From its creation in 1977, Mondragon Assembly has been committed to innovation as a means of achieving growth, dedicating large part of its resources to promoting new product research and development, and extending its comprehensive service offering. Additionally, the group has had its own technology centre since 2002, aimed at developing and capturing technologies over the medium and long term.
Its main areas of research include:
- New photovoltaic module production technologies: Back Contact interconnection, Lead Free soldering, Conductive adhesives for Heterojunction and flexible cells, Multiwire interconnection
- New processes: Automatic cell breakage detection via EL, lamination alternative to EVA.
- Production yield optimisation: Production control software, production tracking systems, total production flexibility (seamless model changing).
- New automation technologies: Industry 4.0: Self-learning and self-aware machines, collaborative robots that share the workplace with operators.
- New assembly processes: Laser technology, joining of dissimilar materials.
E-MOBILITY & ENERGY STORAGE
- Development of a lithium-ion module assembly line with cylindrical, prismatic and pouch cells.
- Development of fuel cells assembly lines.
Mondragon Assembly has become a European benchmark for automation and assembly technologies, participating in numerous innovation projects.
The GOPV project aims to reduce the cost of photovoltaic energy generation in European plants by 50%. To this end, Mondragon Assembly is contributing to the project with the development of machinery capable of assembling high-power photovoltaic modules automatically. These modules use HJT technology cells and the connection is made using electrically conductive adhesives.
ZDMP is a Horizon 2020 Project for innovation in the EU aimed at developing solutions that allow zero-defect manufacturing by means of the use of cloud-based IT platforms that provide specific services.
To do so, an open-source platform will be developed, as well as the development environment, the marketplace and the apps to allow industries to access the tools that allow the zero-defect paradigm to be achieved.
FLOIM is a Horizon 2020 Project for innovation in the EU aimed at developing solutions that allow the manufacture of optoelectronics by means of plastic injection processes.
These components are currently manufactured by means of processes that are far more expensive, and the development of injection processes that achieve the requirements of the optoelectronic market will enable an extraordinary reduction in the cost of these components.
PICKPLACE is an EU 2020 Horizon 2020 innovation project aimed at developing solutions that combine the capabilities of robots and people in a safe, flexible and reliable environment. The collaboration is planned in an intralogistics environment for which new solutions will be developed: dynamic packaging planning, flexible capture strategies, and a multifunction clamp. These advances will be combined with a perception system and action strategies to create a safe environment for collaboration between the person and the robot.
LAY2FORM is an EU Horizon 2020 research and development project aiming at the manufacturing of 3D pieces lightened by means of the hybridisation of metals with composite materials of the thermoplastic matrix. The manufacturing platform will respond to a flexible line concept with cognitive automation, monitoring, and online inspection. In addition, the process will be modelled to provide real-time optimisation of the products that are manufactured in the line.
Manufacturing is undergoing immense yet gradual Industry 4.0 transformation with the help of advancements including predictive maintenance. SMART-PDM’s objective is to acquire manufacturing data to provide diagnosis and prognosis information while rendering the underlying technology financially feasible. This will result in lower costs of maintenance, waste and parts as well as improvements in quality and throughput. The technological advancements validated by the demonstrators will help enhance the know-how, technologies, solution offerings and toolsets of the partners.
Productive 4.0, an Europen project where Mondragon Assembly participate, is a project to improve the digitalization of the European industry by electronics and ICT. Almost half of the budget is funded, partly by the EU, partly by ECSEL Joint Undertaking and the national authorities of involved countries. There are involved 109 partners and 19 countries
The aim is to create a user platform across value chains and industries, thus promoting the digital networking of manufacturing companies, production machines and products.
The participating partners will examine methods, concepts and technologies for service-oriented architecture as well as for components and infrastructure in the Internet of Things. Other aspects are standardization and process virtualization, in other words, simulating manufacturing processes to optimize real workflows. The platform can be used in the three interlocked process pillars for managing the supply chains, the product life cycle and digital production.
The core of the HIPERION project is a disruptive solar photovoltaic (PV) module technology, based on planar optical micro-tracking, which concentrates sunlight on multi-junction solar cells on top of a conventional silicon backplane, integrated within a static frame.
This innovative module architecture achieves more than 30% efficiency under direct sunlight, while still harvesting diffuse sunlight with its underlying PV backplane.
Compatible with any type of installation from rooftop to ground-mounted trackers, the solution produces up to 50% more energy than conventional c-Si modules with the same form-factor.
BIPV refers to building elements that, together with their role as building cladding, produce renewable solar energy thanks to PV integration.
The overall ambition of the BIPVBOOST project focuses on bringing down the cost of multifunctional building-integrated photovoltaic (BIPV) systems, limiting the overcost compared to traditional, non-PV, construction solutions and non-integrated PV modules.
This will be done through an effective implementation of short and medium-term cost reduction roadmaps addressing the whole BIPV value chain and demonstration of the contribution of the technology towards mass realization of nearly Zero Energy Buildings.
MONDRAGON ASSEMBLY S.COOP. participates in the project entitled “Digital Value Network for Advanced Services Based on Connected Machines”, which has been co-financed with ERDF funds and subsidised by the Basque Government.
The MADINET project is an initiative whose main objective is to develop advanced data analytics applications to optimise production processes (quality, productivity, maintenance). The development of the applications will be carried out evenly in the implementation and validation in cases of real use.
MONDRAGON ASSEMBLY S.COOP. participates in the project entitled “Battery as a Service: Services in Li-ion Batteries with technology 4.0”, which has been co-financed with ERDF funds and subsidised by the Basque Government.
The BATTERY4.0 project is an initiative whose main objective is to develop technologies of total traceability, both at the level of raw materials and as productive processes and operating conditions in the field. This technology is developed with the aim of offering advanced services to the end users of the batteries. The development of the technology and implantation in the pilots will allow the validation of results in real conditions.
MONDRAGON ASSEMBLY S.COOP. participates in the project entitled “CLOUD PLATFORM FOR REAL-TIME QUALITY CONTROL OF PHOTOVOLTAIC MODULES IN DIFFERENT PRODUCTION PLANTS, BASED ON THE AUTOMATED RECOGNITION OF ELECTROLUMINESCENCE IMAGES”, which has been co-financed with ERDF funds and subsidised by the Basque Government.
The CLOUDEL project is an initiative whose main objective is to develop artificial intelligence technologies for self-detection of breaks in photovoltaic panels, allowing objective quality control. In addition to the development of classification technology, a “cloud2” version of the platform will be implemented, which will allow the detection of errors in a production plant based on knowledge acquired in other production plants, and which will be automatically integrated into the “learning” of ML algorithms. The development of the technology and implantation in the pilots will allow the validation of results in real conditions.
MONDRAGON ASSEMBLY S.COOP. participates in the project entitled “DEVELOPMENT OF MANUFACTURING TECHNOLOGY FOR PHOTOVOLTAIC MODULES BASED ON THE SHINGLING CONCEPT”, which has been co-financed with ERDF funds and subsidised by the Basque Government.
The SHINGLING project is an initiative whose main objective is to develop photovoltaic modules with the shingling concept in which the interconnection of the cells is carried out without conductive wires, providing a great aesthetic value while increasing the power density per area unit (W/m2). Alongside the development of module technology, manufacturing equipment will be developed, and a prototype will be built and validated by Tecnalia. The development of the technology and the manufacture of the prototype will allow the validation of results in real conditions.
MONDRAGON ASSEMBLY S.COOP. takes part in the “Intelligent Digital Assets in Industrial Environments” project, which has been co-financed with ERDF funds and subsidised by the Basque Government.
The ADIERA project is an initiative with the main objective of generating and “productivising” industrial knowledge, equipping industrial solutions and services with smart and autonomous digital assets to further advance the digital transformation in industry.
This industrial research project proposes a leap forward, starting from the concept of a digital platform explored in previous projects, with an innovative proposal based on the transversal application of Artificial Intelligence to all digital assets or segments of the digital value network.
MONDRAGON ASSEMBLY S.COOP. takes part in the “Artificial Intelligence Solutions for the Automation and Control of Production Systems and Processes” project, which has been co-financed with ERDF funds and subsidised by the Basque Government.
The AUTOMATIA project is an initiative with the main objective of developing new advanced control and automation algorithms based on artificial intelligence for drives, machines and manufacturing processes.
The aim is to introduce the new paradigm of Artificial Intelligence into the field of process control and automation in both process and manufacturing industries, in order to provide companies in the industrial sector with new technology and new capabilities.
MONDRAGON ASSEMBLY S.COOP. takes part in the “Integration of digital identity and BlockChain to create value-added services based on Industrial SmartContracts” project, which has been co-financed with ERDF funds and subsidised by the Basque Government.
The SmartCON project is an initiative, driven by the AFM cluster, with the main objective of researching and developing digitalisation solutions that enable machine tool companies to maximise the added value of their current industrial products, optimising the efficiency, availability, interoperability and quality of their resources, maintenance services, design and production processes, as well as the creation of innovative business models for their multiple customers and suppliers in the new global digital ecosystem of the process industry. This project will respond to the needs of the priority areas defined in the RIS 3 strategy of the Basque Country.
Proposed solutions should be based on the latest standards and on CPS/IoT/Cloud disruptive technologies that maximise efficiency in industrial production, as well as the control and maintenance of machinery throughout the value network.
MONDRAGON ASSEMBLY S.COOP. takes part in the “Development of virtual commissioning technologies based on digital twins of turnkey production plants” project, which has been co-financed with ERDF funds and subsidised by the Basque Government.
The VIRTUCOM project is an initiative with the main objective of developing virtual models of photovoltaic panel manufacturing lines, based on digital twins of each process station, so that each customer can be offered a customised optimisation according to their needs from the quotation phase.