopCon, SMBB, or xBC) with minimal changeover time, ensuring flexible and profitable production.

Main Technical Features of a PV Tabber & Stringer

Designed to balance productivity and quality control, Mondragon Assembly’s PV Tabber & Stringers integrate smart automation and process traceability solutions:

• Up to 6,000 cycles per hour.
• Cell breakage rate < 0.2%, even at high speed.
• Compatibility with up to 24 wires / bus bars (BB).
• Infrared soldering with optional ECA conductive adhesive for low-temperature processes.
• Precise temperature control across multiple stages.
• Anti-camber systems to ensure ribbon straightness.
• Easy MES integration for complete traceability.

Complying with European Standards in Photovoltaic Automation

With over 20 years of experience in solar automation, Mondragon Assembly designs and manufactures its PV Tabber & Stringer machines in line with the highest European quality and safety standards.

This approach ensures process reliability, repeatable results, and compliance with international regulations for solar-module production.

Why Choose Mondragon Assembly’s Tabber & Stringer Machines?

The reliability of a solar assembly line depends on both performance and process stability.
Mondragon Assembly’s Tabber & Stringer machines deliver both, integrating advanced inspection and control technologies to guarantee consistent results in every production cycle.

• Key differentiators: Integration of inspection technologies such as photoluminescence to detect invisible defects before they affect module performance.
• Advanced traceability control that records every process parameter to ensure repeatable, verifiable production.
• Proprietary patents, including the continuous string system, which improves overall efficiency and reduces defects during assembly.
• Unique process-definition and control system ensuring every cell follows a uniform pattern, preventing deviations or quality loss at batch start-ups or recipe changes.

Through this approach, Mondragon Assembly meets European quality and reliability standards and stands as a benchmark in photovoltaic automation for manufacturers seeking stable, scalable lines with dedicated technical support.

Three Solutions for Different Production Levels and Solar Technologies

HMTS 3000 – Flexibility for Versatile Solar Assembly Lines

Designed for mainstream processes such as TopCon and SMBB, the MTS 3000 offers adaptability to various cell formats and the option to upgrade to emerging technologies like xBC.
Ideal for manufacturers seeking a robust, configurable machine that adapts to different production requirements with low changeover costs.

MTS 6000 – High Performance for Large-Scale Photovoltaic Production

Designed for high-volume lines, the MTS 6000 is compatible with back-contact cells, SMBB, and low-temperature adhesive bonding processes.

Its design minimizes downtime and ensures stable operation in continuous production environments, providing maximum productivity and traceability.

MTS-ECA – Innovation in Conductive Adhesive (ECA) Interconnection

The most advanced solution in the range enables cell interconnection via electrically conductive adhesive or soldering, featuring precise curing control and servo-assisted transport.

Targeted at manufacturers embracing next-generation interconnection technologies that demand greater thermal flexibility and reduced mechanical stress on cells.

Smart Automation for a More Efficient and Sustainable Solar Manufacturing

At Mondragon Assembly, Smart Automation goes beyond basic process automation.
It means integrating process intelligence, data traceability, and predictive control so that each stage of the solar line — from cell soldering to final module assembly — operates in a coordinated, efficient, and adaptive way.

This approach enables manufacturers to:

• Monitor and optimize critical parameters in real time, reducing errors and variability.
• Ensure complete traceability of each cell and string produced.
• Anticipate deviations or downtime through diagnostics and predictive maintenance systems.
• Reduce OPEX without compromising final product quality.

The result is a more stable, profitable, and sustainable photovoltaic manufacturing process, ready to adapt to new solar cell technologies.

How Can Mondragon Assembly Help You?

At Mondragon Assembly, we support solar manufacturers in the design and implementation of efficient, automated, and scalable assembly lines, adapted to each cell technology and production volume.

Our PV Tabber & Stringer machine is a key element within this ecosystem: it combines precision, reliability, and flexibility to ensure perfect cell interconnection and long-term production stability.

With over two decades of experience in the photovoltaic industry, we provide specialized technical support, complete traceability, and customized solutions that maximize profitability while reducing operational costs.

We act as a trusted European technology partner, bringing innovation, reliability, and local support to every project.

Mondragon Assembly — Your European Partner for Efficient Solar Manufacturing.

BMS testing in battery pack assembly: why it matters and how to get it right

What is BMS testing and why it’s critical in battery pack manufacturing

A Battery Management System (BMS) is the brain behind every battery pack. It monitors critical parameters like voltage, temperature and current, balances the cells, protects the system from unsafe conditions, and ensures proper communication with external devices. BMS testing in battery assembly ensures that all these functionalities are operating correctly before the battery leaves the production line.

Typical tests include:

• Communication validation (e.g. CAN, LIN protocols)

• Overvoltage and undervoltage protection

• Temperature monitoring

• Charge and discharge cycles

These tests are critical for the safety, reliability, and performance of the final product.

Where BMS testing fits in the battery assembly process

BMS testing is typically integrated towards the end of the battery pack assembly line, after all cells and electronic components have been installed. At this stage, the BMS is connected to the pack and ready to be activated and tested.

Depending on the type of product and production strategy, manufacturers can take different approaches:

In some cases, the BMS is tested as part of an end-of-line (EOL) station, where the entire battery pack undergoes a final round of functional and safety checks. This is common in automotive applications, where full traceability and performance validation are essential before shipping.

In smaller-scale or modular systems (for example, in micromobility or industrial storage) BMS testing may be performed earlier in the process, on individual modules rather than the full pack.

Some manufacturers use standalone BMS test stations, especially during development or pilot phases. Others integrate testing directly into an automated sequence, where the BMS is validated in parallel with other systems like cooling or final sealing.

The choice depends on factors like production volume, product complexity, level of automation, and regulatory requirements.

Key challenges when integrating BMS testing into a production line

Integrating BMS testing in a high-throughput environment involves several challenges: 

Protocol variability

Different customers use different communication standards (CAN, LIN, UART, etc.), and the system must be able to switch and interpret accordingly. 

Electrical and isolation requirements

Proper high-voltage isolation and grounding must be considered for safety and accuracy. 

Cycle time vs. test duration

Functional testing can take longer than standard assembly steps. The line must be designed to handle this without creating bottlenecks. 

MES integration and traceability

BMS test results must be linked to the serial number of each battery pack and stored for quality control and compliance. 

To address these challenges, Mondragon Assembly designs and integrates automated test solutions that adapt to each project’s specifications. From multi-protocol communication to full traceability and safe electrical configurations, our systems are engineered to keep performance and reliability at the core of the process. 

How automation improves BMS testing reliability and efficiency

Automating BMS testing enables capabilities that would be nearly impossible to achieve manually.

For example, in high-density battery packs where access to terminals is limited, automated stations can use programmable fixtures that adapt dynamically to the pack geometry, ensuring precise connections under safe conditions. During testing, the system communicates with the BMS via CAN or LIN protocols and validates response times down to milliseconds,  a level of granularity that’s critical for advanced EV or energy storage applications.

What to look for in BMS testing station provider

If you are a battery pack manufacturer, an integrator in the mobility sector, or a company entering the energy storage market, integrating BMS testing it’s a strategic decision. It will define how reliable, scalable, and compliant your production line is from day one.

The ideal partner must go beyond delivering a machine. Look for someone who:

• Understands battery systems: Including electrochemical behavior, thermal dynamics, and cell variability.

• Masters automation: Capable of designing and seamlessly integrating custom test stations into your line — without disrupting your flow.

• Offers long-term collaboration: With service, upgrades, and flexibility to grow with your production roadmap.

Mondragon Assembly works with companies like yours — whether you’re scaling up a line, launching a new pack, or transitioning from pilot to full production. Our team combines industrial automation know-how with deep battery expertise to help you make every pack count.

How Mondragon Assembly Automates Prismatic Battery Assembly for a leading european Solar Panel Manufacturer 

Implementation of a pilot automated line enabling greater efficiency, flexibility, and quality control in the production of prismatic batteries for energy storage. 

Energy storage innovation through industrial automation 

The energy storage sector is growing fast, driven by the demand for sustainable and efficient solutions. In this context, a leading European manufacturer of solar panels part of the BOD Group technology consortium, with diverse industrial activities, faced a critical challenge to support its growth strategy: diversifying its business and expanding its product portfolio. Until now, its operations had focused exclusively on solar panel manufacturing, but the increasing demand for energy storage solutions led the company to explore new opportunities.  

The challenge: Expanding into energy storage 

Solar power generation does not always align with peak consumption times, making battery storage systems essential. However, this solar technology company lacked in-house expertise in battery manufacturing. To overcome this, they sought a partner with proven skills in industrial automation and battery assembly lines. 

Mondragon Assembly’s solution: a pilot automated assembly line 

Together with the manufacturer, Mondragon Assembly designed and implemented a flexible pilot assembly line for prismatic batteries. The system integrates automation, scalability, and adaptability, allowing the company to manufacture different formats without major modifications. 

Key features of the automated battery assembly line 

The solution includes advanced automation technologies to guarantee efficiency, flexibility, and quality control: 

• Battery Check (OCV Testing): A robot performs charge and discharge tests to verify the condition of each cell before assembly, ensuring that only optimal units continue through the line. 

• Insulation Placement: This phase features a precise application system for insulation material, guaranteeing the protection and safety of each battery cell. 

• Thermographic Imaging and Thickness Control: Thermal imaging technology is used to check material uniformity, ensuring defect-free manufacturing. 

• Laser Cleaning: This phase is essential to ensure precise welding. Removing impurities via laser technology significantly enhances material adhesion and prevents connection defects. 

• 4kW Laser Welding: One of the most critical phases, where an automatic positioning system enables two types of high-precision welds—BB-CELL and LEX PCB-BB—ensuring robust and durable connections. Laser calibration is crucial in this phase, as any deviation could affect the final product quality. 

• Final Assembly Stage: In this final phase, the battery is sealed and finished to ensure protection and proper operation before distribution. 

Results and benefits 

The project has enabled the solar panel manufacturer to strengthen its position in the renewable energy storage market by achieving: 

• Time and cost optimisation through automation. 

• Product diversification, combining solar generation with storage solutions. 

• Improved reliability thanks to cutting-edge technologies such as 4kW laser welding. 

 What’s Next? 

This collaboration marks the start of a long-term strategy to transform energy storage manufacturing. The company’s commitment to innovation, combined with Mondragon Assembly’s industrial automation expertise, opens the door to future technological advances in the renewable energy sector 

Looking to automate your battery manufacturing process? Discover how Mondragon Assembly can design scalable and efficient assembly lines tailored to your energy storage needs. 

Contact us today. 

Customized Solar Panel Production Lines: Flexibility and Innovation for a Changing Market

How the photovoltaic market is evolving and why customization is crucial 

The photovoltaic industry is rapidly changing. Growing demand for clean energy and the need to reduce costs are driving innovation in solar panel production lines. Standardized solutions are no longer enough—manufacturers now require customized solar production equipment that adapts to new regulations, applications, and installation formats. 

The rise of new solar module formats and their impact on production lines 

One of today’s major challenges is the production of solar modules for non-conventional locations. For example, architects and developers are increasingly integrating PV modules into windows, façades, and non-conventional structures. This calls for innovative solar manufacturing equipment that adapt to the physical constraints of the environment. 

These developments cannot be addressed with traditional solar panel production lines. Machinery must be capable of manufacturing modules with unique characteristics: special dimensions, different materials, and custom designs, among others. Adaptability thus becomes a strategic factor. 

Why flexibility in solar panel production machinery provides a competitive advantage 

A flexible solar panel production line is now an essential requirement. With solar panel production machinery that can be reconfigured, scaled, or adjusted, manufacturers gain a clear advantage over their competitors. 

This not only involves having advanced machinery, but also an integrated approach that covers everything from panel analysis to defining the manufacturing process. The ability to modify, scale, or reconfigure a production line allows for agile responses to the sector’s evolving demands. 

Collaboration between manufacturers and machinery suppliers: the key to successful pv projects 

Developing customized solar production lines requires close collaboration between the machinery supplier and the module manufacturer. Each new project involves technical and developmental challenges that must be addressed jointly, from the conceptual phase to the commissioning of the line. 

In this process, trust and confidentiality are fundamental. Sharing critical information, working as a team, and maintaining fluid communication are key to ensuring project success. Mondragon Assembly works as a strategic partner in building tailor-made PV manufacturing solutions. 

Mondragon assembly’s expertise in developing tailor-made solar panel production solutions 

Thanks to our extensive experience in the sector, Mondragon Assembly has identified the customization of solar production lines as a decisive factor for competing in such a dynamic market. Our approach is based on designing tailor-made solutions adapted to each client’s specific needs. One of the pillars of this approach is our team of experts in new developments, who support clients throughout the entire process: from the initial idea to the commissioning and operation of the line. This team brings not only technical knowledge but also strategic vision to anticipate market trends. 

This collaborative philosophy has materialized in numerous successful projects, where flexibility, customization, and experience have been key to achieving our clients’ goals: 

Flexible front-end lines for multiple PV designs 

In some cases, solar module manufacturing is done in small batches or even individually, as our clients offer customized solutions. In these cases, having machines that adapt to each design is essential, as the time required to adjust the line to different designs is critical for our client’s efficiency and productivity. That’s why we developed a flexible front-line where machines adapt simply and efficiently to different models, ensuring high productivity even with constant model changes. 

Custom laminators for advanced materials 

In other cases, the challenge is not efficiency but rather the design of the module or the materials used, which require modifications to the manufacturing process. For example, in a project where one of the materials is heat-insulating, using a standard laminator limits the process and manufacturing efficiency. That’s why our solution was to develop a laminator with the heating plate on the top, thus simulating a standard process even when the material doesn’t allow it. 

Automated backend systems for flexible solar modules 

Another trend is solar flexible panels, where transporting the panel during production becomes a challenge. At Mondragon Assembly, we have worked with several of these, and for each one, we developed a different solution, as each of our clients has a unique goal. For example, in a project where the panel was flexible and our client didn’t want any operators in the backend, we developed a backend system combining our machines with customized panel handling. Thanks to this automated solar production machinery, all tests were carried out fully automatically, with complete accuracy and no manual intervention. 

From idea to manufacturing line: turning your solar project into reality 

The transformation of the solar market doesn’t slow down, and the ability to adapt with innovative and customized solutions makes the difference between keeping pace or falling behind. At Mondragon Assembly, innovation is in our DNA. We work side by side with our clients to develop special applications that respond to the sector’s new challenges.

Do you have an idea, a technical challenge, or a project that needs a tailor-made solution? Get in touch with us today and let’s turn it into the next generation of solar production technology. 

How do our specialized services improve the performance of a photovoltaic production line? 

At Mondragon Assembly, we understand that an efficient photovoltaic production line goes beyond having the right equipment. True value comes from offering specialized services that support the customer at every stage—from layout definition to technical support once the line is in full operation. Our goal is to ensure each project runs at full capacity from day one, with the confidence of a long-term partner.

Customized design and consulting for solar manufacturing lines

Each manufacturer has a unique setup. That’s why we offer a customized layout design service, adapted to the specific characteristics of each facility, available space, and final product. This includes equipment integration, material flow planning, and optimal station layout—such as stringing and lamination.

Logistics Optimization and Process Efficiency 

The photovoltaic industry evolves rapidly. Ensure your machinery can adapt to new technologies like HJT, TOPCon, or back-contact. Choosing flexible equipment ensures your solar production line can continue manufacturing panels with different cell types and configurations, staying competitive in a changing market.

Turnkey Commissioning of Photovoltaic Lines 

Production from Day One

A well-installed photovoltaic module line should be ready to produce from day one. Our global project experience allows us to ensure efficient installation and controlled commissioning, minimizing deviations and accelerating return on investment.

Calibration, Validation and Guided First Batches

Beyond mechanical and electrical installation, we provide process calibration, equipment validation, and guided initial productions—helping clients achieve operational stability and maximum efficiency right from the start.

Technical Training for Operators and Maintenance Staff 

Specialized Training by Role

We train operators, maintenance technicians, and line managers to maximize the potential of each machine. Our programs include tailored training for photovoltaic line operators according to each plant role, ensuring efficient and safe machinery use.

Practical Methodology and Continuous Support

Our training combines theory and practice and is aligned with critical processes such as stringing, lay-up, lamination, or testing. We also provide technical manuals, instructional videos, and remote support to ensure effective knowledge transfer.

Preventive and Corrective Maintenance for Automated Solar Lines

Prevention to Ensure Uptime

Ensuring operational availability is essential. That’s why we offer scheduled preventive maintenance and regular technical audits—helping anticipate failures, extend equipment lifespan, and avoid costly unplanned downtime.

Quick Support and Strategic Spare Parts

Our after-sales service ensures availability of strategic spare parts, fast response to incidents, and continuous improvements to extend system lifetime. Whether via remote support or on-site service, we respond quickly to reduce production impact.

Already Have a Line Installed and Want to Improve Its Performance?

We also work on the continuous improvement of existing lines. We analyze bottlenecks, redesign critical stations, add automation, and help scale up processes. The goal: get the most out of your existing resources and adapt to new technological demands.

Let’s Talk About Optimizing Your Solar Module Production Plant

Our team can help you define, install or upgrade your photovoltaic module production line with specialized services tailored to your industrial reality.

Contact us here.

6 key factors for choosing equipment in an efficient photovoltaic production line

How to make the right decisions from the start in a photovoltaic production line 

Choosing the right equipment for a photovoltaic production line not only impacts the quality of solar modules, but also the efficiency, traceability, maintenance, and scalability of the entire operation. In this article, we present the 6 key factors you should consider when selecting the best photovoltaic module manufacturing equipment. 

• Real-time traceability and production control 

Real-time data monitoring throughout the entire solar manufacturing line is essential to ensure module quality. Integrating a traceability system that tracks every component and operation helps detect deviations, reduce rework, and offer stronger guarantees to customers. 

• Equipment adaptable to new solar technologies 

The photovoltaic industry evolves rapidly. Ensure your machinery can adapt to new technologies like HJT, TOPCon, or back-contact. Choosing flexible equipment ensures your solar production line can continue manufacturing panels with different cell types and configurations, staying competitive in a changing market.

• Intuitive interface and specialized training 

In solar manufacturing, where every minute counts, ease of use and fast operator training are critical. Having intuitive interfaces, operator-assist systems, and strong initial training—especially for lay-up, soldering, and EL testing—is key to reaching full performance of your solar module production line quickly and efficiently. 

• Smart investment to optimize OPEX 

Solar panel manufacturing involves high energy use, sensitive materials, and processes where any error can cause costly waste. A good CAPEX decision not only improves energy efficiency and reduces scrap, but also lowers maintenance, reduces downtime, and ensures operational reliability. Investing in the right solar automation solution is crucial for long-term profitability. 

• Planned maintenance and fast support 

Old soldering, faulty laminations, or misalignments can lead to rejected modules or unplanned downtime. A full maintenance strategy is essential to avoid these issues and keep your photovoltaic production line running reliably. This strategy should include: 

• • Preventive maintenance plan: Avoid unexpected stops through scheduled inspections, replacement of critical parts, and control of key parameters. 
  • Fast and reliable technical support: When an issue arises, quick response is vital. A responsive technical service, with remote and on-site assistance, ensures your solar automation line stays productive with minimal delays. 
  • Availability of critical spare parts: Make sure you have key replacement parts available—either managed by your provider or stocked internally—to minimize downtime when repairs are needed. 

• Automation tailored to your application 

Each manufacturer must find the right balance between automation and flexibility. It’s not the same to produce standard solar modules for utility-scale plants as it is to create custom solutions for architectural or mobile integration. Depending on your production scale, budget, and quality goals, consider the following: 

• • Full automation for high-volume manufacturing: To achieve maximum efficiency and consistency, a fully automated production line with equipment such as tabber stringer machines and an automated lay-up system enables high output with minimal manual intervention. 

• • Semi-automated processes for more flexibility: Some factories choose to keep certain operations manual or semi-automated, such as assembly or final testing, which may be more cost-effective for medium or low production volumes. 

• • Custom technical evaluation: Working with a specialized partner allows you to design a hybrid or scalable solution tailored to your current and future needs. 

How a photovoltaic production line proves its value on the shop floor 

At Mondragon Assembly, we’ve been designing and supplying solar panel manufacturing lines worldwide for over two decades—adapting to all technologies and applications. This experience has taught us that concepts like traceability, robustness, efficiency, and technical support only prove their value when integrated into a real production line. 

Investing in a well-designed turnkey photovoltaic module line is the best way to accelerate ROI and ensure reliable production from day one. We see it every day, working closely with manufacturers around the world—because it’s on the production floor where automation, engineering, and service truly deliver results. 

Are you evaluating new machinery for your plant? Find out how we can help you with a customised photovoltaic line: https://www.mondragon-assembly.com/es/contactar/