Junction box welding inspection method

Abstract

The application discloses a kind of junction box welding detection methods, belong to product detection technical field.Junction box welding detection method includes: the position of first detection camera is calibrated, so that junction box product can fall in the field of view range of first detection camera when incoming material;The position of first detection camera is adjusted to be close to junction box product, and pre-welding detection is carried out to junction box and bus bar, and the detection content includes the position of junction box and the quality of bus bar;According to the position of detected junction box, move the head module, press the tin block on the two sides of junction box respectively on the two sides of bus bar, and the head module and junction box product are synchronously moved to welding station;Bus bar is welded by laser, and second detection camera detects bus bar during welding process;After welding is completed, release the head module, and move the junction box product to the lower side of first detection camera, and the appearance of welded junction box is detected by first detection camera, to ensure the final welding quality of junction box and bus bar.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of product detection, and in particular to a junction box welding detection method. BACKGROUND

[0002] In the production and manufacturing process of photovoltaic modules, the junction box product includes a junction box and a busbar, and a process of automatically completing the welding of the busbar and the junction box. The equipment for completing this process is generally a junction box welding machine. Due to various external disturbances in the automatic welding process, some welding defects such as busbar position deviation, junction box position deviation or welding position contamination may occur. The above problems are extremely easy to affect the final welding quality.

[0003] Therefore, there is an urgent need to provide a junction box welding detection method to solve the above problems. SUMMARY

[0004] The purpose of the present application is to provide a junction box welding detection method, which can detect the pre-welding positioning and quality of the junction box and the busbar before welding, detect the busbar during welding, and detect the appearance of the junction box after welding, thereby ensuring the final welding quality of the junction box and the busbar.

[0005] To achieve the above purpose, the following technical solutions are provided:

[0006] The junction box welding detection method comprises the following steps:

[0007] The position of the first detection camera is calibrated so that the junction box product can fall within the field of view of the first detection camera when it is received;

[0008] The position of the first detection camera is adjusted to be close to the junction box product;

[0009] The first detection camera is used to detect the junction box and the busbar of the junction box product before welding, and the detection content includes the position of the junction box and the quality of the busbar;

[0010] The position of the junction box is detected, and the pressing head module is moved to be located directly above the junction box; the pressing head module is pressed down to press the two sides of the busbar on the tin blocks on the two sides of the junction box, and the pressing head module and the junction box product are synchronously moved to a welding station;

[0011] The busbar is laser welded, and the second detection camera detects the busbar during welding to detect the welding quality during welding;

[0012] After the welding is completed, the pressure head module is released, the junction box product is moved below the first detection camera, and the appearance of the welded junction box is detected by the first detection camera.

[0013] As an alternative to the junction box welding detection method, the position adjustment of the first detection camera specifically includes the following steps:

[0014] Moving the first detection camera to an initial position allows the junction box product to appear within the field of view of the first detection camera;

[0015] Taking a photo of the junction box product, analyzing the overall proportion of the junction box product in the first detection camera's photo range;

[0016] Adjust the height and horizontal position of the first detection camera, analyze the imaging proportion of the junction box product in the photo, until the proportion reaches the preset proportion range.

[0017] As an alternative to the junction box welding detection method, the preset proportion range is 30%-70%.

[0018] As an alternative to the junction box welding detection method, the method of adjusting the position of the first detection camera specifically includes the following steps:

[0019] Define the area of the first detection camera photo without the junction box product as white space, and preset the proportion range m of the corresponding two side white space widths. The actual proportion of the relative two side white space widths is N. The analysis of the first detection camera's photo result includes the proportion of the photo relative to the two side white space and the imaging proportion of the junction box product:

[0020] When the imaging proportion of the junction box product does not reach the preset proportion range,

[0021] If 1 / m≥N or N≥m, horizontally move the first detection camera until 1 / m<N<m,

[0022] If 1 / m<N<m, it is determined that no translation is needed, the first detection camera is lowered, the first detection camera's photo result is analyzed again, and the first detection camera is adjusted horizontally or vertically according to the result until the imaging proportion of the junction box product reaches the preset proportion range.

[0023] As an alternative to the junction box welding detection method, the specific method of horizontally moving the first detection camera includes the following steps:

[0024] Preset the single horizontal movement amplitude of the first detection camera as a fixed length L;

[0025] The first detection camera analyzes the width proportion of the blank on the opposite sides again after moving a length L, if 1 / m >= N and N >= m are located on the two adjacent translation operations in the same direction, the horizontal moving range of the first detection camera is halved, the first detection camera is moved to the side with narrower blank according to the current position of the first detection camera, the steps of amplitude reduction and moving are repeated until 1 / m < N < m.

[0026] As an alternative of the junction box welding detection method, the suitable proportion of the blank width on the left and right sides is m1, the actual proportion is N1, the suitable proportion of the blank width on the upper and lower sides is m2, the actual proportion is N2, after the translation operation of the first detection camera, 1 / m1 < N1 < m1 and 1 / m2 < N2 < m2 are required.

[0027] As an alternative of the junction box welding detection method, if the value of N1 or N2 is 0 or positive infinity, the first detection camera is moved upward, the moving range of the first detection camera is set to be smaller than the downward moving range of the first detection camera, the photographing analysis is performed once after each upward moving, until the four sides of the imaging of the first detection camera all show the blank part, and this imaging is taken as the final result for appearance analysis and feedback.

[0028] As an alternative of the junction box welding detection method, in the post-welding detection step, the first detection camera analyzes the welding information of the welding scar of the junction box product, if it is judged that the welding scar is unqualified, a warning signal is sent and the junction box product is removed from the production queue by the conveying device.

[0029] As an alternative of the junction box welding detection method, the welding information includes the length, number, explosion point and appearance of the welding scar.

[0030] As an alternative of the junction box welding detection method, in the welding detection step, the second detection camera identifies the reflected light, visible light and infrared light generated by the welding position, detects the welding state in the welding through deep learning light source waveform, and the welding state includes whether false welding is generated.

[0031] Compared with the prior art, the beneficial effects of the present application are:

[0032] The wire junction box welding detection method provided by the application has the following advantages: the wire junction box product is in the detection field of view of the first detection camera when the product is delivered, the position of the first detection camera is lower than that of the second detection camera, the position of the first detection camera is closer to the product, the target image captured by the first detection camera is larger, the target image is enlarged, the clear imaging and visual positioning of the first detection camera have obvious advantages, and the surface defects of the product can be analyzed; the first detection camera can automatically detect the wire junction box and the bus bar on the wire junction box product, the actual position of the wire junction box is detected before welding, the pressing head module is moved to the upper side of the wire junction box according to the detected position of the wire junction box, and then the bus bar is pressed on the tin block on the two sides of the wire junction box, so that the contact between the bus bar and the wire junction box is stable, the wrong welding position is prevented, the generation of waste products is reduced, resources are saved, and the production cost is reduced; the quality of the bus bar is detected before welding, and unqualified wire junction box products to be welded are screened out in advance, only qualified wire junction box products can enter the welding process, and the welding success rate of the product is improved; the pressing head module and the wire junction box product are synchronously moved to the welding station, the second detection camera is used for welding detection of the bus bar, the welding quality in the welding process is detected, and whether there is virtual welding is detected in time; after welding, the pressing head module is released, the wire junction box product is moved back to the lower side of the first detection camera, the detection function of the first detection camera is used, a third detection camera does not need to be additionally arranged, and the complexity of the detection system is reduced; the appearance of the welded wire junction box is detected by the first detection camera, unqualified welding products are screened out, and only qualified welding products can flow into the subsequent process production line. BRIEF DESCRIPTION OF DRAWINGS

[0033] In order to more clearly illustrate the technical solutions in the embodiments of the present application, the following will briefly introduce the drawings needed to be used in the description of the embodiments of the present application. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art according to the contents of the embodiments of the present application and the drawings without any creative effort.

[0034] Figure 1 The structure schematic diagram of the bus bar (in a bent state) and the wire junction box before welding in the embodiment of the present application;

[0035] Figure 2 The structure schematic diagram of the bus bar (in a bent state) and the wire junction box after welding in the embodiment of the present application;

[0036] Figure 3 The first perspective structure schematic diagram of the detection system and the photovoltaic panel in the embodiment of the present application;

[0037] Figure 4The second perspective view of the detection system and the photovoltaic panel in the embodiment of the present application is shown in the figure.

[0038] Figure 5 The second moving module with the second detection camera and the pressure head module and the photovoltaic panel in the embodiment of the present application are shown in the figure.

[0039] Figure 6 The second moving module with the second detection camera and the pressure head module and the photovoltaic panel in the embodiment of the present application are shown in the figure.

[0040] Figure 7 The schematic diagram of the visual unit and the processor in the embodiment of the present application is shown in the figure.

[0041] Figure 8 The flow chart of the junction box welding method in the embodiment of the present application is shown in the figure.

[0042] Figure 9 The flow chart of the first detection camera adjustment in the embodiment of the present application is shown in the figure.

[0043] Reference signs:

[0044] 100, photovoltaic panel; 200, junction box; 300, busbar; 400, welding scar;

[0045] 1, first detection camera; 2, second detection camera; 3, pressure head module; 4, first moving module; 5, second moving module; 6, moving track. DETAILED DESCRIPTION

[0046] In order to make the objects, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, but not all the embodiments. The components of the embodiments of the present application described and shown in the drawings herein can be arranged and designed in various different configurations.

[0047] Therefore, the detailed description of the embodiments of the present application provided in the drawings below is not intended to limit the scope of the claimed present application, but only represents selected embodiments of the present application. All other embodiments obtained by those of ordinary skill in the art based on the embodiments in the present application without creative labor are within the scope of protection of the present application.

[0048] It should be noted that: similar signs and letters represent similar items in the following drawings, therefore, once an item is defined in one drawing, it does not need to be further defined and explained in the subsequent drawings.

[0049] In the description of the present application, it needs to be explained that the terms "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, or the orientation or positional relationship when the product of the present application is usually placed, which is only for the convenience of describing the present application and simplifying the description, and does not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application. In addition, the terms "first", "second", "third" and the like are only used for differentiation and cannot be understood as indicating or implying relative importance. In the description of the present application, unless otherwise specified, the meaning of "a plurality of" is two or more.

[0050] In the description of the present application, it also needs to be explained that, unless otherwise explicitly specified and limited, the terms "arranged", "connected" should be understood broadly, for example, it can be fixedly connected, or detachably connected, or integrally connected; it can be mechanically connected, or electrically connected. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0051] In the present application, unless otherwise explicitly specified and limited, "on" or "under" of a first feature to a second feature can include that the first and second features are in direct contact, or that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, "on", "above" and "over" of the first feature to the second feature includes that the first feature is directly above and obliquely above the second feature, or only indicates that the first feature is higher in horizontal height than the second feature. "Under", "below" and "underneath" of the first feature to the second feature includes that the first feature is directly below and obliquely below the second feature, or only indicates that the first feature is lower in horizontal height than the second feature.

[0052] The embodiments of the present application are described in detail below, and examples of the embodiments are shown in the drawings, wherein the same or similar reference signs represent the same or similar elements or elements having the same or similar functions throughout. The embodiments described below by referring to the drawings are exemplary and are only used to explain the present application, and cannot be understood as a limitation on the present application.

[0053] In the production and manufacturing process of photovoltaic modules, due to various external disturbances, some welding defects occur in the automatic welding process, such as bus bar position deviation, junction box position deviation or welding position contamination, etc., which are extremely easy to affect the final welding quality.

[0054] In order to be able to pre-weld the junction box and the bus bar before welding and quality inspection, the bus bar welding detection, and the appearance of the junction box after welding is detected, the final welding quality of the junction box and the bus bar is ensured, and the embodiment provides a junction box welding detection method, as follows Figures 1 to 9 The specific content of the embodiment is described in detail.

[0055] In the embodiment, please refer to Figure 1 and Figure 2 , the incoming welding product (junction box product) is a photovoltaic panel 100, the photovoltaic panel 100 has a lead-out bus bar 300, the junction box 200 has been installed on the photovoltaic panel 100 in the previous process, and the welding position of the bus bar 300 (in a bent state) is bent above the welding position inside the junction box 200.

[0056] The welding detection system used in the junction box welding detection method is derived to optimize the welding yield, that is, to optimize the welding operation of the bent bus bar 300 and the welding position inside the junction box 200.

[0057] Exemplarily, please refer to Figures 3 to 6 , the welding detection system of the junction box 200 includes a vision unit, an image processing unit, an information processing unit, and a control unit. The vision unit includes a first detection camera 1 and a second detection camera 2. The second moving module 5 is installed on the first moving module 4, the first detection camera 1 is installed on the first moving module 4 through the adjusting mechanism (including the horizontal moving mechanism and the lifting moving mechanism), and the adjusting mechanism (including the horizontal moving mechanism and the lifting moving mechanism) is not shown in the figure. The pressure head module 3 is installed on the second moving module 5. Among them, the first moving module 4 is a large distance moving module with low moving precision, which can quickly move a large distance and improve the moving speed. The second moving module 5 is a small distance moving module with high moving precision, which can fine-tune a small distance and improve the accuracy.

[0058] The incoming welding product photovoltaic panel 100 is provided with multiple groups of parallel junction boxes 200 and bus bars 300, which need to be welded. Due to the influence of the incoming material of the previous process, there is a certain slight deviation in the position of each group of junction boxes 200. The first moving module 4 is only provided with one group, so a large range of movement is adopted to achieve approximate positioning to the preset position, and the second moving module 5 is used to compensate the remaining position deviation of each group of welding points for secondary compensation movement to achieve accurate movement.

[0059] In some application scenarios, the first detection camera 1 and the adjusting mechanism (including the horizontal moving mechanism and the lifting moving mechanism) can be moved to above the terminal box 200 through the first moving module 4; when it is necessary to press the pressure head, the pressure head module 3 is first moved to above the terminal box 200 through the first moving module 4, at the same time, the first detection camera 1 is also moved away from the first moving module 4 to avoid, and then the pressure head module 3 is further adjusted in position through the second moving module 5. The second detection camera 2 is installed above the pressure head module 3 through the moving track 6, and the second detection camera 2 can move above the pressure head module 3 through the moving track 6. The pressure head and the support plate supporting the pressure head are both provided with perspective slots, and the perspective slots are correspondingly arranged to form a perspective window, and the second detection camera 2 can take pictures through the perspective window.

[0060] As shown in Figure 7 The image processing unit, the information processing unit, the storage unit and the control unit can be arranged in the same processor (such as a computer, a central control machine, etc.), and the processor can be connected with the first detection camera 1 and the second detection camera 2 through wireless connection or wired connection to realize transmission of image information. At the same time, the processor can also be connected with the laser welding device through wireless or wired connection, so that the control unit can control the opening, closing and displacement of the related devices such as the conveying device, the pressure head module 3 and the moving track 6 in the welding device.

[0061] Further, since the storage unit is arranged in the processor, the information processing unit can store the obtained information data in the storage unit, so as to realize traceability of data, and at the same time, the offset condition of the terminal box 200 and the bus bar 300, the quality condition of the bus bar 300 and the welding condition between the bus bar 300 and the terminal box 200 can be summarized according to the stored information, and the corresponding parameters of the device can be adjusted according to the summarized condition data.

[0062] Further, a light supplementing device is arranged before the first detection camera 1 takes pictures of the welding scar 400, and the added light supplementing device can compensate light when the first detection camera 1 detects the welding scar 400, so as to improve the detection accuracy of the detection camera under the optimal light. The light supplementing device is provided with a light source and a support, the light source is installed on the support, and the support is provided with a structure capable of adjusting the light source, so as to adjust the light source in a large range of angles, and meet the adjustment requirement due to the adjustment of the detection position of the detection camera. The first detection camera 1 is also used for analyzing the deformation and sliding of the bus bar 300 after being pressed. Since the silica gel layer is arranged below the pressure head module, the first camera is also used for analyzing the deformation and sliding of the bus bar after being pressed, so as to reduce the influence of the sliding of the bus bar.

[0063] In the embodiment, as shown in Figure 8As shown, the junction box welding detection method comprises the following steps: calibrating the position of the first detection camera 1 so that the junction box product can fall within the field of view of the first detection camera 1 when it is delivered; wherein the position of the first detection camera 1 is lower than that of the second detection camera 2.

[0064] The position of the first detection camera 1 is adjusted to be close to the junction box product, and the first detection camera 1 is used to detect the junction box 200 and the bus bar 300 of the junction box product before welding, and the detection content includes the position of the junction box 200 and the quality of the bus bar 300. According to the detected position of the junction box 200, the pressure head module 3 is moved to be directly above the junction box 200; the pressure head module 3 is pressed down to press the bus bar 300 on both sides of the tin block on both sides of the junction box 200, and the pressure head module 3 and the junction box product are synchronously moved to the welding station.

[0065] Specifically, the first detection camera 1 takes a picture of the junction box 200 and transmits the captured image to the processor; the processor can calculate the distance deviation between the pressure head module 3 and the junction box 200 according to the actual position information of the junction box 200 and form offset data. The first detection camera 1 is moved to the upper side of the junction box 200 by the first moving module 4 to take a picture, the actual position information of the junction box 200 is obtained by the image processing unit of the processor, the offset data is calculated by the information processing unit of the processor, and the position of the pressure head module 3 is adjusted by the control unit of the processor to move the pressure head module 3 to the upper side of the junction box 200. Specifically, the first detection camera 1 sends the captured image to the image processing unit, and obtains the coordinates of the center position of the junction box 200 in the picture through the image processing unit to form the actual position information of the junction box 200. The image processing unit sends the actual position information of the junction box 200 to the information processing unit, the information processing unit simultaneously obtains the actual position information of the pressure head, compares the position information of the junction box 200 with the position information of the pressure head, calculates the distance deviation between the pressure head and the junction box 200, forms offset data, and sends the offset data to the control unit of the processor, and the control unit of the processor adjusts the displacement of the pressure head module 33.

[0066] In some application scenarios, the control unit moves the pressure head module 3 to the upper side of the junction box 200 through the first moving module 4 and then through the second moving module 5 according to the offset data. The two control instructions of the control unit are: first, move the pressure head module 3 to the approximate position above the junction box 200 through the first moving module 4, and then control the second moving module 5 to accurately move the pressure head module 3 to the upper side of the junction box 200, so that the pressure head can accurately press on a specific position of the junction box 200.

[0067] The information processing unit of the processor stores the compliance information of the busbar 300, and compares the quality information of the busbar 300 with the compliance information, so as to determine whether the quality of the busbar 300 meets the quality information. The quality information includes the length and appearance of the busbar 300. For example, whether the length of the busbar 300 is too long or too short, whether there are stains, gaps and the like on the appearance of the busbar 300; if the quality of the busbar 300 meets the quality, the information processing unit sends a signal to the control unit, and the control unit moves the pressure head module 3 twice according to the control instruction and makes the pressure head on the pressure head module 3 press on the busbar 300 and the junction box 200.

[0068] Before welding, the laser welding device parameter compensation is further included: the first detection camera 1 takes a picture of the busbar 300 again and transmits the captured image to the processor; the processor obtains the actual position information of the busbar 300 through the image processing unit, and the control unit adjusts the parameters of the laser welding device according to the actual position information of the busbar 300.

[0069] Further, in the laser welding device parameter compensation step, the image processing unit of the processor obtains the actual position information of the busbar 300, the information processing unit of the processor calculates the position information of the target welding point on the busbar 300 according to the actual position information of the busbar 300, the information processing unit of the processor obtains the initial position information of the laser welding head in the laser welding device and the initial offset angle, and calculates the actual welding point actually reached by the laser emitted by the laser welding head, and then the information processing unit of the processor calculates the difference between the target welding point and the actual welding point, and forms the adjustment data of the laser welding device.

[0070] Further, the adjustment data mentioned in the embodiment includes the movement distance parameter, the deflection angle parameter and the focal length parameter of the laser welding head. The control unit of the processor moves the position of the laser welding head and the deflection angle, focal length and the like parameters according to the adjustment data, so that the laser welding device accurately shoots the laser beam to the welding position on the busbar 300 for laser welding.

[0071] The busbar 300 is laser welded, and the second detection camera 2 detects the welding process of the busbar 300 during welding, for detecting the welding quality during welding. In the welding detection step, the second detection camera 2 identifies the reflected light, visible light and infrared light generated at the welding position, detects the welding state in the welding process through deep learning light source waveform, and the welding state includes whether virtual welding is generated.

[0072] After the welding is completed, the pressure head module 3 is released, and the junction box product is moved below the first detection camera 1, and the appearance of the welded junction box 200 is detected by the first detection camera 1. In the post-welding detection step, the first detection camera 1 analyzes the welding information of the welding scar 400 of the junction box product; if it is judged that the welding scar 400 is unqualified, an alarm signal is sent out and the junction box product is removed from the production queue by the conveying device. The welding information includes the length, number, burst point and appearance of the welding scar 400.

[0073] The first detection camera 1 is used to take pictures of the welding scar 400 in the junction box 200, and the image of the welding scar 400 is transmitted to the image processing unit. The image processing unit obtains the length, number, burst point and appearance of the welding scar 400 in the image, summarizes the welding information, and sends the welding information to the information processing unit; the information processing unit obtains the pre-stored welding scar 400 standard information, compares the welding information extracted from the image with the standard information, judges whether the welding scar 400 meets the standard, for example, whether the length of the welding scar 400 exceeds or is shorter than the standard length, whether the number is less than or more than the standard number, and whether there is blackening or welding through on the appearance, etc.

[0074] The junction box 200 welding method provided by the application has the advantages that the junction box product is in the detection field of view of the first detection camera 1 when the product is delivered, the position of the first detection camera 1 is lower than that of the second detection camera 2, the position of the first detection camera 1 is closer to the product, the target image captured by the first detection camera 1 is larger, the target image is enlarged, the clear imaging and visual positioning of the first detection camera 1 are obviously advantageous, and the surface defects of the product are analyzed; the first detection camera 1 can automatically detect the junction box 200 and the bus bar 300 on the junction box product, the actual position of the junction box 200 is detected by the first detection camera 1 before welding, the ram module 3 is moved to the upper side of the junction box 200 according to the detected position of the junction box 200, and the bus bar 300 is pressed on the tin blocks on the two sides of the junction box 200, so that the contact between the bus bar 300 and the junction box 200 is stable, the wrong welding position is prevented, the generation of waste products is reduced, resources are saved, and production costs are reduced; the quality of the bus bar 300 is detected by the first detection camera 1 before welding, the unqualified junction box product to be welded is screened in advance, only the qualified junction box product can enter the welding process, and the welding success rate of the product is improved; the ram module 3 and the junction box product are synchronously moved to the welding station, the second detection camera 2 is used for welding detection of the bus bar 300, the welding quality in the welding process is detected, and whether there is virtual welding is detected in time; after welding, the ram module 3 is released, the junction box product is moved back to the lower side of the first detection camera 1, the detection function of the first detection camera 1 is used, a third detection camera does not need to be additionally arranged, and the complexity of the detection system is reduced; the appearance of the welded junction box 200 is detected by the first detection camera 1, the unqualified welding product is screened out, and only the qualified welding product can flow into the subsequent process production line.

[0075] Further, the position adjustment of the first detection camera 1 specifically includes the following steps:

[0076] The first detection camera 1 is moved to an initial position, so that the junction box product can appear in the field of view of the first detection camera 1;

[0077] The junction box product is photographed, and the overall proportion of the junction box product in the photographing range of the first detection camera 1 is analyzed;

[0078] Adjusting the height position and horizontal position of the first detection camera 1, analyzing the imaging proportion of the junction box product in the photographed image, until the proportion reaches the preset proportion range. For enlarging the proportion of the junction box product in the image, improving the clarity of the photograph to facilitate more accurate analysis and detection of the appearance of the product, and avoiding detection errors. In this embodiment, since the junction box product is black and tends to be rectangular in shape (the battery piece is blue as a whole, and there is obvious boundary division in the region), the area of the image presented by the junction box product can be estimated by the rectangular area calculation method.

[0079] Further, the preset proportion range is 30%-70%. For example, the preset proportion range is 35%-65%, 40%-60%, 45%-55%, etc., which can be adaptively adjusted according to the amplitude of the downward adjustment of the camera, and is not limited here.

[0080] Further, the method of adjusting the position of the first detection camera 1 specifically includes the following steps:

[0081] Defining the area part without the junction box product in the photograph of the first detection camera 1 as the blank, and presetting the proportion range m of the relative width of the blank on both sides, and the actual proportion of the relative width of the blank on both sides is N; analyzing the photographing result of the first detection camera 1, and the analysis content includes the proportion of the blank on both sides of the photograph and the imaging proportion of the junction box product:

[0082] When the imaging proportion of the junction box product does not reach the preset proportion range,

[0083] If 1 / m≥N or N≥m, horizontally move the first detection camera 1 until 1 / m<N<m,

[0084] If 1 / m<N<m, it is judged that no translation is needed, the first detection camera 1 is lowered, the photographing result of the first detection camera 1 is analyzed again, and the first detection camera 1 is adjusted horizontally or vertically according to the result until the imaging proportion of the junction box product reaches the preset proportion range. By making 1 / m<N<m, the first detection camera 1 is adjusted to the central imaging position of the junction box product before being adjusted downward, which helps to prevent the junction box image from being out of the photographable field of view during the downward adjustment of the first detection camera 1, and finally through the enlargement of the junction box product image, it is convenient for more accurate appearance detection of the photographed image, which is beneficial to the automatic adjustment of industrial automation.

[0085] Further, the specific method of horizontally moving the first detection camera 1 includes the following steps:

[0086] Presetting the single horizontal movement amplitude of the first detection camera 1 as a fixed length L;

[0087] The first detection camera 1 moves a fixed length L each time, and then analyzes the width ratio of the white space on the opposite sides again. If 1 / m>N and N>m are located on two adjacent translation operations in the same direction, it is determined that the horizontal movement amplitude is too large, and the junction box imaging cannot be adjusted to the appropriate central position. At this time, the horizontal movement amplitude needs to be reduced to ensure that the junction box product is more accurately centered, or m is increased to meet the needs. In this scheme, the horizontal movement amplitude of the first detection camera 1 is halved, and the first detection camera 1 is moved to the side with narrower white space according to the current position of the first detection camera 1. Since the horizontal movement amplitude is reduced, if 1 / m>N and N>m are located on two adjacent translation operations in the same direction, the reduction setting and moving steps need to be repeated. The horizontal movement amplitude reduction will be L / 4, L / 8, L / 16, and so on, until 1 / m<N<m. In the steps of this embodiment, the horizontal movement amplitude can be continuously halved to make the junction box product tend to be imaged in the central position. Similarly, m or 1 / m can also be the smallest number close to 1 at the preset time to ensure the imaging central position. If the junction box imaging is inclined to the horizontal position of the photo, the white space width can be calculated as the average of the imaging side length between the two side end distances.

[0088] Further, the appropriate ratio of the white space width on the left and right sides is m1, and the actual ratio is N1. The appropriate ratio of the white space width on the top and bottom sides is m2, and the actual ratio is N2. After the first detection camera 1 performs the translation operation, 1 / m1<N1<m1 and 1 / m2<N2<m2 need to be satisfied.

[0089] Illustratively, since the junction box product is usually rectangular, the white space ratio on the top and bottom sides is more relaxed than the appropriate ratio requirement of the white space on the left and right sides. Therefore, when arranging m1 and m2, m2 can be preferably greater than m1 to improve work efficiency. For example, the ratio range of the white space width on the left and right sides can be set as m1=2, and the ratio range of the white space width on the top and bottom sides can be set as m2=3. After the first detection camera 1 performs the translation operation, 1 / 2<N1<2 and 1 / 3<N2<3 need to be satisfied.

[0090] Further, if the value of N1 or N2 is 0 or positive infinity, it means that the white space on one side disappears, and the junction box product cannot be completely imaged. At this time, the first detection camera 1 needs to be moved upwards, and the upward movement amplitude of the first detection camera 1 is set to be smaller than the downward movement amplitude of the first detection camera 1. Each time the first detection camera 1 is moved upwards, the first detection camera 1 is photographed and analyzed. Until the first detection camera 1 images four sides with white space, and this imaging is taken as the final result for appearance analysis and feedback. In this embodiment, the smaller the upward movement amplitude of the first detection camera 1, the larger the final imaging ratio. If it is necessary to save control procedures or time, the upward movement amplitude can be directly set as the downward movement amplitude.

[0091] In the above embodiment, the first detection camera 1 needs to continuously take pictures and store them during the adjustment process, but the purpose is to finally retain an image that can be used for appearance detection. Therefore, during the adjustment process, the excess pictures can be deleted according to the progress of the adjustment to save device resource space.

[0092] For example, as shown in Figure 9 The first detection camera 1 is shown in one of the implementation flowcharts for adjustment:

[0093] X100, move the first detection camera 1 to a specified position, move the junction box 200 to the lower side of the first detection camera 1, and take a picture of the junction box 200;

[0094] X200, determine whether the ratio of the image area of the junction box 200 to the area of the entire picture is less than a set ratio (for example, the set ratio is 40%-60%). If not, enter the working state; if yes, enter the next step;

[0095] X300, determine whether the relative side margin ratio of the junction box 200 image is greater than the set margin ratio value. If yes, adjust the first detection camera 1 through the horizontal movement mechanism; if not, lower the first detection camera 1 through the lifting movement mechanism;

[0096] X400, determine again whether the relative side margin ratio of the junction box 200 image is greater than the set margin ratio value. If not, enter step X200; if yes, enter the next step;

[0097] X500, determine whether all sides of the junction box 200 image have margins. If yes, adjust the first detection camera 1 through the horizontal movement mechanism and enter step X400; if not, move the first detection camera 1 upward through the lifting movement mechanism until all sides of the junction box 200 image are exposed, then stop moving upward and complete the adjustment of the first detection camera 1.

[0098] Among them, the first detection camera 1 only retains the last picture and a final analysis result for the photographed product, and deletes all pictures for the purpose of adjusting the position of the first detection camera 1 to save resource space.

[0099] The adjustment method of the first camera group can effectively magnify and recognize the product photographed by the first detection camera 1, effectively realize clear adjustment imaging of the product, and further ensure the accuracy of the appearance detection result.

[0100] Note that the above merely describes preferred embodiments of the present application and the principles of the technology applied. Those skilled in the art will understand that the present application is not limited to the specific embodiments described herein, and that various obvious changes, modifications and substitutions can be made thereto without departing from the scope of the present application. Therefore, although the present application has been described in detail through the above embodiments, the present application is not limited to the above embodiments, and can include more other equivalent embodiments without departing from the concept of the present application, and the scope of the present application is determined by the scope of the claims.

Claims

1. A method of detecting a joint box weld, characterized by, The method comprises the following steps: Calibrate the position of the first detection camera (1) so that the junction box product can fall within the field of view of the first detection camera (1) when it is delivered; Adjust the position of the first detection camera (1) to be close to the junction box product; the position adjustment of the first detection camera (1) specifically comprises the following steps: move the first detection camera (1) to an initial position so that the junction box product can appear within the field of view of the first detection camera (1); take a photo of the junction box product, analyze the overall proportion of the junction box product in the photo taken by the first detection camera (1); adjust the height and horizontal position of the first detection camera (1), take a photo and analyze the imaging proportion of the junction box product in the photo until the proportion reaches the preset proportion range; wherein the area part without the junction box product in the photo of the first detection camera (1) is defined as the blank, and a suitable proportion m of the width of the relative two side blanks is preset, and the actual proportion N of the relative two side blank widths; the analysis of the first detection camera (1) photo result includes the proportion of the relative two side blanks and the imaging proportion of the junction box product: When the imaging proportion of the junction box product does not reach the preset proportion range, If 1 / m≥N or N≥m, horizontally move the first detection camera (1) until 1 / m<N<m, If 1 / m<N<m, it is judged that no translation is needed, the first detection camera (1) is lowered, the photo result of the first detection camera (1) is analyzed again, and the first detection camera (1) is adjusted horizontally or vertically according to the result until the imaging proportion of the junction box product reaches the preset proportion range; Use the first detection camera (1) to detect the junction box (200) and the busbar (300) of the junction box product before welding, and the detection content includes the position of the junction box (200) and the quality of the busbar (300); Move the pressure head module (3) according to the detected position of the junction box (200) so that the pressure head module (3) is located directly above the junction box (200); press down the pressure head module (3) to press the busbar (300) on both sides of the tin block on both sides of the junction box (200), respectively, and move the pressure head module (3) and the junction box product to the welding station synchronously; Laser weld the busbar (300), and the second detection camera (2) detects the busbar (300) during welding to detect the welding quality during welding; After welding, release the pressure head module (3), move the junction box product below the first detection camera (1), and detect the appearance of the welded junction box (200) by the first detection camera (1).

2. The junction box weld inspection method of claim 1, wherein, The preset proportion range is 30%-70%.

3. The junction box weld inspection method of claim 1, wherein, The specific method for horizontally moving the first detection camera (1) comprises the following steps: Pre-set the single horizontal movement amplitude of the first detection camera (1) as a fixed length L; The first detection camera (1) is moved by a length L each time, and then the width ratio of the white space on the opposite sides is analyzed again. If 1 / m≥N and N≥m are located on two adjacent translation operations in the same direction, the horizontal movement range of the first detection camera (1) is halved, and the first detection camera (1) is moved to the side with narrower white space according to the current position of the first detection camera (1). The steps of amplitude reduction and movement are repeated until 1 / m<N<m.

4. The junction box weld inspection method of claim 1, wherein, The appropriate ratio of the white space width on the left and right sides is m1, and the actual ratio is N1. The appropriate ratio of the white space width on the top and bottom sides is m2, and the actual ratio is N2. After the first detection camera (1) performs the translation operation, 1 / m1<N1<m1 and 1 / m2<N2<m2 are required.

5. The junction box weld inspection method of claim 1, wherein, If the value of N is 0 or positive infinity, the first detection camera (1) is moved upward, and the amplitude of the upward movement of the first detection camera (1) is set to be smaller than the amplitude of the downward movement of the first detection camera (1). The first detection camera (1) is photographed and analyzed once each time it is moved upward until the four sides of the image of the first detection camera (1) all show white space, and this image is taken as the final result for appearance analysis and feedback.

6. The junction box weld inspection method of any one of claims 1-5, wherein, In the post-weld detection step, the first detection camera (1) analyzes the welding information of the welding scar (400) of the junction box product. If the welding scar (400) is determined to be unqualified, a warning signal is issued and the junction box product is removed from the production queue by the conveying device.

7. The junction box weld inspection method of claim 6, wherein, The welding information includes the length, number, burst point and appearance of the welding scar (400).

8. The junction box weld inspection method of any of claims 1-5, wherein, In the welding detection step, the second detection camera (2) identifies the reflected light, visible light and infrared light generated by the welding position, and detects the welding state in the welding process through deep learning of the light source waveform. The welding state includes whether a false weld is generated.

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