Electromagnetic welding head mechanism for photovoltaic module junction box

Abstract

The application discloses a photovoltaic module junction box electromagnetic welding sealing welding head mechanism, which comprises a sealing welding head and a base. The sealing welding head comprises a mounting seat, the top surface of the mounting seat is provided with a mounting hole for mounting a welding machine, and the middle is a cooling water channel hole. The other end of a welding pipe is connected with a sealing head for preventing deformation of a coil, the sealing head is made of high-temperature-resistant epoxy resin and is plasticized, the other end of the welding pipe is welded on the mounting base, the welding coil copper pipe inside the bottom end of the sealing head is wrapped into a rotary body, the bottom end of the sealing head is inlaid with a ceramic part, the ceramic part is provided with a ceramic sheet guide column in the center, the inner hole of the welding head spiral body is assembled with the ceramic sheet guide column, and then the sealing is performed. After the sealing, the stability of the welding head is enhanced, the ceramic at the bottom of the sealed welding head is not easy to stick with flux and tin, automatic cleaning can be used, the service life is prolonged, the use cost of the welding head is reduced, and the labor cleaning cost is saved.

Description

Technical Field

[0001] This invention belongs to the field of high-frequency electromagnetic welding machine technology, specifically relating to the electromagnetic welding encapsulation welding head mechanism for photovoltaic module junction boxes. Background Technology

[0002] Currently, the welding heads of high-frequency electromagnetic welding machines for photovoltaic junction boxes on the market are made of thin copper tubing. During use, they are prone to attracting flux and molten solder. Excessive solder can cause the welding head to short-circuit and burn out. Furthermore, solder on the coil welding head during welding poses a risk of lifting the junction box. Failure to clean it promptly can deform the shape of the welding head and the welding surface, affecting the welding quality of the photovoltaic module junction box.

[0003] Cleaning these types of welding heads requires highly skilled workers. The process involves removing the flux from the welding head surface without altering its shape or position. Manual cleaning is inefficient, infrequent, and prone to welding head deformation and displacement, leading to poor welding and high labor and rework costs. Summary of the Invention

[0004] The purpose of this invention is to provide an electromagnetic welding head encapsulation mechanism for photovoltaic module junction boxes. The welding head is encapsulated with encapsulation material to form a whole, so that the welding head is not easily deformed. Ceramic is inlaid at the bottom of the welding head to increase its welding surface and improve welding quality. The ceramic does not stick to solder and is not easy to stick to flux, making it easier to clean. The high hardness of the ceramic surface makes it more wear-resistant and improves the service life of the welding head, thereby solving the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A photovoltaic module junction box electromagnetic welding encapsulation welding head mechanism includes an encapsulation welding head and a base for mounting a cleaning box. The encapsulation welding head includes a mounting seat for mounting a welding tube. The top surface of the mounting seat has a mounting hole for mounting a welding machine. There are two sets of mounting seats, and the bottom ends of the two sets of mounting seats have insertion holes. The interior of the mounting seat has cooling water holes for cooling the copper tube of the welding coil. The interior of each insertion hole is welded and fixed to one end of the welding tube. The other end of the welding tube is encapsulated with an encapsulation head that fixes and prevents the coil from deforming. The encapsulation head is made of high-temperature resistant epoxy resin. The copper tube of the welding coil is inserted and fixed inside the other end of the welding tube. The copper tube of the welding coil is located inside the bottom end of the encapsulation head and is wound into a spiral structure. A ceramic plate is embedded in the bottom end of the encapsulation head. A ceramic plate guide post is integrally formed in the center of the ceramic plate. The spiral structure formed by the copper tube of the welding coil contacts and assembles with the ceramic plate guide post.

[0007] Preferably, the encapsulation welding head is equipped with a cleaning box, a gearbox is installed on the side wall of the cleaning box, the input shaft of the gearbox is fixedly installed with the output shaft of the motor, a control box is installed on the side wall of the motor, and the output shaft of the gearbox is fixedly installed with the rotating rod.

[0008] Preferably, the cleaning box has a cleaning port inside, and a dirt collection box is provided inside one side wall of the cleaning box, and the side wall of the rotating rod is rotatably connected to the slot.

[0009] Preferably, the end of the rotating rod located inside the cleaning port is welded to the center of one side of the limiting plate, and an installation rod is welded to the center of the other side of the limiting plate. A cross block is welded to the side wall of the installation rod, and the cross block is inserted into the cross groove inside the cleaning wheel. A cleaning copper brush sleeve is installed on the side wall of the cleaning wheel.

[0010] Preferably, the end of the mounting rod is provided with a threaded groove, and the mounting rod is connected to the internal thread of the nut through the threaded groove on the end. A washer is provided between the nut and the cleaning wheel, and a closed pin for limiting the position of the nut is inserted through the side wall of the mounting rod.

[0011] Preferably, a limiting groove is formed on the other side wall of the cleaning box, and a moving rod is slidably connected inside the limiting groove. A limiting plate is fixedly connected to the side wall of the moving rod located inside the limiting groove. The limiting plate is slidably connected to the inside of the limiting groove, and a spring is provided inside the limiting groove. The spring is sleeved on the side wall of the moving rod and abuts against one side of the limiting plate.

[0012] Preferably, a movable base is fixedly connected to the end of the movable rod located inside the cleaning port, and a rotating groove is opened inside the movable base. One end of the mounting rod is rotatably connected to the inside of the rotating groove.

[0013] Preferably, the bottom surface of the cleaning port is provided with a groove, and a dirt collection box is slidably connected inside the groove. A handle is installed on the side wall of the dirt collection box.

[0014] Technical effects and advantages of the present invention: Compared with the prior art, the electromagnetic welding encapsulation welding head mechanism for photovoltaic module junction boxes proposed in this invention has the following beneficial effects:

[0015] 1. This invention provides an electromagnetic welding encapsulation welding head mechanism for photovoltaic module junction boxes. The improved welding head, by sealing the side wall of the welding tube with high-temperature resistant epoxy resin, can fix and prevent the internal welding coil copper tube from deforming during use and enhance stability. Furthermore, by embedding and installing a ceramic plate at the bottom of the encapsulation head, flux and solder are less likely to stick during the welding process, thus extending the service life and reducing the cost of using the welding head.

[0016] 2. This invention provides a welding head mechanism for electromagnetic welding of photovoltaic module junction boxes. By adding a cleaning box to the welding machine and driving it with a motor, gearbox and rotating rod, the cleaning wheel with a cleaning copper brush sleeve installed in the cleaning box rotates, which can automatically clean the residual flux or tin on the ceramic sheet, improve the cleanliness of the welding head during use and save on manual cleaning costs.

[0017] Other features and advantages of the invention will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures pointed out in the description and the drawings. Attached Figure Description

[0018] Figure 1 This is a three-dimensional structural diagram of the welding head assembly of the present invention;

[0019] Figure 2 This is a schematic diagram of the internal structure of the welding head of the present invention;

[0020] Figure 3 This is a schematic diagram of the assembly structure of the welded pipe, the copper tube of the welding coil, and the mounting base of the present invention.

[0021] Figure 4 This is a schematic diagram of the cleaning box and welding head of the present invention;

[0022] Figure 5 This is a schematic diagram of the internal structure of the cleaning box of the present invention.

[0023] The diagram labels are as follows: 1. Mounting base; 2. Mounting hole; 3. Cooling water hole; 4. Welded pipe; 5. Encapsulation head; 7. Insertion hole; 8. Welded coil copper tube; 9. Ceramic plate guide post; 10. Ceramic plate; 11. Base; 12. Dirt collection box; 13. Cleaning copper brush sleeve; 14. Motor; 15. Control box; 16. Gearbox; 17. Cleaning box; 18. Cleaning port; 19. Handle; 20. Rotating rod; 21. Slot; 23. Slide groove; 24. Limiting plate; 25. Mounting rod; 26. Cross block; 27. Cleaning wheel; 28. Cross groove; 29. ​​Limiting groove; 30. Washer; 31. Nut; 32. Closing pin; 33. Moving base; 34. Rotating groove; 35. Moving rod; 36. Limiting plate; 37. Spring. Detailed Implementation

[0024] The same or similar components are designated by the same reference numerals in different figures; in addition, please understand that terms such as "first", "second", "third", "upper", "lower", "front", "rear", "inner", "outer", "end", "part", "segment", "width", "thickness", "area" and similar terms are only for the convenience of the reader to refer to the structure in the figures and are only used to help describe the present invention, and are not intended to limit the present invention.

[0025] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The specific embodiments described herein are merely used to explain the present invention and are not intended to limit the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] This invention provides, for example Figure 1-5 The photovoltaic module junction box electromagnetic welding encapsulation welding head mechanism shown includes an encapsulation welding head and a base 11 for mounting a cleaning box 17. The encapsulation welding head includes a mounting seat 1 for mounting the welding pipe 4. By mounting the base 11 on an electromagnetic welding machine, the welding head can be automatically cleaned. The top surface of the mounting seat 1 has a mounting hole 2 for mounting the welding machine. There are two sets of mounting seats 1, and the bottom ends of the two sets of mounting seats 1 have insertion holes 7. The interior of the mounting seat 1 has cooling water holes 3 for cooling the copper tube 8 of the welding coil. The interior of the insertion holes 7 is... One end of the welded tube 4 is inserted and fixed, and the other end of the welded tube 4 is encapsulated with an encapsulation head 5 to fix and prevent the coil from deforming. The encapsulation head 5 is made of high-temperature resistant epoxy resin. The other end of the welded tube 4 is inserted and fixed with a welding coil copper tube 8. The welding coil copper tube 8 located inside the bottom end of the encapsulation head 5 is wound into a rotating body. A ceramic plate 10 is embedded in the bottom end of the encapsulation head 5. A ceramic plate guide post 9 is integrally formed in the center of the ceramic plate 10. The interior of the rotating body formed by the welding coil copper tube 8 is inserted and in contact with the side wall of the ceramic plate guide post 9.

[0027] Both the ceramic sheet 10 and the ceramic sheet guide post 9 are made of zirconia ceramic. Zirconia ceramic has excellent properties such as high melting point, high boiling point, high hardness, insulation at room temperature and insulation at high temperature. This allows the copper tube 8 of the welding coil to generate an induced current with the workpiece when energized. The internal resistance of the workpiece melts instantly under the action of the induced current, thereby achieving the welding requirements. The ceramic sheet 10 has a large pressure surface during welding, making the welding firm. The ceramic does not easily stick to flux or tin, making it easy to clean.

[0028] In use, 1. First, seal the bottom of the weld tube 4 with high-temperature resistant epoxy resin to form an encapsulation head 5, which can fix the coil and prevent deformation. 2. During encapsulation, embed a ceramic plate 10 at the bottom of the encapsulation head 5 to fix and position the welded coil copper tube 8. 3. Using a mold for encapsulation can ensure the consistency of the weld head and standardize its use.

[0029] The top surface of the base 11 is integrally formed with a cleaning box 17. A gearbox 16 is installed on the side wall of the cleaning box 17. The input shaft of the gearbox 16 is fixedly installed with the output shaft of the motor 14. A control box 15 is installed on the side wall of the motor 14. The output shaft of the gearbox 16 is fixedly installed with the rotating rod 20. The motor 14 drives the gear in the gearbox 16 to rotate, thereby increasing the speed through the gearbox 16, which in turn enables the rotating rod 20 to rotate quickly. The control method of this application is automatic control through the control box 15. The control circuit of the control box 15 can be implemented by simple programming by those skilled in the art and is common knowledge in the field. Since this application is mainly used to protect mechanical devices, the control method and circuit connection will not be explained in detail. The device is powered by an external power supply. The gearbox 16 is also a common gearbox 16 on the market that can increase the speed, used to increase the speed of the rotating rod 20.

[0030] The cleaning box 17 has a cleaning port 18 inside, and a slot 21 is provided inside one side wall of the cleaning box 17. The side wall of the rotating rod 20 is rotatably connected to the slot 21, so that the rotating rod 20 can rotate in the cleaning port 18 of the cleaning box 17 under the drive of the gearbox 16.

[0031] The end of the rotating rod 20 located inside the cleaning port 18 is welded to the center of one side of the limiting plate 24. The center of the other side of the limiting plate 24 is welded to the mounting rod 25. A cross block 26 is welded to the side wall of the mounting rod 25. The cross block 26 is inserted into the cross groove 28 inside the cleaning wheel 27. A cleaning copper brush sleeve 13 is installed on the side wall of the cleaning wheel 27. By inserting the cross block 26 on the rotating rod 20 into the cross groove 28 in the cleaning wheel 27, the cleaning wheel 27 can rotate with the rotating rod 20, so that the cleaning copper brush sleeve 13 installed on the cleaning wheel 27 can clean the flux and tin residue on the ceramic plate 10.

[0032] The end of the mounting rod 25 is provided with a threaded groove, and the mounting rod 25 is connected to the internal thread of the nut 31 through the threaded groove on the end. A washer 30 is provided between the nut 31 and the cleaning wheel 27. A closed pin 32 for limiting the position of the nut 31 is inserted through the side wall of the mounting rod 25. The cleaning wheel 27 can be fixed between the limiting plate 24 and the washer 30 by the nut 31, thereby positioning the cleaning position. The closed pin 32 can prevent the nut 31 from loosening during the long-term rotation of the mounting rod 25.

[0033] A limiting groove 29 is formed on the other side wall of the cleaning box 17. A moving rod 35 is slidably connected inside the limiting groove 29. A limiting plate 36 is fixedly connected to the side wall of the moving rod 35 inside the limiting groove 29. The limiting plate 36 is slidably connected to the inside of the limiting groove 29. A spring 37 is provided inside the limiting groove 29. The spring 37 is sleeved on the side wall of the moving rod 35 and abuts against one side of the limiting plate 36. A moving seat 33 is fixedly connected to the end of the moving rod 35 inside the cleaning port 18. A rotating groove 34 is formed inside the moving seat 33. One end of the mounting rod 25 is rotatably connected to the inside of the rotating groove 34. By connecting the mounting rod 25 and the moving rod 35, a moving seat 33 is formed. The rotating groove 34 inside the seat 33 rotates. A bearing can be installed inside the rotating groove 34 to increase lubrication, so that the rotating rod 20 and the mounting rod 25 can rotate on the same axis of the cleaning box 17, avoiding the shaking that occurs during the rotation of the cleaning wheel 27. When it is necessary to replace the cleaning copper brush sleeve 13 on the cleaning wheel 27, the moving seat 33 moves to the side, and the moving rod 35 slides in the limiting groove 29, so that the limiting plate 36 can compress the spring 37. After the cleaning copper brush sleeve 13 is replaced, the moving seat 33 can be reconnected to the mounting rod 25 under the action of the spring 37.

[0034] The bottom surface of the cleaning port 18 is provided with a groove 23, and a dirt collection box 12 is slidably connected inside the groove 23. A handle 19 is installed on the side wall of the dirt collection box 12 so that after the cleaning brush sweeps the flux and solder off the ceramic plate 10, they can fall into the dirt collection box 12. By pulling the handle 19, the dirt collection box 12 can slide out of the groove 23 and out of the cleaning box 17, so that the flux and solder swept off the inside of the dirt collection box 12 can be poured out, thereby achieving automatic cleaning efficiency of flux and solder on the solder head.

[0035] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A photovoltaic module junction box electromagnetic welding encapsulation welding head mechanism, comprising an encapsulation welding head and a base (11) for mounting a cleaning box (17), characterized in that: The encapsulated welding head includes a mounting base (1) for mounting the welding tube (4). The top surface of the mounting base (1) is provided with mounting holes (2) for mounting the welding machine. The mounting base (1) is provided in two sets. The bottom end of the two sets of mounting bases (1) is provided with insertion holes (7). The interior of the mounting base (1) is provided with cooling water holes (3) for cooling the copper tube (8) of the welding coil. The interior of each insertion hole (7) is welded and fixed to one end of the welding tube (4). The other end of the welding tube (4) is encapsulated with an encapsulation head (5) to fix and prevent the coil from deforming. The encapsulation head (5) is made of high-temperature resistant epoxy resin. The other end of the welding tube (4) is inserted and fixed with a copper tube (8) of the welding coil, located at the bottom end of the encapsulation head (5). The internal welding coil copper tube (8) is wound into a spiral structure. A ceramic plate (10) is embedded at the bottom of the encapsulation head (5). A ceramic plate guide post (9) is integrally formed at the center of the ceramic plate (10). The spiral structure formed by the welding coil copper tube (8) contacts and is assembled with the ceramic plate guide post (9). Both the ceramic plate (10) and the ceramic plate guide post (9) are made of zirconia ceramic. The encapsulation welding head is equipped with a cleaning box (17). A gearbox (16) is installed on the side wall of the cleaning box (17). The input shaft of the gearbox (16) is fixedly installed with the output shaft of the motor (14). A control box (15) is installed on the side wall of the motor (14). The output shaft of the gearbox (16) is fixedly installed with the rotating rod (20). The cleaning box (17) has a cleaning port (18) inside, and a dirt collection box (12) is opened inside one side wall of the cleaning box (17). The side wall of the rotating rod (20) is rotatably connected to the slot (21). The end of the rotating rod (20) located inside the cleaning port (18) is welded to the center of one side of the limiting plate (24). The center of the other side of the limiting plate (24) is welded to the mounting rod (25). The side wall of the mounting rod (25) is welded to a cross block (26). The cross block (26) is inserted into the cross groove (28) inside the cleaning wheel (27). The side wall of the cleaning wheel (27) is equipped with a cleaning copper brush sleeve (13). The end of the mounting rod (25) is provided with a threaded groove, and the mounting rod (25) is connected to the end of the screw. The groove is connected to the internal thread of the nut (31), and a washer (30) is provided between the nut (31) and the cleaning wheel (27). A closed pin (32) for limiting the position of the nut (31) is inserted through the side wall of the mounting rod (25). A limiting groove (29) is opened on the other side wall of the cleaning box (17). A moving rod (35) is slidably connected inside the limiting groove (29). A limiting plate (36) is fixedly connected to the side wall of the moving rod (35) located inside the limiting groove (29). The limiting plate (36) is slidably connected to the inside of the limiting groove (29), and a spring (37) is provided inside the limiting groove (29). The spring (37) is sleeved on the side wall of the moving rod (35) and abuts against one side of the limiting plate (36).A movable rod (35) located inside the cleaning port (18) has a movable base (33) fixedly connected to its end. A rotating groove (34) is provided inside the movable base (33), and one end of the mounting rod (25) is rotatably connected to the inside of the rotating groove (34).

2. The photovoltaic module junction box electromagnetic welding encapsulation welding head mechanism according to claim 1, characterized in that: The bottom surface of the cleaning port (18) is provided with a groove (23), and a dirt collection box (12) is slidably connected inside the groove (23). A handle (19) is installed on the side wall of the dirt collection box (12).

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