图②隆基绿能嘉兴“灯塔工厂”每16秒下线一块组件公司供图
自动搬运车搭载着一架架薄薄的硅片往来穿梭；机械臂和传送带在透明小格子间里高效地焊接、装框、装接线盒，精准而迅速地完成着每一个生产环节……这是记者在隆基绿能嘉兴基地车间里看到的一幕。
2023年，隆基绿能嘉兴基地入选世界经济论坛公布的“灯塔工厂”名单，这也是全球光伏行业首个“灯塔工厂”。 数字化转型网（www.szhzxw.cn）
“灯塔工厂”被誉为“世界上最先进的工厂”和“全球化4.0”的创新示范者，由世界经济论坛和麦肯锡咨询公司共同组织评选。“灯塔工厂”入围要求十分严苛，需要集成至少5个世界级领先水平的技术应用，而隆基绿能嘉兴基地自2020年投产以来，已经开发实施了30多项数字化用例推动智能制造。
作为光伏行业的首个“灯塔工厂”，隆基绿能嘉兴基地有哪些“黑科技”？在光伏行业竞争加剧的当下，隆基绿能的“灯塔工厂”在推动光伏行业高质量发展方面有没有标杆意义？
一、解决行业难题
据介绍，隆基绿能嘉兴基地主要生产隆基BC（背接触电池技术）系列高效太阳能电池组件，隆基绿能嘉兴基地现有嘉兴一期、二期、三期工厂，总占地面积1300多亩，隆基绿能嘉兴基地具有51条智能化生产线，整体组件产能超35GW，是行业内规模较大的产业集群。
“在隆基绿能嘉兴基地，每隔16秒，生产线上就有一个组件下线。”隆基绿能嘉兴基地智能化项目负责人杜国祥对记者表示。 数字化转型网（www.szhzxw.cn）
由于电池片的隐裂用肉眼极难察觉，此前，电池片组成成品后，在终检环节发现问题，整个成品就要报废。同时，传统条码追溯不适用、虚拟码追溯准确率低，一直是困扰光伏组件生产的行业难题。
如今，嘉兴基地创新应用AI精准追溯技术，在生产过程中每18秒就可以判断出12串组件是否有缺陷。“同时，缺陷是哪条流水线哪个机台生产出来的，都可以进行识别和追溯。这一技术不仅能保证整个生产过程的高效率，还提高了对客户的响应速度。”杜国祥对记者表示，基于图像特征的AI追溯技术，是行业首创专利技术，解决了困扰光伏行业组件生产过程中传统条码追溯不适用、虚拟码追溯准确率低的行业难题。
这仅仅是隆基绿能嘉兴基地智能化、数字化的一个缩影。
在这座“灯塔工厂”中，隆基绿能大规模采用工业互联网、大数据、人工智能、数字孪生等新技术，成功实施了30余项数字化用例。其中包括五大核心“黑科技”，即机器视觉赋能的柔性自动化、AI赋能的全流程检测及追溯、订单生产交付周期智慧管理、AI算法赋能的电池资源匹配及动态纠偏、智能人力管理。
隆基绿能组件制造中心精益智造部负责人胡智锋介绍：“我们设计了人工智能和机器视觉赋能的柔性自动化，设备柔性化兼容多种产品型号尺寸，可实现生产线的快速切换，满足客户个性化需求。更智能的人力规划，可以保障高效能产出。” 数字化转型网（www.szhzxw.cn）
胡智锋透露，“灯塔工厂”项目实施后，产品品质可靠性提升43%，产品生产交付周期缩短84%，生产基地整体单位能耗降低20%，单位小时产量提升35%。
二、构建差异化优势
隆基绿能的数字化转型升级，为公司正在迭代升级的BC技术产品奠定了更好的发展基础。
“在外部环境发生变化，行业竞争加剧的情况下，企业更要注重修炼内功。‘内功’不是简简单单的自动化，而是真正实现数字化转型，要基于数据来挖掘更多的价值，实现成本的下降，质量的提升，客户更高的满意度，打造隆基绿能自身过硬的竞争力。”杜国祥表示。
BC技术是隆基绿能未来几年布局的重点方向。按照公司未来三年的规划，隆基绿能的BC电池年产能将达到100GW，单晶组件年产能将达到150GW。
多年来，BC技术的发展一直受制于成本、工序、良率等问题。也正是因为这些问题，让BC技术难以商业化，难以走进大众市场。 数字化转型网（www.szhzxw.cn）
围绕这些技术难点，早在2017年，隆基绿能就开始BC技术的商业化研发。“公司围绕BC技术问题开展研发，取得了重大技术突破。”隆基绿能中央研究院一院负责人童洪波表示，比如开发了一种新型材料，能将原来的BC技术的步骤减少四步，减少后的工艺流程较现有的TOPCon技术还少两步。
去年9月份，隆基绿能正式官宣其新一代的技术路线为BC技术。在隆基绿能看来，有了智造加持，公司的BC产品将在降本增效提质上迈向新台阶。
但对于隆基绿能而言，打造“灯塔工厂”还有更深考量。
“在过去相当长一段时间里，隆基绿能一直都在思考一个问题，即如何通过技术研发提高光电转换效率，解决光伏发电的最大痛点，简单来说就是‘练内功’。如今，经过多年努力，光电转换效率已经不断接近理论极限。下一步，如何更好地做组件，更好地满足客户多元化需求，这是隆基绿能努力的方向。”隆基绿能副总裁张海濛对记者表示。 数字化转型网（www.szhzxw.cn）
自去年9月份官宣BC技术至今，隆基绿能发布多个场景化组件新品，不论是防积灰还是耐湿热，其核心目的都是通过差异化的创新来满足客户的定制化需求。张海濛进一步介绍：“隆基绿能不仅要从研发端提升产品发电效率，同时也需要制造环节效率更高，满足客户多样化要求，更快向客户交付，以及对不同场景的定制产品能够柔性自动化生产出来。”
三、“灯塔工厂”的示范作用
7月9日，工信部发布的《光伏制造行业规范条件（2024年本）》（征求意见稿）中提到，鼓励企业将自动化、信息化、智能化及绿色化等贯穿于设计、生产、管理、检测和服务的各个环节，积极开展智能制造，提升本质安全水平，降低运营成本，缩短产品生产周期，提高生产效率，降低产品不良品率，提高能源利用率。
在业内看来，随着信息技术的不断发展，智能化、数字化将成为光伏行业发展的新引擎，是推动光伏行业高质量发展的重要驱动力。同时，数字化也将推动光伏行业的商业模式创新和市场拓展，为行业带来新的增长点。 数字化转型网（www.szhzxw.cn）
在隆基绿能的思维中，“灯塔工厂”的革新不只是在生产线自动化与智能化方面的改造，而是重构了生产关系，让AI智能成为生产管理的大脑，基于大数据模型，不断自主革新，实现真正意义的智造升级自驱力，为提质增效保驾护航。
张海濛透露，隆基绿能将持续把嘉兴“灯塔工厂”敏捷智造模式快速横向展开，推广至更多生产制造基地，实现生产智造能力的全方位提升，为光伏行业高质量发展树立数智化范本。
在业界看来，“灯塔工厂”的示范作用和成功经验可以引导其他企业向更高端、更智能、更绿色的方向迈进，推动产业结构优化，提高资源利用效率。
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翻译：
Longji Green Energy “Lighthouse factory” : follow the “light” intelligent manufacturing custom demand
Figure ① Intelligent flexible production process of photovoltaic modules
Figure 2 Longi Green Energy Jiaxing “Lighthouse factory” every 16 seconds down a component company for drawing
Automated trucks shuttle thin frames of silicon wafers; The robotic arm and conveyor belt efficiently weld, frame and install junction boxes in a transparent small cubicle, accurately and quickly completing each production link… This is reporter saw the scene in the workshop of Longi Green Jiaxing base.
In 2023, Longi Green Energy Jiaxing Base was selected into the list of “lighthouse factories” announced by the World Economic Forum, which is also the first “lighthouse factory” in the global photovoltaic industry.
The Lighthouse Factory is hailed as “the world’s most advanced factory” and an innovation demonstrator of “Globalization 4.0”, jointly organized by the World Economic Forum and McKinsey Consulting company. “Lighthouse Factory” shortlisted requirements are very strict, need to integrate at least 5 world-class leading level of technology applications, and Longi Green Energy Jiaxing base since the production in 2020, has developed and implemented more than 30 digital use cases to promote intelligent manufacturing. 数字化转型网（www.szhzxw.cn）
As the first “lighthouse factory” in the photovoltaic industry, what “black technology” does Longi Green Energy Jiaxing Base have? In the current intensified competition in the photovoltaic industry, does Longi Green Energy’s “lighthouse factory” have benchmarking significance in promoting the high-quality development of the photovoltaic industry?
1. Solve industry problems
According to reports, Longi Green Energy Jiaxing base mainly produces Longi BC (back contact battery technology) series of high-efficiency solar cell modules, the existing Jiaxing phase I, II, III factories, a total area of more than 1300 acres, with 51 intelligent production lines, the overall component production capacity of more than 35GW, is the industry’s largest industrial cluster.
”At Longi Green Energy’s Jiaxing base, every 16 seconds, a component comes off the production line.” Longi Green Energy Jiaxing base intelligent project leader Du Guoxiang told reporters.
Because the hidden crack of the battery is extremely difficult to detect with the naked eye, previously, after the battery is composed of the finished product, the problem is found in the final inspection link, and the entire finished product will be scrapped. At the same time, the traditional bar code traceability is not applicable, and the virtual code traceability accuracy is low, which has been a problem for the photovoltaic module production industry. 数字化转型网（www.szhzxw.cn）
Today, the innovative application of AI precision traceability technology in the Jiaxing base can determine whether 12 strings of components are defective every 18 seconds in the production process. “At the same time, the defects are produced by which assembly line and which machine can be identified and traced.” This technology not only ensures the efficiency of the entire production process, but also improves the speed of response to customers.” Du Guoxiang told reporters that the AI tracing technology based on image characteristics is the first patented technology in the industry, which solves the industry problems that plague the traditional bar code tracing and the low accuracy of virtual code tracing in the production process of photovoltaic industry components.
This is just a microcosm of the intelligent and digital Jiaxing base of Longi Green Energy.
In this “lighthouse factory”, Longi Green Energy has adopted new technologies such as industrial Internet, big data, artificial intelligence, and digital twins on a large scale, and successfully implemented more than 30 digital use cases. These include five core “black technologies”, namely, flexible automation enabled by machine vision, whole-process detection and traceability enabled by AI, intelligent management of order production and delivery cycle, battery resource matching and dynamic correction enabled by AI algorithm, and intelligent human management.
Hu Zhifeng, head of the Fine Intelligence Manufacturing Department of Longi Green Energy Component Manufacturing Center, introduced: “We have designed the flexible automation of artificial intelligence and machine vision, and the equipment is flexible and compatible with a variety of product models and sizes, which can realize the fast switching of the production line and meet the individual needs of customers.” Smarter workforce planning ensures high productivity.”
Hu Zhifeng revealed that after the implementation of the “Lighthouse factory” project, product quality reliability has been improved by 43%, product production and delivery cycle has been shortened by 84%, overall unit energy consumption of the production base has been reduced by 20%, and unit hourly output has been increased by 35%.
2. Build differentiated advantages
The digital transformation and upgrading of Longi Green Energy has laid a better foundation for the development of the BC technology products that the company is iterating and upgrading.
”In the case of changes in the external environment and intensifying competition in the industry, enterprises should pay more attention to the cultivation of internal skills.” “Internal work” is not simply automation, but the real realization of digital transformation, based on data to mine more value, to achieve cost reduction, quality improvement, higher customer satisfaction, to create Longji green energy itself excellent competitiveness.” Du Guoxiang said.
BC technology is the key direction of Longi Green Energy layout in the next few years. According to the company’s planning for the next three years, Longi Green Energy’s annual production capacity of BC batteries will reach 100GW, and the annual production capacity of single crystal components will reach 150GW. 数字化转型网（www.szhzxw.cn）
For many years, the development of BC technology has been limited by the cost, process, yield and other issues. It is precisely because of these problems that BC technology is difficult to commercialize and enter the mass market.
Around these technical difficulties, as early as 2017, Longi Green Energy began the commercial research and development of BC technology. “The company carried out research and development around BC technology issues and made major technological breakthroughs.” Tong Hongbo, head of the Central Research Institute of Longi Green Energy, said that, for example, a new material has been developed that can reduce the steps of the original BC technology by four steps, and the reduced process flow is two steps less than the existing TOPCon technology.
In September last year, Longi Green Energy officially announced its new generation of technology route for BC technology. In Longji Green Energy’s view, with the wisdom of the blessing, the company’s BC products will move to a new level in cost reduction, efficiency and quality improvement.
However, for Longi Green Energy, there are deeper considerations to build a “lighthouse factory”.
”In the past quite a long period of time, Longi Green Energy has been thinking about a problem, that is, how to improve the photoelectric conversion efficiency through technology research and development, to solve the biggest pain point of photovoltaic power generation, simply put, ‘practice internal work’.” Today, after years of efforts, the photoelectric conversion efficiency has been approaching the theoretical limit. In the next step, how to make better components and better meet the diversified needs of customers is the direction of Longi Green Energy’s efforts.” Longi green energy vice president Zhang Haimeng told reporters. 数字化转型网（www.szhzxw.cn）
Since the official announcement of BC technology in September last year, Longi Green Energy has released a number of new scenario-based components, whether it is ash prevention or humidity and heat resistance, its core purpose is to meet the customized needs of customers through differentiated innovation. Zhang Haimeng further introduced: “Longi Green Energy not only needs to improve the power generation efficiency of products from the research and development side, but also needs to be more efficient in the manufacturing process, meet the diversified requirements of customers, faster delivery to customers, and flexible automated production of customized products in different scenarios.”
3. The demonstration role of “lighthouse factory”
On July 9, the “Photovoltaic Manufacturing industry Specification Conditions (2024)” (draft for comment) issued by the Ministry of Industry and Information Technology mentioned that enterprises are encouraged to automate, information, intelligent and green throughout all aspects of design, production, management, testing and service, actively carry out intelligent manufacturing, improve the essential safety level, reduce operating costs, and shorten the production cycle of products. Improve production efficiency, reduce the rate of defective products, improve energy utilization.
In the view of the industry, with the continuous development of information technology, intelligence and digitalization will become a new engine for the development of the photovoltaic industry, and an important driving force to promote the high-quality development of the photovoltaic industry. At the same time, digitalization will also promote the PV industry’s business model innovation and market expansion, bringing new growth points to the industry.
In the thinking of Longji Green Energy, the innovation of “lighthouse factory” is not only the transformation of production line automation and intelligence, but the reconstruction of production relations, so that AI intelligence becomes the brain of production management, based on big data models, continuous independent innovation, to achieve the true sense of intelligent manufacturing upgrade self-drive, and escort for improving quality and efficiency.
Zhang Haimeng revealed that Longi Green Energy will continue to rapidly expand the agile intelligent manufacturing model of Jiaxing “Lighthouse factory” and promote it to more production and manufacturing bases, so as to achieve an all-round improvement of production intelligent manufacturing capacity and establish a digital intelligent model for the high-quality development of the photovoltaic industry. 数字化转型网（www.szhzxw.cn）
In the view of the industry, the demonstration role and successful experience of the “lighthouse factory” can guide other enterprises to move towards a more high-end, smarter and greener direction, promote the optimization of industrial structure and improve the efficiency of resource utilization.
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