A busbar welding device, a layout and stitch welding equipment and a stitch welding method

Abstract

This invention provides a busbar welding device, a stacking welding equipment, and a stacking welding method. The busbar welding device is used to weld busbars to each component unit in a battery string assembly. Each component unit includes two battery strings, and several component units form a battery string assembly. The busbar welding device includes a first busbar preparation mechanism, a second busbar preparation mechanism, a busbar transfer mechanism, a first busbar support mechanism, a second busbar support mechanism, a third busbar support mechanism, a stacking welding gripper, and a welding mechanism. This invention achieves automatic welding of busbars in battery string assemblies. By configuring the busbar preparation mechanism and the busbar support mechanism, and controlling the stacking welding gripper to stepwise transport the battery string assembly, only three busbar support mechanisms are needed to carry the busbars to be welded. The busbar preparation mechanism only needs to prepare three to four busbars at a time. This invention significantly reduces the number of busbar support mechanisms and the number of busbars that need to be prepared each time.

Description

Technical Field

[0001] This invention relates to the field of battery manufacturing, specifically to a busbar welding device, a stacking welding equipment, and a stacking welding method. Background Technology

[0002] Solar cell modules convert solar energy into electrical energy and are increasingly being adopted. During the production of solar cell modules, there is a process of welding busbars, which involves welding the busbars to the extended solder strips of the cell string. To facilitate subsequent junction box installation, some busbars need to be bent. The bent ends of the busbars are inserted into the junction box and welded there, thus allowing the current generated by the cell module to be discharged through the junction box. The length and number of busbars are related to the specifications and number of cell strings contained in the cell string assembly.

[0003] For example, such as Figure 1 As shown, when welding a battery string assembly consisting of 6 groups of 12 battery strings, four intermediate busbars are required, namely busbar M1, busbar M2, busbar M3 and busbar M4. Among them, busbar M1 is used to weld battery strings PA1 and PB1, busbar M2 is used to weld battery strings PA2, PB2, PA3 and PB3, busbar M3 is used to weld battery strings PA4, PB4, PA5 and PB5, and busbar M4 is used to weld battery strings PA6 and PB6. Bus M1 needs to be connected to a junction box at its end near bus M2, so it needs to be bent upwards, resulting in a roughly L-shaped bus. Both ends of bus M2 and bus M3 also need to be connected to junction boxes, so they also need to be bent upwards, resulting in a roughly U-shaped bus. Bus M4 needs to be connected to a junction box at its end near bus M3, so it also needs to be bent upwards, resulting in a roughly L-shaped bus.

[0004] In addition, three straight busbars need to be welded to the beginning of each battery string assembly: busbar A1 for battery strings PA1 and PA2, busbar A2 for battery strings PA3 and PA4, and busbar A3 for battery strings PA5 and PA6. Three straight busbars need to be welded to the end of each battery string assembly: busbar B1 for battery strings PB1 and PB2, busbar B2 for battery strings PB3 and PB4, and busbar B3 for battery strings PB5 and PB6.

[0005] Currently, the common method of busbar welding involves welding all the busbars on the entire module at once after all the battery strings have been arranged. This welding method requires a busbar support mechanism on the busbar welding device, corresponding to each busbar, to support the busbars during the welding process. It also requires a busbar preparation mechanism to simultaneously prepare all the busbars for welding. Figure 1 Taking the 6 groups of 12-string photovoltaic modules shown as an example, three straight busbars need to be welded at the first end, three straight busbars need to be welded at the last end, and two L-shaped and two U-shaped busbars need to be welded in the middle. Correspondingly, 10 busbar support mechanisms need to be set up, and the busbar preparation mechanism prepares 10 busbars at the same time, which greatly increases the manufacturing cost and floor space of the busbar welding device. Summary of the Invention

[0006] To solve the above-mentioned technical problems, the present invention provides a busbar welding device, which adopts the following technical solution:

[0007] A busbar welding device is used to weld busbars to each component unit in a battery string assembly. Each component unit includes two battery strings arranged side-by-side along a first horizontal direction, and a plurality of component units arranged side-by-side along a second horizontal direction to form a battery string assembly. The second horizontal direction is perpendicular to the first horizontal direction. The busbar welding device includes a first busbar preparation mechanism, a second busbar preparation mechanism, a busbar transfer mechanism, a first busbar support mechanism, a second busbar support mechanism, a third busbar support mechanism, a welding gripper, and a welding mechanism, wherein:

[0008] The first busbar preparation mechanism is configured to prepare a head straight busbar, an L-shaped bent busbar, and a U-shaped bent busbar, and the second busbar preparation mechanism is configured to prepare at least a tail straight busbar;

[0009] The first busbar support mechanism, the second busbar support mechanism, and the third busbar support mechanism are arranged sequentially along the first horizontal direction. The first busbar support mechanism is configured to support a straight busbar at the head, the second busbar support mechanism is configured to support an L-shaped bent busbar and a U-shaped bent busbar simultaneously, and the third busbar support mechanism is configured to support a straight busbar at the tail.

[0010] The lap welding gripper is used to pick up each component unit and step and transport each component unit along the second horizontal direction;

[0011] The busbar transfer mechanism is used to pick up a first straight busbar from the first busbar preparation mechanism and transfer the picked-up first straight busbar to the first busbar support mechanism; the welding mechanism is used to weld the first straight busbar supported on the first busbar support mechanism to the extended welding strip at the head of the module unit when the module unit to be welded to the first straight busbar steps above the first busbar support mechanism;

[0012] The busbar transfer mechanism is also used to pick up an L-shaped bent busbar and / or a U-shaped bent busbar from the first busbar preparation mechanism and transfer the picked-up L-shaped bent busbar and / or U-shaped bent busbar to the second busbar support mechanism; the welding mechanism is also used to weld the L-shaped bent busbar and / or U-shaped bent busbar carried on the second busbar support mechanism to the extended welding strip in the middle of the component unit when the component unit to be welded with the L-shaped bent busbar and / or U-shaped bent busbar steps above the second busbar support mechanism;

[0013] The busbar transfer mechanism is also used to pick up a straight busbar at the tail end from the second busbar preparation mechanism and transfer the picked-up straight busbar at the tail end to the third busbar support mechanism; the welding mechanism is also used to weld the straight busbar at the tail end carried on the third busbar support mechanism to the extended welding strip at the tail end of the module unit when the module unit to be welded to the straight busbar at the tail end steps up above the third busbar support mechanism.

[0014] The busbar welding device of the present invention realizes the automatic welding of busbars for battery strings. In particular, by setting up the busbar preparation mechanism and the busbar carrying mechanism, and by controlling the stacking gripper to stepwise transport the battery strings, the busbar welding device of the present invention only requires three busbar carrying mechanisms to carry the busbars to be welded, and the busbar preparation mechanism only needs to prepare three to four busbars before each welding. The present invention greatly reduces the number of busbar carrying mechanisms and the number of busbars to be prepared each time, thereby reducing equipment costs and space requirements.

[0015] In some embodiments, the first busbar preparation mechanism includes a first straight busbar preparation section and a first bent busbar preparation section, and the second busbar preparation mechanism includes at least a second straight busbar preparation section, wherein: the first straight busbar preparation section and the second straight busbar preparation section are respectively used to prepare the head straight busbar and the tail straight busbar, and the first bent busbar preparation section is used to prepare the L-shaped bent busbar and / or the U-shaped bent busbar.

[0016] By configuring the first busbar preparation mechanism and the second busbar preparation mechanism, the first busbar preparation mechanism is able to prepare the head straight busbar, the L-shaped bent busbar and the U-shaped bent busbar, while the second busbar preparation mechanism is able to prepare at least the tail straight busbar.

[0017] In some embodiments, the busbar welding apparatus further includes a fourth busbar support mechanism disposed between the second busbar support mechanism and the third busbar support mechanism; the second busbar preparation mechanism further includes a second bent busbar preparation section, which is used to prepare L-shaped bent busbars and U-shaped bent busbars; the busbar transfer mechanism is further used to pick up one L-shaped bent busbar and / or one U-shaped bent busbar from the second busbar preparation mechanism and transfer the picked-up L-shaped bent busbar and / or U-shaped bent busbar to the fourth busbar support mechanism; the welding mechanism is further used to weld the L-shaped bent busbar and / or U-shaped bent busbar carried on the fourth busbar support mechanism to the extended welding strip in the middle of the component unit when the component unit to be welded with the L-shaped bent busbar and / or U-shaped bent busbar steps above the fourth busbar support mechanism.

[0018] If all L-shaped and U-shaped bent busbars in the middle of the battery string are prepared by the first bent busbar preparation unit and carried by the second busbar support mechanism, there may be a long waiting time during the welding process, which is not conducive to improving the production cycle. By setting a fourth busbar support mechanism and configuring the second busbar preparation unit to prepare both L-shaped and U-shaped bent busbars, the preparation speed of L-shaped and U-shaped bent busbars is improved. The second and fourth busbar support mechanisms can work alternately, reducing equipment waiting time and improving welding efficiency.

[0019] In some embodiments, the first bending busbar preparation unit includes a first traction assembly, a bending mechanism, and a first cutting mechanism, wherein: the first traction assembly is used to traction the busbar so that the busbar passes through the first cutting mechanism; the first cutting mechanism is used to cut the busbar to obtain a busbar to be bent; the first traction assembly is also used to traction the busbar to be bent to a predetermined position on the bending mechanism; the busbar to be bent is one or two; the bending mechanism is used to bend one end of the busbar to be bent to obtain an L-shaped bent busbar, and / or the bending mechanism is used to bend both ends of the busbar to be bent to obtain a U-shaped bent busbar; the busbar transfer mechanism picks up the L-shaped bent busbar and / or the U-shaped bent busbar from the bending mechanism.

[0020] By configuring the first bending busbar preparation unit, the first bending busbar preparation unit can pull out the busbar from the busbar supply mechanism, and perform a bending operation on the busbar after cutting it, thereby realizing the automatic preparation of L-shaped bending busbars and / or U-shaped bending busbars.

[0021] In some embodiments, the bending mechanism includes a first mounting base, and a first bending assembly, a second bending assembly, a third bending assembly, and a fourth bending assembly sequentially mounted on the first mounting base, wherein: the first bending assembly includes a first bending support platform and a first bending portion disposed outside the first bending support platform, the first bending portion being used to bend the end of the busbar to be bent on the first bending support platform upwards; the second bending assembly includes a second bending support platform, a third bending support platform, and a second bending portion, wherein: a first bending gap is maintained between the second bending support platform and the third bending support platform, and the second bending portion is configured to bend the busbar to be bent upwards through the first bending gap. The second bending support platform and / or the end of the busbar to be bent supported on the third bending support platform; the third bending assembly includes a fourth bending support platform, a fifth bending support platform and a third bending section, wherein: a second bending gap is maintained between the fourth bending support platform and the fifth bending support platform, and the third bending section is configured to bend the end of the busbar to be bent supported on the fourth bending support platform and / or the fifth bending support platform through the second bending gap; the fourth bending assembly includes a sixth bending support platform and a fourth bending section disposed outside the sixth bending support platform, the fourth bending section being used to bend the end of the busbar to be bent supported on the sixth bending support platform upward.

[0022] By configuring the bending mechanism, it can bend one end of a busbar to produce an L-shaped bent busbar each time, or bend both ends of a busbar to produce a U-shaped bent busbar each time, or simultaneously bend one end of a busbar and both ends of another busbar to simultaneously produce an L-shaped bent busbar and a U-shaped bent busbar. Furthermore, it can also produce L-shaped bent busbars with different bending directions.

[0023] In some embodiments, the first mounting base is provided with a first slide rail and a locking mechanism. The first bending component, the second bending component, the third bending component and the fourth bending component are slidably connected to the first slide rail, and the locking mechanism is used to lock the first bending component, the second bending component, the third bending component and the fourth bending component onto the first slide rail.

[0024] By setting a first slide rail and a locking mechanism, the bending mechanism can bend busbars of different lengths, thereby enabling the first bending busbar preparation unit to prepare L-shaped and U-shaped bending busbars of different lengths, thus improving the compatibility of the first bending busbar preparation unit.

[0025] In some embodiments, the second busbar support mechanism includes a first lifting drive mechanism, a second mounting base, a first support platform, a second support platform, and a third support platform, wherein: the second mounting base is connected to the drive end of the first lifting drive mechanism, and the first lifting drive mechanism is used to drive the second mounting base to lift; the first support platform, the second support platform, and the third support platform are sequentially arranged on the second mounting base along a second horizontal direction, wherein the first support platform and the third support platform are configured to move toward or away from the second support platform.

[0026] Because the L-shaped and U-shaped busbars, prepared simultaneously by the bending mechanism, have a large gap between them, they need to be brought close together before welding. By configuring the second busbar support mechanism to include a first support platform, a second support platform, and a third support platform, with the first and third support platforms capable of moving towards or away from the second support platform, the second busbar support mechanism can simultaneously support the L-shaped and U-shaped busbars with a large gap after preparation, and can adjust the gap between them to meet welding requirements. Furthermore, the first lifting drive mechanism can drive the first, second, and third support platforms to rise synchronously, allowing the L-shaped and / or U-shaped busbars to contact the extended welding strip in the center of the module unit, eliminating the need for a welding gripper to lower the module unit.

[0027] In some embodiments, the first busbar support mechanism and the third busbar support mechanism have the same structure. The first busbar support mechanism includes a busbar support platform and a second lifting drive mechanism. The busbar support platform is connected to the drive end of the second lifting drive mechanism, which is used to drive the busbar support platform to move up and down. The second busbar support mechanism also includes a first translation drive mechanism. The first lifting drive mechanism is installed on the drive end of the first translation drive mechanism, which is used to drive the second mounting base to translate along a first horizontal direction.

[0028] By configuring the structures of the first busbar support mechanism and the third busbar support mechanism, the first busbar support mechanism and the third busbar support mechanism can respectively support the first straight busbar and the last straight busbar, and lift the supported first straight busbar and the last straight busbar upwards onto the extended solder strips at the beginning and end of the module unit, thus eliminating the need for the stacking welding gripper to drive the module unit downwards; and by configuring the first translation drive mechanism, the first support, the second support platform and the third support platform can be translated to be close to the first busbar preparation mechanism to receive the L-shaped bent busbar and / or U-shaped bent busbar transferred from the first busbar preparation mechanism by the busbar transfer mechanism.

[0029] In some embodiments, the welding mechanism includes a first welding section, a second welding section, and a third welding section arranged sequentially along a first horizontal direction, wherein: the first welding section is located above the first busbar support mechanism and is used to weld the first straight busbar supported on the first busbar support mechanism to the extended welding strip at the head of the module unit; the second welding section is located above the second busbar support mechanism and is used to weld the L-shaped bent busbar and / or U-shaped bent busbar supported on the second busbar support mechanism to the extended welding strip in the middle of the module unit; the third welding section is located above the third busbar support mechanism and is used to weld the tail straight busbar supported on the third busbar support mechanism to the extended welding strip at the tail of the module unit.

[0030] By configuring the welding mechanism to include a first welding section, a second welding section, and a third welding section arranged sequentially along a first horizontal direction, the welding mechanism can simultaneously perform welding on the head straight busbar, the tail straight busbar, and the L-shaped bent busbar and / or the U-shaped bent busbar, thereby improving welding efficiency.

[0031] In some embodiments, the busbar transfer mechanism includes a first busbar transfer section and a second busbar transfer section, wherein: the first busbar transfer section is used to pick up a head straight busbar from a first busbar preparation mechanism and transfer the picked-up head straight busbar to a first busbar support mechanism; the first busbar transfer section is also used to pick up an L-shaped bent busbar and / or a U-shaped bent busbar from the first busbar preparation mechanism and transfer the picked-up L-shaped bent busbar and / or U-shaped bent busbar to a second busbar support mechanism; the second busbar transfer section is used to pick up a tail straight busbar from the second busbar preparation mechanism and transfer the picked-up tail straight busbar to a third busbar support mechanism.

[0032] By configuring the busbar transfer mechanism to include a first busbar transfer section and a second busbar transfer section, the transfer efficiency of the busbar transfer mechanism is improved.

[0033] The present invention also provides a typesetting and overlay welding device, which includes a typesetting pickup unit, a regularization conveying unit, and the busbar welding device described in any one of the above claims, wherein:

[0034] The typesetting pickup unit is located in front of the straightening conveyor unit, and the typesetting pickup unit places at least one component unit on the straightening conveyor unit at predetermined intervals.

[0035] The tidying and conveying unit is used to tidy up the component units placed by the layout picking unit, and to transport the tidyed component units to the picking station at predetermined intervals.

[0036] The stacking gripper includes picking components arranged one-to-one with each component unit in the battery string group; the stacking gripper moves along the second horizontal direction to drive the picking component corresponding to the component unit at the picking station to the picking station to pick up the component unit.

[0037] The lap welding gripper moves to bring the pick-up string of components with the component units to the welding station. The welding mechanism is used to weld the head straight busbar and the tail straight busbar to the head and tail of the component unit located at the welding station, and to weld the L-shaped bent busbar and / or U-shaped bent busbar to the middle of the component unit located at the welding station.

[0038] The layout and stacking welding equipment of this invention integrates the traditional layout machine and stacking welding machine, saving equipment and processes, avoiding multiple transfers of battery strings, ensuring module quality, and reducing equipment costs. Secondly, it realizes the synchronous operation of layout and stacking welding, which can greatly improve the production efficiency of photovoltaic modules. Thirdly, the alignment and conveying unit steps the module unit at predetermined intervals, instead of waiting for all module units to be laid out before conveying, which can shorten the overall length of the equipment and reduce the equipment footprint.

[0039] In some embodiments, the layout and overlay welding equipment further includes a jumper wire preparation unit and a jumper wire conveying unit, wherein: the jumper wire conveying unit is disposed on the side of the alignment conveying unit and configured to move synchronously with the alignment conveying unit; the jumper wire preparation unit is used to produce jumper wires and place them on the jumper wire conveying unit; when the alignment conveying unit conveys the component unit to the string picking station, the jumper wire conveying unit is used to synchronously convey the jumper wires to the string picking station; the string picking unit synchronously picks up the component unit and jumper wires from the string picking station, and the welding mechanism is also used to perform welding on the jumper wires.

[0040] The layout and overlay welding equipment enables simultaneous welding of jumpers and busbars, making it compatible with the layout and overlay welding of photovoltaic modules with jumpers, and improving the production efficiency of photovoltaic modules.

[0041] The present invention also provides a method for lap welding, which is used to weld busbars to n component units in a battery string group. The component unit includes two battery strings arranged side by side along a first horizontal direction, and a number of component units arranged side by side along a second horizontal direction form a battery string group. The second horizontal direction is perpendicular to the first horizontal direction. The busbar includes a front straight busbar, a rear straight busbar, an L-shaped bent busbar, and a U-shaped bent busbar. The L-shaped bent busbar and the U-shaped bent busbar are both middle busbars.

[0042] Overlay welding methods include:

[0043] The component units are conveyed by stepping along the second horizontal direction, with one or two component units moving forward each time. Welding stations are set up on the stepping conveying path of the component units. The welding stations can accommodate a maximum of one head straight busbar, one tail straight busbar, one L-shaped bent busbar and one U-shaped bent busbar at the same time.

[0044] When a component unit with a head straight busbar and a tail straight busbar to be welded is in the welding station at the same time, a head straight busbar and a tail straight busbar are welded simultaneously.

[0045] When a component unit with an L-shaped bend busbar and a U-shaped bend busbar to be welded are both in the welding station, the L-shaped bend busbar and the U-shaped bend busbar are welded simultaneously.

[0046] The shingling method of the present invention, by setting up the welding station and coordinating with the step-by-step conveyor of each component unit, can perform multi-stage welding of all busbars to be welded in the battery string group. For the first straight busbar, only one is welded at a time; for the last straight busbar, only one is welded at a time; for the middle busbar, one L-shaped bent busbar and one U-shaped bent busbar can be welded simultaneously. This simplifies the shingling equipment and reduces the space occupied by the shingling equipment. Furthermore, since one L-shaped bent busbar and one U-shaped bent busbar can be welded simultaneously, the number of welding operations can be reduced, thereby improving the shingling efficiency of photovoltaic modules.

[0047] In some embodiments, the overlay welding method further includes:

[0048] When the component unit of the i-th central busbar to be welded reaches the welding station, it is determined whether the next step will cause the component unit of the i-th central busbar to leave the welding station, where i <n;

[0049] If the next step causes the component unit of the i-th central busbar to leave the welding station, then all central busbars located at the welding station will be welded before the next step.

[0050] If the next step will not cause the component unit of the i-th central busbar to leave the welding station, then wait for the next step.

[0051] When the component unit to be welded for the nth central busbar is stepped to the welding station, the nth central busbar is welded.

[0052] By applying the above judgment rules, the number of times the central busbar is welded can be reduced, and simultaneous welding of two central busbars can be achieved as much as possible to improve welding efficiency. Attached Figure Description

[0053] Figure 1This is a schematic diagram of the welded battery string assembly in one embodiment of the present invention;

[0054] Figure 2 This is a schematic diagram of the structure of the busbar welding device provided in an embodiment of the present invention;

[0055] Figure 3 This is a schematic diagram of the structure of the first busbar preparation mechanism in an embodiment of the present invention;

[0056] Figure 4 This is a schematic diagram of the bending mechanism in an embodiment of the present invention;

[0057] Figure 5 A schematic diagram illustrating the bending mechanism in the embodiment of the invention simultaneously bending to prepare an L-shaped bending busbar and a U-shaped bending busbar;

[0058] Figure 6 This is a schematic diagram of the structure of the first busbar transfer section in an embodiment of the present invention;

[0059] Figure 7 This is a schematic diagram of the structure of the second busbar support mechanism in an embodiment of the present invention;

[0060] Figure 8 This is a schematic diagram of the layout and overlay welding equipment provided in an embodiment of the present invention;

[0061] Figure 9 This is a schematic diagram of the welded battery string assembly in another embodiment of the present invention;

[0062] Figure 10 This is a schematic diagram of the jumper preparation unit and jumper delivery unit in an embodiment of the present invention;

[0063] Figures 11-12 This is a schematic diagram of the welding process of the busbar welding device for the first type of battery string group in an embodiment of the present invention;

[0064] Figures 13-14 This is a schematic diagram of another welding process of the busbar welding device for the first type of battery string group in an embodiment of the present invention;

[0065] Figures 15-16 This is a schematic diagram of the welding process of the busbar welding device for the second type of battery string group in an embodiment of the present invention;

[0066] Figure 17 This is a schematic diagram of the welding process of the busbar welding device for the third type of battery string group in an embodiment of the present invention;

[0067] Figures 1 to 17 Includes:

[0068] Busbar welding device 10:

[0069] First busbar preparation mechanism 1:

[0070] First straight busbar preparation unit 11: second traction assembly 111, tape receiving platform 112, second cutting mechanism 113;

[0071] First bending busbar preparation unit 12: First traction assembly 121, bending mechanism 122, first cutting mechanism 123, first mounting base 124, first bending support platform 125, first bending section 126, second bending support platform 127, third bending support platform 128, second bending section 129, fourth bending support platform 1210, fifth bending support platform 1211, third bending section 1212, sixth bending support platform 1213, fourth bending section 1214, pressing section 1215;

[0072] Busbar supply unit 13;

[0073] Second busbar preparation mechanism 2;

[0074] Busbar transfer mechanism 3:

[0075] First busbar transfer unit 31: translation drive module 311, lifting drive module 312, busbar pickup unit 313, first pickup assembly 314, second pickup assembly 315;

[0076] Second busbar transfer section 32;

[0077] First busbar support mechanism 4:

[0078] Second busbar support mechanism 5:

[0079] First lifting drive mechanism 51, second mounting base 52, first support platform MH1, second support platform MH2, third support platform MH3;

[0080] Third busbar support mechanism 6:

[0081] Welding mechanism 7:

[0082] First welding part 71, second welding part 72, third welding part 73;

[0083] 8-layer welding gripper;

[0084] Layout Picking Department 20;

[0085] 30. Organizing and conveying section;

[0086] Jumper preparation unit 40;

[0087] Jumper wire delivery unit 50. Detailed Implementation

[0088] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0089] The present invention is a busbar welding device for welding busbars to each component unit in a battery string assembly. The component unit includes two battery strings arranged side by side along a first horizontal direction, and a number of component units arranged side by side along a second horizontal direction to form a battery string assembly. The second horizontal direction is perpendicular to the first horizontal direction.

[0090] like Figure 1 The battery string assembly comprises six component units: a first component unit PA1-PB1 consisting of battery strings PA1 and PB1; a second component unit PA2-PB2 consisting of battery strings PA2 and PB3; a third component unit PA3-PB3 consisting of battery strings PA3 and PB3; a fourth component unit PA4-PB4 consisting of battery strings PA4 and PB4; a fifth component unit PA5-PB5 consisting of battery strings PA5 and PB5; and a sixth component unit PA6-PB6 consisting of battery strings PA6 and PB6. The two battery strings in each component unit are aligned along a first horizontal direction (e.g., ...). Figure 1 The six component units are arranged side-by-side along the X-axis direction, and along the second horizontal direction (e.g., ...). Figure 1 The batteries are arranged side by side along the Y-axis to form 6 groups of 12-string battery strings.

[0091] like Figure 2 As shown, the busbar welding device 10 of the present invention includes a first busbar preparation mechanism 1, a second busbar preparation mechanism 2, a busbar transfer mechanism 3, a first busbar support mechanism 4, a second busbar support mechanism 5, a third busbar support mechanism 6, and a lap welding gripper. Figure 2 (not shown in the image) and welding mechanism 7, wherein:

[0092] The first busbar preparation mechanism 1 is configured to prepare a head straight busbar, an L-shaped bent busbar, and a U-shaped bent busbar, while the second busbar preparation mechanism 2 is configured to prepare at least a tail straight busbar. The L-shaped bent busbar and the U-shaped bent busbar are both middle busbars with a long solder strip to be welded to the middle of the battery string assembly.

[0093] The first busbar support mechanism 4, the second busbar support mechanism 5, and the third busbar support mechanism 6 are along the first horizontal direction (e.g., Figure 2The components are arranged sequentially along the X-axis direction. The first busbar support mechanism 4 is configured to support a straight head busbar, the second busbar support mechanism 5 is configured to support both an L-shaped bent busbar and a U-shaped bent busbar, and the third busbar support mechanism 6 is configured to support a straight tail busbar.

[0094] The lap welding gripper is used to pick up each component unit and move along the second horizontal direction (e.g.) Figure 2 The component units are conveyed step by step in the Y-axis direction.

[0095] Busbar transfer mechanism 3 is used to pick up a first straight busbar from the first busbar preparation mechanism 1 and transfer the picked-up first straight busbar to the first busbar support mechanism 4. Welding mechanism 7 is used to weld the first straight busbar supported on the first busbar support mechanism 4 to the extended solder strip at the head of the component unit when the component unit to be welded moves above the first busbar support mechanism 4.

[0096] The busbar transfer mechanism 3 is also used to pick up an L-shaped bent busbar and / or a U-shaped bent busbar from the first busbar preparation mechanism 1, and transfer the picked-up L-shaped bent busbar and / or U-shaped bent busbar to the second busbar carrying mechanism 5. The welding mechanism is also used to weld the L-shaped bent busbar and / or U-shaped bent busbar carried on the second busbar carrying mechanism 5 to the extended welding strip in the middle of the component unit when the component unit to be welded with the L-shaped bent busbar and / or U-shaped bent busbar steps above the second busbar carrying mechanism 5.

[0097] The busbar transfer mechanism 3 is also used to pick up a straight busbar at the tail end from the second busbar preparation mechanism 2 and transfer the picked-up straight busbar at the tail end to the third busbar support mechanism 6. The welding mechanism 7 is also used to weld the straight busbar at the tail end, which is supported on the third busbar support mechanism 6, to the extended solder strip at the tail end of the module unit when the module unit to be welded with the straight busbar at the tail end steps up above the third busbar support mechanism 6.

[0098] As can be seen, the busbar welding device 10 of the present invention realizes the automatic welding of busbars for battery strings. In particular, by setting up the busbar preparation mechanism and the busbar carrying mechanism, and by controlling the stacking gripper to stepwise transport the battery strings, the busbar welding device of the present invention only needs to set up three busbar carrying mechanisms to carry the first, middle and last busbars to be welded, respectively. Moreover, the busbar preparation mechanism only needs to prepare three to four busbars before each welding. Compared with the existing busbar welding methods, the present invention greatly reduces the number of busbar carrying mechanisms and the number of busbars to be prepared each time, thereby reducing equipment costs and space requirements.

[0099] like Figure 3 As shown, optionally, the first busbar preparation mechanism 1 includes a first straight busbar preparation section 11 and a first bent busbar preparation section 12, wherein the first straight busbar preparation section 11 is used to prepare the head straight busbar, and the first bent busbar preparation section 12 is used to prepare the L-shaped bent busbar and / or the U-shaped bent busbar. The second busbar preparation mechanism includes at least a second straight busbar preparation section, which is used to prepare the tail straight busbar.

[0100] Optionally, the first straight busbar preparation section 11 and the second straight busbar preparation section have the same structure. Taking the first straight busbar preparation section 11 as an example, as follows... Figure 3 As shown, it includes a second traction assembly 111, a receiving platform 112, and a second cutting mechanism 113, wherein: the second traction assembly 111 is used to pull a busbar from the busbar supply mechanism 13, so that the busbar passes through the first cutting mechanism 113, and the second cutting mechanism 113 is used to cut the busbar to obtain a straight head busbar. The second traction assembly 111 is also used to pull the obtained straight head busbar onto the receiving platform 112, and the busbar transfer mechanism 3 picks up the straight head busbar from the receiving platform 112.

[0101] Continue to refer to Figure 3 As shown, optionally, the first bending busbar preparation unit 12 includes a first traction assembly 121, a bending mechanism 122, and a first cutting mechanism 123, wherein: the first traction assembly 121 is used to pull the busbar from the busbar supply mechanism 13, so that the busbar passes through the first cutting mechanism 123, and the first cutting mechanism 123 is used to cut the busbar to obtain a busbar to be bent. The first traction assembly 121 is also used to pull the busbar to be bent to a predetermined position of the bending mechanism 122. The busbar to be bent is one or two, and the bending mechanism 122 is used to bend one end of the busbar to be bent to obtain an L-shaped bent busbar, and / or the bending mechanism 122 is used to bend both ends of the busbar to be bent to obtain a U-shaped bent busbar. The busbar transfer mechanism 3 picks up the L-shaped bent busbar and / or the U-shaped bent busbar from the bending mechanism 122.

[0102] like Figure 4 As shown, optionally, the bending mechanism 122 includes a first mounting base 124, and a first bending assembly, a second bending assembly, a third bending assembly, and a fourth bending assembly sequentially mounted on the first mounting base 124, wherein:

[0103] The first bending assembly includes a first bending support platform 125 and a first bending portion 126 disposed on the outside of the first bending support platform 125. The first bending portion 126 is used to bend the end of the busbar to be bent that is supported on the first bending support platform upward.

[0104] The second bending assembly includes a second bending support platform 127, a third bending support platform 128, and a second bending portion 129, wherein: a first bending gap is maintained between the second bending support platform 127 and the third bending support platform 128, and the second bending portion 129 is configured to bend the end of the busbar to be bent, which is supported on the second bending support platform 127 and / or the third bending support platform 128, upward through the first bending gap.

[0105] The third bending assembly includes a fourth bending support platform 1210, a fifth bending support platform 1211, and a third bending portion 1212, wherein: a second bending gap is maintained between the fourth bending support platform 1210 and the fifth bending support platform 1211, and the third bending portion 1212 is configured to bend the end of the busbar to be bent, which is supported on the fourth bending support platform 1210 and / or the fifth bending support platform 1211, upward through the second bending gap.

[0106] The fourth bending assembly includes a sixth bending support platform 1213 and a fourth bending portion 1214 disposed on the outside of the sixth bending support platform 1213. The fourth bending portion 1214 is used to bend the end of the busbar to be bent that is supported on the sixth bending support platform 1213.

[0107] Optional, such as Figure 5 Each of the first bending support platform 125, the second bending support platform 127, the third bending support platform 128, the fourth bending support platform 1210, the fifth bending support platform 1211, and the sixth bending support platform 1213 is provided with a clamping part 1215, which is used to clamp the end of the busbar before bending. Of course, the clamping part 1215 can also be provided independently, as long as it can clamp the end of the busbar before bending.

[0108] Continue to refer to Figure 4 and Figure 5 As shown, in one embodiment, the component unit currently arriving above the busbar welding device includes a central busbar to be welded, comprising a preceding L-shaped bent busbar and a following U-shaped bent busbar, wherein the length of the L-shaped bent busbar is approximately half that of the U-shaped bent busbar. The bending process of the bending mechanism 122 is as follows:

[0109] The first traction assembly 121 places the busbar L1 cut by the first cutting mechanism 123 onto the bending mechanism 122, wherein the first end of the busbar L1 is located on the first bending support platform 125 and extends outward from the first bending support platform 125, and the second end of the busbar L1 is located on the second bending support platform 127 and extends outward into the first bending gap. The first traction assembly 121 places the busbar U1 cut by the first cutting mechanism 123 onto the bending mechanism 122, wherein the first end of the busbar U1 is located on the third bending support platform 128 and extends outward into the first bending gap, and the second end of the busbar U1 is located on the sixth bending support platform 1213 and extends outward from the sixth bending support platform 1213.

[0110] Next, the clamping part 1215 fixes the first end and the second end of the busbar L1, as well as the first end and the second end of the busbar U1.

[0111] Finally, the second bending section 129 simultaneously bends the second end of busbar L1 and the first end of busbar U1 upwards, and the fourth bending section 1214 bends the second end of busbar U1 upwards. Thus, an L-shaped bent busbar and a U-shaped bent busbar are obtained simultaneously.

[0112] Continue to refer to Figure 4 and Figure 5 As shown, in another embodiment, the component unit currently arriving above the busbar welding device includes a central busbar to be welded, comprising a preceding U-shaped bent busbar and a following L-shaped bent busbar, wherein the length of the L-shaped bent busbar is approximately half that of the U-shaped bent busbar. The bending process of the bending mechanism 122 is as follows:

[0113] The first traction assembly 121 places the busbar U2 cut by the first cutting mechanism 123 onto the bending mechanism 122. The first end of the busbar U2 is located on the first bending support platform 125 and extends outward from the platform. The second end of the busbar U2 is located on the fourth bending support platform 1210 and extends outward into the second bending gap. The first traction assembly 121 also places the busbar L2 cut by the first cutting mechanism 123 onto the bending mechanism 122. The first end of the busbar L2 is located on the fifth bending support platform 1211 and extends outward into the second bending gap. The second end of the busbar L2 is located on the sixth bending support platform 1213 and extends outward from it.

[0114] Next, the clamping part 1215 fixes the first end and the second end of the busbar U2, as well as the first end and the second end of the busbar L2.

[0115] Finally, the first bending assembly 126 bends the first end of the busbar U2 upward, and the third bending part 1212 simultaneously bends the second end of the busbar U2 and the first end of the busbar L2 upward, thereby obtaining a U-shaped bent busbar and an L-shaped bent busbar.

[0116] As can be seen from the above two embodiments, the bending mechanism of the present invention can not only simultaneously produce a U-shaped bent busbar and an L-shaped bent busbar, but also produce L-shaped bent busbars with different bending directions, thus meeting the requirements for producing L-shaped bent busbars with different bending directions at both ends of the battery string.

[0117] Since the lengths of the U-shaped and L-shaped busbars to be bent may differ in different embodiments, in order to implement the bearing and bending of busbars of different lengths, optionally, the first mounting base 124 is provided with a first slide rail and a locking mechanism, and the first bending component, the second bending component, the third bending component and the fourth bending component are respectively slidably connected to the first slide rail; the locking mechanism is used to lock the first bending component, the second bending component, the third bending component and the fourth bending component respectively on the first slide rail.

[0118] By controlling the first bending component, the second bending component, the third bending component, and the fourth bending component to slide on the first mounting base 124, the distance between the first bending component, the second bending component, the third bending component, and the fourth bending component can be flexibly adjusted. This allows the bending mechanism 122 to carry and bend busbars of different lengths, so as to produce U-shaped and L-shaped bent busbars of different lengths, meeting the busbar manufacturing requirements of different types of photovoltaic modules.

[0119] If all the L-shaped and U-shaped bent busbars in the middle of the battery string are prepared by the first bent busbar preparation unit and carried by the second busbar carrying mechanism, there may be a long waiting time during the welding process, which is not conducive to improving the production cycle.

[0120] To address this issue, optionally, the busbar welding apparatus of the present invention further includes a fourth busbar carrying mechanism disposed between the second busbar carrying mechanism 5 and the third busbar carrying mechanism 6. The second busbar preparation mechanism 2 also includes a second bending busbar preparation section, which is used to prepare L-shaped bending busbars and U-shaped bending busbars. That is, in addition to preparing straight-tailed busbars, the second busbar preparation mechanism 2 can simultaneously prepare L-shaped bending busbars and / or U-shaped bending busbars. Optionally, the structure of the second bending busbar preparation section is the same as that of the first bending busbar preparation section.

[0121] The busbar transfer mechanism 3 is also used to pick up an L-shaped bent busbar and / or a U-shaped bent busbar from the second busbar preparation mechanism 2, and transfer the picked-up L-shaped bent busbar and / or U-shaped bent busbar to the fourth busbar carrying mechanism.

[0122] The welding mechanism 7 is also used to weld the L-shaped bent busbar and / or U-shaped bent busbar carried on the fourth busbar support mechanism to the extended welding strip in the middle of the component unit when the component unit to be welded moves to the upper part of the fourth busbar support mechanism.

[0123] By setting a fourth busbar support mechanism and configuring the second busbar preparation mechanism to prepare L-shaped and U-shaped bent busbars, the preparation speed of L-shaped and U-shaped bent busbars is improved. The first and second busbar preparation mechanisms can alternately prepare L-shaped and / or U-shaped bent busbars, and the second and fourth busbar support mechanisms can alternately support L-shaped and / or U-shaped bent busbars, thereby reducing equipment waiting time and improving welding efficiency.

[0124] like Figure 5 As shown, the L-shaped and U-shaped busbars prepared by the bending mechanism 122 have a large gap between them, while the gap between them is smaller during welding. Therefore, the gap between the L-shaped and U-shaped busbars needs to be adjusted before welding.

[0125] To adjust the spacing between L-shaped and U-shaped busbars, such as... Figure 7 As shown, optionally, the second busbar support mechanism 5 includes a first lifting drive mechanism 51, a second mounting base 52, a first support platform MH1, a second support platform MH2, and a third support platform MH3, wherein: the second mounting base 52 is connected to the drive end of the first lifting drive mechanism 51, and the first lifting drive mechanism 51 is used to drive the second mounting base 52 to lift. The first support platform MH1, the second support platform MH2, and the third support platform MH3 are along a second horizontal direction (e.g., ...). Figure 7 The first support platform MH1 and the third support platform MH3 are sequentially arranged on the second mounting base 52 in the Y-axis direction, wherein the first support platform MH1 and the third support platform MH3 are configured to move toward or away from the second support platform MH2.

[0126] Thus, the busbar transfer mechanism 3 can pick up L-shaped and U-shaped busbars with a large spacing from the first busbar preparation mechanism 1 and place them directly onto the second busbar carrying mechanism 5, whereby the second busbar carrying mechanism 5 adjusts the spacing between the L-shaped and U-shaped busbars.

[0127] For example, when the U-shaped bend busbar is supported on the first support platform MH1 and the second support platform MH2, and the L-shaped bend busbar is supported on the third support platform MH3, controlling the third support platform MH3 to slide towards the second support platform MH2 can reduce the distance between the U-shaped bend busbar and the L-shaped bend busbar.

[0128] For example, when the U-shaped bend busbar is supported on the second support platform MH2 and the third support platform MH3, and the L-shaped bend busbar is supported on the first support platform MH1, controlling the first support platform MH1 to slide towards the second support platform MH2 can reduce the distance between the U-shaped bend busbar and the L-shaped bend busbar.

[0129] Furthermore, since the second mounting base 52 is mounted on the first lifting drive mechanism 51, the second mounting base 52 is raised by controlling the first lifting drive mechanism 51 to drive the L-shaped bending busbar and / or U-shaped bending busbar to rise synchronously to contact the extended solder strip in the middle of the module unit, thus eliminating the need for the stacking gripper to lower the module unit.

[0130] Optionally, the second busbar carrying mechanism 5 further includes a first translation drive mechanism. A first lifting drive mechanism 51 is mounted on the drive end of the first translation drive mechanism. The first translation drive mechanism is used to drive the second mounting base 52 to translate along a first horizontal direction. This allows the first carrying platform MH1, the second carrying platform MH2, and the third carrying platform MH3 to be moved closer to the first busbar preparation mechanism 1 to receive the L-shaped bent busbar and / or U-shaped bent busbar transferred from the first busbar preparation mechanism 1 by the busbar transfer mechanism 3.

[0131] Optionally, the first busbar support mechanism 4 and the third busbar support mechanism 6 have the same structure. Taking the first busbar support mechanism as an example, it includes a busbar support platform and a second lifting drive mechanism. The busbar support platform is connected to the drive end of the second lifting drive mechanism, which drives the busbar support platform to move up and down. The busbar support platform carries the first straight busbar transferred by the busbar transfer mechanism 3, while the first lifting drive mechanism controls the busbar support platform to rise, so that the first straight busbar contacts the extended solder strip at the head of the module unit, thus eliminating the need for the stacking gripper to lower the module unit.

[0132] Continue to refer to Figure 2As shown, optionally, the welding mechanism 7 includes a first welding section 71, a second welding section 72, and a third welding section 73 arranged sequentially along a first horizontal direction. The first welding section 71 is located above the first busbar support mechanism 4 and is used to weld the first straight busbar supported on the first busbar support mechanism 4 to the extended welding strip at the head of the module unit. The second welding section 72 is located above the second busbar support mechanism 5 and is used to weld the L-shaped bent busbar and / or U-shaped bent busbar supported on the second busbar support mechanism 5 to the extended welding strip in the middle of the module unit. The third welding section 73 is located above the third busbar support mechanism 6 and is used to weld the tail straight busbar supported on the third busbar support mechanism 6 to the extended welding strip at the tail of the module unit.

[0133] By configuring the welding mechanism 7 to include a first welding section 71, a second welding section 72, and a third welding section 73 arranged sequentially along a first horizontal direction, the welding mechanism 7 can simultaneously perform welding on the head straight busbar, the tail straight busbar, and the L-shaped bent busbar and / or the U-shaped bent busbar, thereby improving welding efficiency.

[0134] Optionally, the busbar transfer mechanism 3 includes a first busbar transfer section 31 and a second busbar transfer section 32, wherein: the first busbar transfer section 31 is used to pick up the head straight busbar from the first busbar preparation mechanism 1 and transfer the picked-up head straight busbar to the first busbar carrying mechanism 4. The first busbar transfer section 31 is also used to pick up L-shaped bent busbars and / or U-shaped bent busbars from the first busbar preparation mechanism 1 and transfer the picked-up L-shaped bent busbars and / or U-shaped bent busbars to the second busbar carrying mechanism 5. The second busbar transfer section 32 is used to pick up the tail straight busbar from the second busbar preparation mechanism 2 and transfer the picked-up tail straight busbar to the third busbar carrying mechanism 6.

[0135] like Figure 6 As shown, the first busbar transfer unit 31 includes a translation drive module 311, a lifting drive module 312, and a busbar pickup unit 313, wherein: the lifting drive module 312 is connected to the drive end of the translation drive module 311, and the busbar pickup unit 313 is connected to the drive end of the lifting drive module 312. The translation drive module 311 and the lifting drive module 312 are used to drive the busbar pickup unit 313 to translate and lift, respectively.

[0136] The busbar pickup unit 313 includes a first pickup component 314 and a second pickup component 315. The first pickup component 314 can simultaneously pick up one L-shaped bent busbar and one U-shaped bent busbar, while the second pickup component 315 is used to pick up a busbar with a straight head. For example, both the first pickup component 314 and the second pickup component 315 include several suction cups arranged side-by-side. The number of suction cups on the first pickup component 314 is sufficient to stably and simultaneously pick up one L-shaped bent busbar and one U-shaped bent busbar. Figure 6 For example, the first pickup component 314 includes 5 suction cups, of which three suction cups are used to pick up U-shaped bends of the busbar and the remaining two suction cups are used to pick up L-shaped bends of the busbar; the number of suction cups on the second pickup component 315 is sufficient to pick up a straight busbar.

[0137] As mentioned in the previous embodiments, if the second busbar preparation mechanism 2 is provided with a second bent busbar preparation section, that is, the second busbar preparation mechanism 2 is also used to prepare L-shaped bent busbars and U-shaped bent busbars. Correspondingly, the second busbar transfer section 32 needs to transfer not only the tail-end straight busbars prepared by the second busbar preparation mechanism 2, but also the L-shaped bent busbars and U-shaped bent busbars prepared by the second busbar preparation mechanism 2. Therefore, in this case, optionally, the second busbar transfer section 32 can adopt the same structure as the first busbar transfer section 31 described above.

[0138] Of course, if the second busbar preparation mechanism 2 is only used to prepare the tail-end straight busbar, then the second busbar transfer section 32 only needs to transfer the tail-end straight busbar. Therefore, in this case, the second busbar transfer section 32 can adopt a different structure from the first busbar transfer section 31 described above. For example, its busbar pickup section may only include a pickup component for picking up the tail-end straight busbar.

[0139] The present invention also provides a typesetting and overlay welding device, such as... Figure 8 As shown, the typesetting and overlay welding equipment of the present invention includes a typesetting pickup unit 20, a straightening and conveying unit 30, and a busbar welding device 10 as described in any of the above embodiments, wherein:

[0140] The typesetting pickup unit 20 is located in front of the straightening conveyor unit 30, and the typesetting pickup unit 20 places at least one component unit on the straightening conveyor unit 30 at predetermined intervals.

[0141] The aligning and conveying unit 30 is used to align the component units placed by the layout picking unit, and to transport the aligned component units to the picking station at predetermined intervals.

[0142] The busbar welding device 10 includes a stacking gripper 8 comprising string-picking components arranged one-to-one with each component unit in the battery string assembly. The stacking gripper 8 is positioned along a second horizontal direction (e.g., ...). Figure 8The component is translated along the Y-axis to move the picking component corresponding to the component unit at the picking station to the picking station to pick up the component unit.

[0143] The lap welding gripper 8 moves to bring the picking string of components with the component units to the welding station. The welding mechanism 7 is used to weld the head straight busbar and the tail straight busbar to the head and tail of the component unit located at the welding station, and to weld the L-shaped bent busbar and / or the U-shaped bent busbar to the middle of the component unit located at the welding station.

[0144] The layout and lamination equipment of this invention integrates traditional layout and lamination machines, saving equipment and processes, avoiding multiple transfers of battery strings, ensuring module quality, and reducing equipment costs. Secondly, it achieves simultaneous layout and lamination, significantly improving the production efficiency of photovoltaic modules. Thirdly, the alignment and conveying unit advances the module unit at predetermined intervals, instead of waiting for all module units to be laid out before conveying, thereby shortening the overall length of the equipment and reducing its footprint.

[0145] Some battery pack designs require soldered jumpers, for example, Figure 9 The five sets of 10-cell battery strings shown have jumper wires C soldered between the second component unit PA2-PB2 and the third component unit PA3-PB3. The first end of jumper wire C is soldered to busbar A2, the second end is soldered to busbar B2, and the middle part is soldered to busbar M2.

[0146] In order to enable soldering of jumper C, optional methods include... Figure 10 As shown, the layout and stacking equipment of the present invention further includes a jumper wire preparation unit 40 and a jumper wire conveying unit 50, wherein the jumper wire conveying unit 50 is disposed on the side of the alignment conveying unit 20 and is configured to move synchronously with the alignment conveying unit 20. The jumper wire preparation unit 40 is used to produce jumpers and place them on the jumper wire conveying unit 50. When the alignment conveying unit 20 conveys the module unit to the string picking station, the jumper wire conveying unit 50 is used to synchronously convey the jumper wire to the string picking station. The string picking unit synchronously picks up the module unit and the jumper wire from the string picking station, and the welding mechanism 7 is also used to perform welding on the jumper wire. It can be seen that the layout and stacking equipment can synchronously weld the jumper wire and the corresponding busbar into the battery string, so that the layout and stacking equipment can be compatible with the layout and stacking of photovoltaic modules with jumpers, and improves the production efficiency of photovoltaic modules.

[0147] Since the jumper conveyor and the straightening conveyor are transported synchronously, in order to simplify the structure and save costs, the jumper conveyor and the straightening conveyor can use the same set of conveying drive system.

[0148] This invention also provides a method for lap welding, used to weld busbars to n component units in a battery string assembly. Each component unit includes two battery strings arranged side-by-side along a first horizontal direction, and several component units arranged side-by-side along a second horizontal direction form the battery string assembly. The second horizontal direction is perpendicular to the first horizontal direction. The busbars include a front straight busbar, a rear straight busbar, an L-shaped bent busbar, and a U-shaped bent busbar, with the L-shaped and U-shaped bent busbars being both central busbars.

[0149] The overlay welding method of the present invention can be implemented using the overlay welding equipment of any of the above embodiments of the present invention. Specifically, the overlay welding method of the present invention includes:

[0150] The component units are conveyed by stepping along the second horizontal direction, advancing one or two component units at a time. Welding stations are set up along the stepping conveying path of the component units, and each welding station can simultaneously accommodate a maximum of one head straight busbar, one tail straight busbar, one L-shaped bent busbar, and one U-shaped bent busbar.

[0151] When a component unit with a head straight busbar and a tail straight busbar to be welded is in the welding station at the same time, the head straight busbar and the tail straight busbar are welded simultaneously.

[0152] When a component unit with an L-shaped bend busbar and a U-shaped bend busbar to be welded are both in the welding station, the L-shaped bend busbar and the U-shaped bend busbar are welded simultaneously.

[0153] The shingling method of the present invention, by setting up the welding station and coordinating with the step-by-step conveyor of each component unit, can perform multi-stage welding of all busbars to be welded in the battery string group. For the first straight busbar, only one is welded at a time; for the last straight busbar, only one is welded at a time; for the middle busbar, one L-shaped bent busbar and one U-shaped bent busbar can be welded simultaneously. This simplifies the shingling equipment and reduces the space occupied by the shingling equipment. Furthermore, since one L-shaped bent busbar and one U-shaped bent busbar can be welded simultaneously, the number of welding operations can be reduced, thereby improving the shingling efficiency of photovoltaic modules.

[0154] Optionally, when the component unit to be welded with the i-th middle bus bar steps to the welding station, it is judged whether the next step will cause the component unit to be welded with the i-th middle bus bar to leave the welding station, where i < n; if the next step causes the component unit to be welded with the i-th middle bus bar to leave the welding station, then all the middle bus bars located at the welding station are welded before the next step. If the next step will not cause the component unit to be welded with the i-th middle bus bar to leave the welding station, then wait for the next step. When the component unit to be welded with the n-th middle bus bar steps to the welding station, the n-th middle bus bar is welded.

[0155] In order to enable those skilled in the art to more clearly understand the stacking welding method of the present invention, the following will exemplarily describe the specific execution process of the stacking welding method of the present invention through four embodiments.

[0156] The first embodiment

[0157] This embodiment is used to implement the stacking welding of a battery string group with a 6-group 12-string version.

[0158] Reference Figures 11-12 As shown, the stacking welding process in this embodiment is as follows:

[0159] As Figure 11 shown, the welding station includes a head bus bar welding station composed of bus bar carriers AH1 and AH2, a middle bus bar welding station composed of carriers MH1, MH2 and MH3, and a tail bus bar welding station composed of bus bar carriers BH1 and BH2.

[0160] The bus bars to be welded are: A1, A2 and A3 are head straight bus bars, B1, B2 and B3 are tail straight bus bars, M1 and M4 are L-shaped bent bus bars, and M2 and M3 are U-shaped bent bus bars.

[0161] In this embodiment, each component unit is stepped forward one by one.

[0162] As Figure 12 shown in (a) of, the battery string group is stepped forward for the first time. At this time, since the next step will not cause the component unit to be welded with the first middle bus bar, that is, the L-shaped bent bus bar M1, to leave the welding station, then wait for the next step, and the L-shaped bent bus bar M1 is not welded this time, that is, no welding action is performed.

[0163] As Figure 12As shown in (b), the battery string group is moved forward for the second time. At this time, the component units PA1-PB1 and PA2-PB2, which are to be welded to the first straight busbar A1 and the last straight busbar B1, move to the welding positions of the first and last busbars, respectively, and thus weld the first straight busbar A1 and the last straight busbar B1 simultaneously. Furthermore, since the next step will not cause the component unit to leave the welding position of the L-shaped bent busbar M1, it waits for the next step and does not weld the L-shaped bent busbar M1 this time.

[0164] like Figure 12 As shown in (c), the battery string is moved forward for the third time. At this time, the component units PA1-PB1, PA2-PB2 and PA3-PB3, which are to be welded L-shaped bent busbar M1 and U-shaped bent busbar M2, are simultaneously at the middle busbar welding station, and L-shaped bent busbar M1 and U-shaped bent busbar M2 are welded at the same time.

[0165] like Figure 12 As shown in (d), the battery string is moved forward for the fourth time. At this time, the module units PA3-PB3 and PA4-PB4, which are to be welded to the first straight busbar A2 and the last straight busbar B2, move to the welding positions of the first and last busbars, respectively. Therefore, the first straight busbar A2 and the last straight busbar B2 are welded simultaneously. Furthermore, since the next step will not cause the module unit to leave the welding position of the third middle busbar, i.e., the U-shaped bent busbar M3, to be welded, it waits for the next step and is not welded this time.

[0166] like Figure 12 As shown in (e), the battery string group is moved forward for the fifth time. Since the next step will not cause the component unit of the third central busbar to be welded, namely the U-shaped bend busbar M3, to leave the welding station, we wait for the next step. This time, the U-shaped bend busbar M3 is not welded, that is, no welding action is performed.

[0167] like Figure 12 As shown in (f), the battery string is moved forward for the sixth time. At this time, the component units PA5-PB5 and PA6-PB6, which are to be welded to the first straight busbar A3 and the last straight busbar B3, move to the first busbar welding station and the last busbar welding station, respectively. At the same time, the component units PA4-PB4, PA5-PB5 and PA6-PB6, which are to be welded to the U-shaped bent busbar M3 and the L-shaped bent busbar M4, move to the middle busbar welding station. Therefore, the first straight busbar A3, the last straight busbar B3, the U-shaped bent busbar M3 and the L-shaped bent busbar M4 are welded at the same time.

[0168] By employing the stacking welding method of the present invention, for a battery string group of 6 groups of 12 strings, although the process involves 6 steps, only 4 welding steps are required, resulting in high welding efficiency.

[0169] Second Embodiment

[0170] This embodiment is used to perform stacking welding on 6 groups of 12-cell battery strings.

[0171] refer to Figures 13-14 As shown, the lap welding process in this embodiment is as follows:

[0172] like Figure 13 As shown, the welding station includes a first busbar welding station consisting of busbar support platforms AH1 and AH2, a middle busbar welding station consisting of support platforms MH1, MH2 and MH3, and a tail busbar welding station consisting of busbar support platforms BH1 and BH2.

[0173] The busbars to be welded are as follows: A1, A2 and A3 are straight busbars at the beginning; B1, B2 and B3 are straight busbars at the end; M1 and M4 are L-shaped bent busbars; and M2 and M3 are U-shaped bent busbars.

[0174] In this embodiment, two component units are moved forward each time.

[0175] like Figure 14 As shown in (a), the battery string is moved forward for the first time. At this time, the component units PA1-PB1 and PA2-PB2 of the first straight busbar A1 and the last straight busbar B1 to be welded are moved to the welding station of the first busbar and the welding station of the last busbar, respectively. Since the next step will cause the component unit of the L-shaped bent busbar M1 to be welded to leave the welding station, the first straight busbar A1, the last straight busbar B1 and the L-shaped bent busbar M1 are welded at the same time.

[0176] like Figure 14 As shown in (b), the battery string is moved forward for the second time. At this time, the component units PA3-PB3 and PA4-PB4 of the first straight busbar A2 and the last straight busbar B2 to be welded are moved to the welding station of the first busbar and the welding station of the last busbar, respectively. Since the next step will cause the component unit of the U-shaped bent busbar M2 to be welded to leave the welding station, the first straight busbar A2, the last straight busbar B2 and the U-shaped bent busbar M2 are welded at the same time.

[0177] like Figure 14As shown in (c), the battery string is moved forward for the third time. At this time, the component units PA5-PB5 and PA6-PB6, which are to be welded to the first straight busbar A3 and the last straight busbar B3, move to the first busbar welding station and the last busbar welding station, respectively. At the same time, the component units PA4-PB4, PA5-PB5 and PA6-PB6, which are to be welded to the U-shaped bent busbar M3 and the L-shaped bent busbar M4, move to the middle busbar welding station. Therefore, the first straight busbar A3, the last straight busbar B3, the U-shaped bent busbar M3 and the L-shaped bent busbar M4 are welded simultaneously.

[0178] By employing the stacking welding method of the present invention, for a battery string group of 6 groups of 12 strings, although the process involves 6 steps, only 3 welding steps are required, resulting in higher welding efficiency than the first embodiment.

[0179] Third Embodiment

[0180] This embodiment is used to perform stacking welding on 5 groups of 10-cell battery strings.

[0181] refer to Figures 15-16 As shown, the lap welding process in this embodiment is as follows:

[0182] like Figure 15 As shown, the welding station includes a first busbar welding station consisting of busbar support platforms AH1 and AH2, a middle busbar welding station consisting of support platforms MH1, MH2 and MH3, and a tail busbar welding station consisting of busbar support platforms BH1 and BH2.

[0183] The busbars to be welded are as follows: A1, A2 and A3 are straight busbars at the beginning; B1, B2 and B3 are straight busbars at the end; M1 and M4 are L-shaped bent busbars; M2 and M3 are U-shaped bent busbars; and the length of M2 is approximately half that of M3.

[0184] Jumper C is connected to component unit PA3-PB3 via head straight busbar A2, tail straight busbar B2, and U-shaped bent busbar M2.

[0185] In this embodiment, one component unit is moved forward each time.

[0186] like Figure 16 As shown in (a), the battery string group is moved forward for the first time. At this time, since the next step will not cause the component unit of the first central busbar to be welded, namely the L-shaped bent busbar M1, to leave the welding station, we wait for the next step. This time, the L-shaped bent busbar M1 is not welded, that is, no welding action is performed.

[0187] like Figure 16As shown in (b), the battery string is moved forward for the second time. At this time, the component units PA1-PB1 and PA2-PB2, which are to be welded to the first straight busbar A1 and the last straight busbar B1, move to the welding positions of the first and last busbars, respectively, and are thus welded simultaneously. Furthermore, since the next step will not cause the component unit to leave the welding position of the L-shaped bent busbar M1, it waits for the next step and does not weld the L-shaped bent busbar M1 this time.

[0188] like Figure 16 As shown in (c), the battery string is moved forward for the third time. At this time, the component units PA3-PB3 of the first straight busbar A2 and the last straight busbar B2 to be welded are moved to the welding station of the first busbar and the welding station of the last busbar, respectively. The next step will cause the component unit of the L-shaped bent busbar M1 to be welded to leave the welding station. Therefore, the first straight busbar A2 and the last straight busbar B2 are welded at the same time, as are all the middle busbars located at the welding station, namely the L-shaped bent busbar M1 and the U-shaped bent busbar M2.

[0189] like Figure 16 As shown in (d), the battery string group is moved forward for the fourth time. Since the next step will not cause the component unit of the third central busbar to be welded, namely the U-shaped bend busbar M3, to leave the welding station, we wait for the next step. This time, the U-shaped bend busbar M3 is not welded, that is, no welding action is performed.

[0190] like Figure 16 As shown in (e), the battery string is moved forward for the fifth time. At this time, PA4-PB5 and PA6-PB6 of the first straight busbar A3 and the last straight busbar B3 to be welded are moved to the welding station of the first busbar and the welding station of the last busbar, respectively. The component units PA3-PB3, PA4-PB4 and PA5-PB5 of the U-shaped bent busbar M3 and the L-shaped bent busbar M4 to be welded are moved to the welding station of the middle busbar. Therefore, the first straight busbar A3, the last straight busbar B3, the U-shaped bent busbar M3 and the L-shaped bent busbar M4 are welded at the same time.

[0191] By employing the stacking welding method of the present invention, for 5 groups of 10-string battery strings, although the process involves 5 steps, only 3 welding steps are required, resulting in high welding efficiency.

[0192] Fourth embodiment

[0193] This embodiment is used to perform stacking welding on 4 groups of 8-string battery strings.

[0194] refer to Figure 17 As shown, the lap welding process in this embodiment is as follows:

[0195] like Figure 17 As shown in (a), the welding station includes a first busbar welding station consisting of busbar support platforms AH1 and AH2, a middle busbar welding station consisting of support platforms MH1, MH2 and MH3, and a tail busbar welding station consisting of busbar support platforms BH1 and BH2.

[0196] The busbars to be welded are as follows: A1 and A2 are straight busbars at the beginning, B1 and B2 are straight busbars at the end, M1 and M3 are L-shaped bent busbars, and M2 is a U-shaped bent busbar.

[0197] In this embodiment, one component unit is moved forward each time.

[0198] like Figure 17 As shown in (a), the battery string group is moved forward for the first time. At this time, since the next step will not cause the component unit of the first central busbar to be welded, namely the L-shaped bent busbar M1, to leave the welding station, we wait for the next step. This time, the L-shaped bent busbar M1 is not welded, that is, no welding action is performed.

[0199] like Figure 17 As shown in (b), the battery string is moved forward for the second time. At this time, the component units PA1-PB1 and PA2-PB2, which are to be welded to the first straight busbar A1 and the last straight busbar B1, move to the first busbar welding station and the last busbar welding station, respectively, and thus weld the first straight busbar A1 and the last straight busbar B1 simultaneously. Furthermore, since the next step will not cause the component unit to leave the welding station for the L-shaped bent busbar M1, it waits for the next step and does not weld the L-shaped bent busbar M1 this time.

[0200] like Figure 17 As shown in (c), the battery string is moved forward for the third time. At this time, the component units PA1-PB1, PA2-PB2, and PA3-PB3 of the L-shaped bent busbar M1 and U-shaped bent busbar M2 to be welded all move to the middle busbar welding station, so the L-shaped bent busbar M1 and U-shaped bent busbar M2 are welded at the same time.

[0201] like Figure 17 As shown in (d), the battery string is moved forward for the fourth time. At this time, the component units PA3-PB3 and PA4-PB4, which are to be welded to the first straight busbar A2 and the last straight busbar B2, move to the first busbar welding station and the second busbar welding station, respectively. The component unit PA4-PB4, which is to be welded to the L-shaped bent busbar M3, moves to the middle busbar welding station. Therefore, the first straight busbar A2, the last straight busbar B2 and the L-shaped bent busbar M3 are welded at the same time.

[0202] By employing the stacking welding method of the present invention, for 4 groups of 8-string battery strings, although the process involves 4 steps, only 3 welding steps are required, resulting in high welding efficiency.

[0203] The present invention has been described above in sufficient detail and with certain specificities. Those skilled in the art should understand that the descriptions in the embodiments are merely exemplary, and all changes made without departing from the true spirit and scope of the invention should fall within the protection scope of the invention. The scope of protection claimed by the present invention is defined by the claims, and not by the above descriptions in the embodiments.

Claims

1. A busbar welding device, characterized in that, The busbar welding device is used to weld busbars to each component unit in the battery string assembly. Each component unit includes two battery strings arranged side-by-side along a first horizontal direction, and several component units arranged side-by-side along a second horizontal direction form the battery string assembly. The second horizontal direction is perpendicular to the first horizontal direction. The busbar welding device includes a first busbar preparation mechanism, a second busbar preparation mechanism, a busbar transfer mechanism, a first busbar support mechanism, a second busbar support mechanism, a third busbar support mechanism, a welding gripper, and a welding mechanism, wherein: The first busbar preparation mechanism is configured to prepare a head straight busbar, an L-shaped bent busbar, and a U-shaped bent busbar, and the second busbar preparation mechanism is configured to prepare at least a tail straight busbar; The first busbar support mechanism, the second busbar support mechanism, and the third busbar support mechanism are arranged sequentially along a first horizontal direction. The first busbar support mechanism is configured to support a straight busbar at the head, the second busbar support mechanism is configured to support both an L-shaped bent busbar and a U-shaped bent busbar simultaneously, and the third busbar support mechanism is configured to support a straight busbar at the tail. The welding gripper is used to pick up each of the component units and transport each of the component units stepping along the second horizontal direction; The busbar transfer mechanism is used to pick up a straight busbar from the first busbar preparation mechanism and transfer the picked-up straight busbar to the first busbar support mechanism; the welding mechanism is used to weld the straight busbar supported on the first busbar support mechanism to the extended welding strip at the head of the component unit when the component unit to be welded to the straight busbar steps above the first busbar support mechanism; The busbar transfer mechanism is further configured to pick up an L-shaped bent busbar and / or a U-shaped bent busbar from the first busbar preparation mechanism, and transfer the picked-up L-shaped bent busbar and / or U-shaped bent busbar to the second busbar support mechanism; the welding mechanism is further configured to weld the L-shaped bent busbar and / or U-shaped bent busbar carried on the second busbar support mechanism to the extended welding strip in the middle of the component unit when the component unit to be welded with the L-shaped bent busbar and / or U-shaped bent busbar steps above the second busbar support mechanism; The busbar transfer mechanism is also used to pick up a straight busbar at the tail end from the second busbar preparation mechanism and transfer the picked-up straight busbar at the tail end to the third busbar carrying mechanism; the welding mechanism is also used to weld the straight busbar at the tail end carried on the third busbar carrying mechanism to the extended welding strip at the tail end of the component unit when the component unit to be welded to the component unit steps above the third busbar carrying mechanism.

2. The busbar welding device as described in claim 1, characterized in that, The first busbar preparation mechanism includes a first straight busbar preparation section and a first bent busbar preparation section, and the second busbar preparation mechanism includes at least a second straight busbar preparation section, wherein: The first straight busbar preparation section and the second straight busbar preparation section are respectively used to prepare the head straight busbar and the tail straight busbar, and the first bent busbar preparation section is used to prepare the L-shaped bent busbar and / or the U-shaped bent busbar.

3. The busbar welding device as described in claim 2, characterized in that, The busbar welding device further includes a fourth busbar support mechanism disposed between the second busbar support mechanism and the third busbar support mechanism; the second busbar preparation mechanism further includes a second bending busbar preparation section, which is used to prepare L-shaped bending busbars and U-shaped bending busbars; the busbar transfer mechanism is further used to pick up one L-shaped bending busbar and / or one U-shaped bending busbar from the second busbar preparation mechanism and transfer the picked-up L-shaped bending busbar and / or U-shaped bending busbar to the fourth busbar support mechanism; the welding mechanism is further used to weld the L-shaped bending busbar and / or U-shaped bending busbar carried on the fourth busbar support mechanism to the extended welding strip in the middle of the component unit when the component unit to be welded with the L-shaped bending busbar and / or U-shaped bending busbar steps above the fourth busbar support mechanism.

4. The busbar welding device as described in claim 2, characterized in that, The first bending busbar preparation unit includes a first traction assembly, a bending mechanism, and a first cutting mechanism, wherein: The first traction assembly is used to traction the busbar so that the busbar passes through the first cutting mechanism; the first cutting mechanism is used to cut the busbar to obtain a busbar to be bent, and the first traction assembly is also used to traction the busbar to be bent to a predetermined position of the bending mechanism. The busbar to be bent is one or two; the bending mechanism is used to bend one end of the busbar to be bent to obtain the L-shaped bent busbar, or / and the bending mechanism is used to bend both ends of the busbar to be bent to obtain the U-shaped bent busbar. The busbar transfer mechanism picks up the L-shaped bent busbar and / or the U-shaped bent busbar from the bending mechanism.

5. The busbar welding device as described in claim 4, characterized in that, The bending mechanism includes a first mounting base, and a first bending assembly, a second bending assembly, a third bending assembly, and a fourth bending assembly sequentially mounted on the first mounting base, wherein: The first bending assembly includes a first bending support platform and a first bending portion disposed on the outside of the first bending support platform. The first bending portion is used to bend the end of the busbar to be bent that is supported on the first bending support platform upward. The second bending assembly includes a second bending support platform, a third bending support platform, and a second bending portion, wherein: a first bending gap is maintained between the second bending support platform and the third bending support platform, and the second bending portion is configured to bend the end of the busbar to be bent that is supported on the second bending support platform and / or supported on the third bending support platform through the first bending gap; The third bending assembly includes a fourth bending support platform, a fifth bending support platform, and a third bending portion, wherein: a second bending gap is maintained between the fourth bending support platform and the fifth bending support platform, and the third bending portion is configured to bend the end of the busbar to be bent, which is supported on the fourth bending support platform and / or the fifth bending support platform, upward through the second bending gap; The fourth bending assembly includes a sixth bending support platform and a fourth bending portion disposed on the outside of the sixth bending support platform. The fourth bending portion is used to bend the end of the busbar to be bent that is supported on the sixth bending support platform upward.

6. The busbar welding device as described in claim 5, characterized in that, The first mounting base is provided with a first slide rail and a locking mechanism. The first bending component, the second bending component, the third bending component and the fourth bending component are slidably connected to the first slide rail. The locking mechanism is used to lock the first bending component, the second bending component, the third bending component and the fourth bending component onto the first slide rail.

7. The busbar welding device as described in claim 1, characterized in that, The second busbar support mechanism includes a first lifting drive mechanism, a second mounting base, a first support platform, a second support platform, and a third support platform, wherein: The second mounting base is connected to the drive end of the first lifting drive mechanism, which is used to drive the second mounting base to move up and down. The first support platform, the second support platform, and the third support platform are sequentially arranged on the second mounting base along the second horizontal direction, wherein the first support platform and the third support platform are configured to move toward or away from the second support platform.

8. The busbar welding device as described in claim 7, characterized in that: The first busbar support mechanism and the third busbar support mechanism have the same structure. The first busbar support mechanism includes a busbar support platform and a second lifting drive mechanism. The busbar support platform is connected to the drive end of the second lifting drive mechanism, which is used to drive the busbar support platform to move up and down. The second busbar support mechanism further includes a first translation drive mechanism. The first lifting drive mechanism is installed on the drive end of the first translation drive mechanism. The first translation drive mechanism is used to drive the second mounting base to translate along a first horizontal direction.

9. The busbar welding device as described in claim 1, characterized in that: The welding mechanism includes a first welding section, a second welding section, and a third welding section arranged sequentially along the first horizontal direction, wherein: The first welding part is located above the first busbar support mechanism and is used to weld the first straight busbar supported on the first busbar support mechanism to the extended welding strip at the head of the component unit; The second welding part is located above the second busbar support mechanism and is used to weld the L-shaped bent busbar and / or U-shaped bent busbar supported on the second busbar support mechanism to the extended welding strip in the middle of the component unit; The third welding section is located above the third busbar support mechanism and is used to weld the tail straight busbar supported on the third busbar support mechanism to the extended welding strip at the tail of the component unit.

10. The busbar welding device as described in claim 1, characterized in that, The busbar transfer mechanism includes a first busbar transfer section and a second busbar transfer section, wherein: The first busbar transfer unit is used to pick up the first straight busbar from the first busbar preparation mechanism and transfer the picked-up first straight busbar to the first busbar carrying mechanism; the first busbar transfer unit is also used to pick up L-shaped bent busbars and / or U-shaped bent busbars from the first busbar preparation mechanism and transfer the picked-up L-shaped bent busbars and / or U-shaped bent busbars to the second busbar carrying mechanism; The second busbar transfer unit is used to pick up the tail-end straight busbar from the second busbar preparation mechanism and transfer the picked-up tail-end straight busbar to the third busbar carrying mechanism.

11. A typesetting and overlay welding device, characterized in that, The layout and welding equipment includes a layout picking unit, a regularization conveying unit, and a busbar welding device as described in any one of claims 1 to 10, wherein: The typesetting pickup unit is located in front of the straightening conveyor unit, and the typesetting pickup unit places at least one of the component units on the straightening conveyor unit at predetermined intervals. The tidying and conveying unit is used to tidy up the component units placed by the layout picking unit, and to transport the tidyed component units to the picking station at predetermined intervals. The stacking gripper includes a string picking component arranged one-to-one with each of the component units in the battery string group; the stacking gripper moves along the second horizontal direction to drive the string picking component corresponding to the component unit at the string picking station to the string picking station to pick up the component unit. The welding gripper moves to move the picking assembly containing the component unit to the welding station. The welding mechanism is used to weld a head straight busbar and a tail straight busbar to the head and tail of the component unit located at the welding station, and to weld an L-shaped bent busbar and / or a U-shaped bent busbar to the middle of the component unit located at the welding station.

12. The typesetting and overlay welding equipment as described in claim 11, characterized in that, The layout and overlay welding equipment also includes a jumper wire preparation unit and a jumper wire conveying unit, wherein: The jumper conveyor is disposed on the side of the straightening conveyor and is configured to move synchronously with the straightening conveyor. The jumper wire preparation unit is used to produce jumpers and place them on the jumper wire conveying unit; when the straightening conveying unit conveys the component unit to the string picking station, the jumper wire conveying unit is used to synchronously convey the jumpers to the string picking station. The picking assembly synchronously picks up the component unit and the jumper wire from the picking station, and the welding mechanism is also used to perform welding on the jumper wire.

13. A method for lap welding, characterized in that, The lap welding method is used to weld busbars to n component units in a battery string group. The component unit includes two battery strings arranged side by side along a first horizontal direction, and several component units arranged side by side along a second horizontal direction form the battery string group. The second horizontal direction is perpendicular to the first horizontal direction. The busbar includes a front straight busbar, a rear straight busbar, an L-shaped bent busbar, and a U-shaped bent busbar. The L-shaped bent busbar and the U-shaped bent busbar are both middle busbars. The lap welding method includes: The component unit is conveyed by stepping along the second horizontal direction, with one or two component units moving forward each time; a welding station is provided on the stepping conveying path of the component unit, and the welding station can simultaneously accommodate one head straight busbar, one tail straight busbar, one L-shaped bent busbar and one U-shaped bent busbar. When a component unit with a head straight busbar and a tail straight busbar to be welded are both in the welding station, the head straight busbar and the tail straight busbar are welded at the same time. When a component unit consisting of an L-shaped bend busbar and a U-shaped bend busbar is simultaneously in the welding station, the L-shaped bend busbar and the U-shaped bend busbar are welded at the same time.

14. The lap welding method as described in claim 13, characterized in that, The lap welding method further includes: When the component unit of the i-th central busbar to be welded steps to the welding station, it is determined whether the next step will cause the component unit of the i-th central busbar to leave the welding station, where i <n; If the next step causes the component unit of the i-th central busbar to leave the welding station, then all central busbars located at the welding station will be welded before the next step. If the next step does not cause the component unit of the i-th central busbar to leave the welding station, then wait for the next step. When the component unit to be welded for the nth central busbar steps to the welding station, the nth central busbar is welded.

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