Trajectory Oriented and Fault Tolerant Based Intelligent Process Control for Flexible CIGS PV Module Manufacturing: Phase 1 Final Technical Report, March 2003

With the assistance of NREL's PV Manufacturing R&D program, ITN Energy Systems, Inc. and Global Solar Energy, Inc. continued the advancement of CIGS production technology by developing trajectory-oriented predictive/control models, fault-tolerance control, control-platform development, in-situ sensors, and process improvements. Modeling activities to date include developing physics-based andempirical models for CIGS and physics-based Mo deposition processing, implementing model-based control for CIGS processing, and applying predictive models to the construction of new evaporation sources. Model-based control is enabled by implementing reduced or empirical models into a control platform. Reliability improvement activities include systematic development of fault-preventionprocedures (e.g., preventative maintenance schedules) and detection/reconfiguration of sensor and other hardware failures for the full range of CIGS PV production deposition processes. In-situ sensor development activities have resulted in improved control and indicate the potential for enhanced process status monitoring and control of all deposition processes. In spite of the short time sincethe program was initiated, substantial process improvements have been made, including significant improvement in CIGS uniformity, thickness control (e.g., 71% reduction in Cu variability), yield, and throughput.