A process for the preparation of high conversion photovoltaic panels

Abstract

The application provides a preparation process of a high-conversion photovoltaic panel, and belongs to the technical field of photovoltaic panel preparation. The process solves the problem that the prior art does not have a process flow for small-scale trial processing of photovoltaic panels to trial-produce high-conversion photovoltaic panels. The preparation process of the high-conversion photovoltaic panel comprises the following steps: selecting a square metal back plate, an insulating plate and a photovoltaic cell plate, pasting the insulating plate on the metal back plate and pasting the photovoltaic cell plate on the insulating plate, and then pressing and fixing to form a photovoltaic panel base material, and then sequentially applying a polyvinyl butyral layer, a polyolefin layer, a polystyrene and polycarbonate polymer layer and an oxide layer on the surface of the photovoltaic panel base material. Compared with the prior art, the process adopted in the application is convenient to schedule, and the trial production can be more conveniently carried out during the processing process to obtain the trial production effect.

Description

Technical Field

[0001] This invention belongs to the field of photovoltaic panel manufacturing technology, and relates to a manufacturing process for a high-conversion-rate photovoltaic panel. Background Technology

[0002] A photovoltaic panel is a power generation device that generates direct current when exposed to sunlight. It consists of thin, solid photovoltaic cells made almost entirely of semiconductor materials (the most common material being silicon).

[0003] To increase the conversion efficiency of photovoltaic (PV) panels, either the total area of ​​PV panels installed must be increased, or the volume of the solar panels within the PV panel must be increased. Since solar PV panels need to be placed in locations with good sunlight to fully absorb heat, residential solar PV panels are generally installed on the roof of houses. However, due to the limited load-bearing capacity of buildings and the limited area available for installation, the overall mass of the PV panels can only be controlled within a certain range.

[0004] To increase the conversion efficiency of photovoltaic panels, the easiest way is to increase the thickness of the panels. However, increasing the thickness of the panels means that the thickness of other encapsulation layers must be reduced accordingly. Secondly, for photovoltaic panel manufacturing, current production lines are relatively fixed and not suitable for small-batch experimental production. Therefore, in scheduling the conversion efficiency of photovoltaic panels, it is necessary to conduct trial production using different material thicknesses and types. Fixed production lines are not suitable for small-scale experimental processing. Summary of the Invention

[0005] The purpose of this invention is to address the problem that existing technologies lack a process flow for small-scale experimental processing of photovoltaic panels to produce high-conversion-capacity photovoltaic panels, and to propose a manufacturing process for high-conversion-capacity photovoltaic panels.

[0006] The objective of this invention can be achieved through the following technical solutions:

[0007] A manufacturing process for a high-conversion-capacity photovoltaic panel, characterized by comprising the following steps:

[0008] Step 1: Select a square metal backplate, an insulating plate, and a photovoltaic panel. Attach the insulating plate to the metal backplate and the photovoltaic panel to the insulating plate. Press them together to form the photovoltaic panel substrate.

[0009] The thickness of the metal backing plate is 0.5–1 mm, and the thickness of the insulating plate is 0.02–0.08 mm.

[0010] Step 2: Install the photovoltaic panel substrate on the tooling fixture, and apply the following layers to the surface of the photovoltaic panel substrate in sequence: polyvinyl butyral coating equipment, polyolefin coating equipment, polystyrene and polycarbonate polymer coating equipment, and oxide coating equipment.

[0011] The oxides in the oxide layer are zirconium dioxide, zinc oxide, and titanium dioxide.

[0012] Step 3: Transfer the photovoltaic panel substrate into the heating equipment, and after curing, obtain the finished photovoltaic panel;

[0013] Step 4: The photovoltaic panel products are sequentially tested for flatness, thickness, and impact strength using flatness testing equipment, thickness testing equipment, impact strength testing equipment, code printing equipment, and packaging equipment. This process yields qualified photovoltaic panels that have passed inspection and are fully packaged.

[0014] Both the flatness detection equipment and the thickness detection equipment use laser displacement sensors.

[0015] In the above-mentioned manufacturing process of a high-conversion-rate photovoltaic panel, the metal backsheet is an aluminum plate or a titanium-zinc plate.

[0016] In the above-mentioned high-conversion photovoltaic panel manufacturing process, the insulating board is rigid polyvinyl chloride or polyethylene terephthalate.

[0017] In the aforementioned high-conversion-capacity photovoltaic panel manufacturing process, the equipment for coating polyvinyl butyral, coating polyolefin, coating polystyrene and polycarbonate polymers, coating oxide, heating equipment, flatness testing equipment, thickness testing equipment, impact strength testing equipment, coding equipment, and packaging equipment are arranged in a circular pattern on a turntable. Multiple equipment mounting positions are evenly distributed around the circumference of the turntable. One side of the turntable is a reference station, where tooling fixtures are set. A main shaft is located at the center of the turntable, and a shifting drive element is fixedly mounted beside the main shaft. A shaft gear is fixedly mounted on the main shaft, and a shifting wheel is fixedly mounted on the output shaft of the shifting drive element. The shifting wheel engages with the shaft gear. The outer ring of the shifting wheel has only partially continuous shifting teeth, which are identical to the teeth of the shaft gear. Each rotation of the shifting wheel only drives the shaft gear to rotate when the shifting teeth mesh with it. Each rotation of the shifting wheel corresponds to the angle measured by the rotation of the main shaft and the shaft gear.

[0018] In the aforementioned high-conversion-rate photovoltaic panel manufacturing process, the tooling fixture includes a support body, a tilting arm that can be flipped and mounted on the box body, a clamping mechanism mounted on the tilting arm for holding the photovoltaic panel substrate, a horizontal platform fixedly mounted on the support body, and a pitch drive structure mounted on the support body for driving the tilting arm to flip. The pitch drive structure can sequentially complete the connecting motion of driving the tilting arm to tilt up and flip, driving the tilting arm to tilt down and flip, and stopping the driving motion of the tilting arm in one cycle. When the driving motion of the tilting arm tilting up and flipping ends, the tilting arm is in a fully tilted state. When the driving motion of the tilting arm tilting down and flipping ends, the tilting arm is in a fully tilted state. The tilting arm has a positioning plane. When the tilting arm is in a fully tilted state, the positioning plane is attached to the horizontal platform so that the photovoltaic panel substrate clamped on the tilting arm is in a completely horizontal state.

[0019] In the aforementioned manufacturing process of a high-conversion-rate photovoltaic panel, the pitch drive structure includes a rotary drive element fixedly mounted on a support, a first shaft connected to the output shaft of the rotary drive element, and a second, third, fourth, and fifth shaft respectively rotatably mounted on the support. The fifth shaft is horizontally and fixedly connected to the bottom of the tilting arm. A first pinion and a pitching drive wheel are fixedly mounted on the first shaft. A second pinion is fixedly mounted on the second shaft. A third pinion and a first large gear are fixedly mounted on the third shaft. A tilting drive wheel and a second large gear are fixedly mounted on the fourth shaft. Pitching gears and tilting gears are fixedly mounted at both ends of the fifth shaft, respectively. The outer rings of the pitching drive wheel and the tilting drive wheel... It has only partially continuous outer ring teeth, which are the same as the teeth of the pinion and gear. The first pinion meshes with the second pinion, the second pinion meshes with the third pinion, and the first gear meshes with the second gear. When the outer rings of the lifting drive wheel and the lifting gear are in contact and mesh with the outer ring teeth of the lifting drive wheel, the lifting drive function is realized. When the outer rings of the lying drive wheel and the lying gear are in contact and mesh with the outer ring teeth of the lying drive wheel, the lying drive function is realized. After the lifting drive function ends, the lying drive function begins. The total number of teeth of the lifting drive wheel and the lying drive wheel is less than the number of teeth of the pinion, so that after the lying drive function ends, the lifting drive wheel and the lying drive wheel continue to rotate for a period of time without driving the operation of the lying arm.

[0020] Compared with existing technologies, this preparation process can use thicker photovoltaic panels and reduce the thickness of other layers to a certain extent to obtain photovoltaic panels with higher conversion rates. Furthermore, the process is easy to schedule and allows for more convenient trial production to obtain experimental results. Attached Figure Description

[0021] Figure 1This is a simplified structural diagram of the turntable and tooling fixtures from an overhead view (the clamping mechanism and processing equipment are hidden).

[0022] Figure 2 This is a simplified structural diagram of the turntable and tooling fixtures from a bottom view (the clamping mechanism and processing equipment are hidden).

[0023] Figure 3 This is a simplified schematic diagram of the tooling fixture in a fully horizontal position (the clamping mechanism is hidden);

[0024] Figure 4 This is a simplified schematic diagram of the tooling fixture in its fully tilted-up position (the clamping mechanism is hidden);

[0025] Figure 5 This is a schematic diagram of the pitch drive structure when the supine arm is in a fully reclined state and about to enter the lifting stage (the support body is hidden).

[0026] Figure 6 This is a schematic diagram of the pitch drive structure during the gradual lifting process of the supine arm (the support structure is hidden);

[0027] Figure 7 This is a schematic diagram of the pitch drive structure when the supine arm has just left the lifting process and is about to enter the lying stage and is in a fully lifted state (the support body is hidden).

[0028] Figure 8 This is a schematic diagram of the pitch-up drive structure during the gradual lying down process of the supine arm (the support structure is hidden);

[0029] Figure 9 This is a schematic diagram of the pitch drive structure when the supine arm has just left the lying position and is in a fully lying position (the support body is hidden).

[0030] Figure 10 This is a schematic diagram of the pitch drive structure with the supine arm in a fully reclined state and the pitch drive wheel and recline drive wheel spinning idly without providing any driving effect to the supine arm (the support body is hidden).

[0031] In the diagram, 1. Support body; 2. Recumbent arm; 3. Horizontal platform; 4. Rotary drive element; 5. First shaft; 6. Second shaft; 7. Third shaft; 8. Fourth shaft; 9. Fifth shaft; 10. First pinion; 11. Second pinion; 12. Third pinion; 13. First large gear; 14. Second large gear; 15. Lifting gear; 16. Reclining gear; 17. Lifting drive wheel; 18. Reclining drive wheel; 19. Outer ring gear; 20. Notch; 21. Turntable; 22. Main shaft; 23. Positioning drive element; 24. Shaft gear; 25. Positioning wheel; 26. Positioning gear; 27. Equipment placement position. Detailed Implementation

[0032] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings. However, the present invention is not limited to these embodiments.

[0033] A manufacturing process for a high-conversion-capacity photovoltaic panel, characterized by comprising the following steps:

[0034] Step 1: Select a square metal backplate, an insulating plate, and a photovoltaic panel. Attach the insulating plate to the metal backplate and the photovoltaic panel to the insulating plate. Press them together to form the photovoltaic panel substrate.

[0035] The thickness of the metal backing plate is 0.5-1mm, the thickness of the insulation plate is 0.02-0.08mm, the metal backing plate is aluminum plate or titanium zinc plate, and the insulation plate is rigid polyvinyl chloride or polyethylene terephthalate.

[0036] Step 2: Install the photovoltaic panel substrate on the tooling fixture, and apply the following layers to the surface of the photovoltaic panel substrate in sequence: polyvinyl butyral coating equipment, polyolefin coating equipment, polystyrene and polycarbonate polymer coating equipment, and oxide coating equipment.

[0037] The oxides in the oxide layer are zirconium dioxide, zinc oxide, and titanium dioxide.

[0038] Step 3: Transfer the photovoltaic panel substrate into the heating equipment, and after curing, obtain the finished photovoltaic panel;

[0039] Step 4: The photovoltaic panel products are sequentially tested for flatness, thickness, and impact strength using flatness testing equipment, thickness testing equipment, impact strength testing equipment, code printing equipment, and packaging equipment. This process yields qualified photovoltaic panels that have passed inspection and are fully packaged.

[0040] Both the flatness detection equipment and the thickness detection equipment use laser displacement sensors.

[0041] This processing technology allows for the use of thicker photovoltaic panels while maintaining appropriate strength, thereby increasing the conversion efficiency. The resulting photovoltaic panels also undergo multiple testing processes to ensure their performance in all aspects.

[0042] Many processes for photovoltaic panels require the use of various processing equipment. From an industrial processing perspective, the processing linkage between the workpiece and the equipment generally falls into two categories: The first is where the equipment remains stationary while the workpiece moves. This involves using a complete assembly line, where each piece of equipment on the line completes one process. After the workpiece finishes processing at one stage, it moves to the next stage. This method requires tooling clamping and positioning each time the workpiece enters a new stage, resulting in a longer process but is well-suited for mass production. The second is where the equipment moves while the workpiece remains stationary. The workpiece is horizontally clamped at a reference position, and multiple pieces of equipment performing specific processes are mounted on a turntable. As the turntable rotates, each piece of equipment passes this reference position to complete its function. In this method, the workpiece only needs to be clamped once, resulting in a shorter process and making it more suitable for small-batch production.

[0043] In this process, in order to improve the conversion efficiency of photovoltaic panels, multiple experiments are required to determine what materials, thicknesses, and order are needed to obtain the optimal conversion efficiency per unit area of ​​photovoltaic panels. Therefore, in most cases, only small-batch production is required, and the equipment used in this process is of the second type.

[0044] Therefore, the present invention specifically developed a turntable capable of assembling the above-mentioned types of equipment.

[0045] like Figure 1 and Figure 2 As shown, equipment for coating polyvinyl butyral, coating polyolefins, coating polystyrene and polycarbonate polymers, coating oxides, heating equipment, flatness testing equipment, thickness testing equipment, impact strength testing equipment, coding equipment, and packaging equipment are arranged in a circular pattern on a turntable 21. Multiple equipment mounting positions 27 are evenly distributed around the circumference of the turntable 21. One side of the turntable 21 is a reference station, where tooling fixtures are set. A main shaft 22 is located at the center of the turntable 21, and a shifting drive element 23 is fixedly installed beside the main shaft 22. Using a motor and a gearbox, a shaft gear 24 is fixedly sleeved on the main shaft 22, and a shift wheel 25 is fixedly sleeved on the output shaft of the shift drive element 23. The shift wheel 25 is connected to the shaft gear 24. The outer ring of the shift wheel 25 only has a portion of continuous shift teeth 26. The shift teeth 26 are the same as the teeth of the shaft gear 24. The shift wheel 25 will drive the shaft gear 24 to rotate only when the shift teeth 26 mesh with the shaft gear 24. The main shaft 22 rotates an angle measured by the shaft gear 24 with each rotation of the shift wheel 25.

[0046] Because the performance of qualified photovoltaic panels produced by the process of this invention needs to be tested in practice, the specific performance of the photovoltaic panels can only be obtained by actual testing after using different materials, thicknesses, and layers of metal backplates, insulating boards, photovoltaic panels, and various polymer layers and oxide layers. Therefore, the order of various equipment used in this invention, the quantity of processing per batch, and the coating materials can be freely matched. Thus, multiple equipment placement positions 27 are set on the turntable 21 to accommodate the installation of various equipment.

[0047] Since each piece of equipment needs to stop for a period of time to complete its processing after moving to the reference station, the shifting drive element 23 used to drive the turntable 21 generally requires a CNC motor. However, since the equipment is evenly distributed on the turntable 21, meaning that the turntable 21 rotates at the same angle each time it switches stations, the turntable 21 of this invention uses a shifting wheel 25 with only some shifting teeth 26 to drive the shaft gear 24 to rotate in terms of rotation drive function. This drive form has two advantages.

[0048] First, it can achieve intermittent motion without using a CNC motor, because the turntable 21 is designed to stop and start. Stopping is for the equipment to complete processing, and starting is for the equipment to switch workstations. Therefore, this structure can directly achieve this purpose.

[0049] Secondly, when using a mouse motor, the process of switching stations on the turntable 21 requires high precision to ensure that the processing equipment is aligned with the reference station. If two full gears are used, and the rotation output of the shift drive element 23 is slightly off, the processing equipment will inevitably fail to align completely with the reference station after switching stations. However, if this periodic quantitative method is used, the turntable 21 will rotate by the unit measurement angle for each rotation output of the shift drive element 23, which is more suitable for quantitative measurement. Moreover, even if the rotation output of the shift drive element 23 is slightly off, because there is a gap between the shift wheel 25 and the shaft gear 24, the shift wheel 25 will not be affected by the drive because it will be in the gap state. This further eliminates the problem of inaccurate positioning caused by output deviation.

[0050] Then, after research and experimentation by the applicant, it was found that the second method of processing has certain difficulties. This is mainly because most processing techniques for photovoltaic panels require processing on both the top and bottom surfaces. This raises another problem: how to simultaneously complete specific processes on both sides of the photovoltaic panel. In this case, either equipment capable of processing the photovoltaic panel surface simultaneously from top to bottom is used, or an additional flipping process is added to the photovoltaic panel. However, regardless of the solution, the photovoltaic panel cannot remain horizontally fixed in the reference position. A retraction process is required to briefly remove the photovoltaic panel from the reference position. During this brief period, either the photovoltaic panel is flipped to prepare for processing on the other side before being returned to the reference position, or equipment capable of processing from top to bottom simultaneously is used, and another piece of equipment is rotated to the reference position before returning the photovoltaic panel to the reference position.

[0051] Because photovoltaic panels need to be placed horizontally at a reference position during processing, there must be a supporting flat platform underneath them. If they slide backward directly, the photovoltaic panels will slide and scrape against the flat platform. Therefore, the fixture should preferably flip and lift the photovoltaic panels rather than retracting them horizontally.

[0052] The tooling fixtures here are not available for direct purchase on the market, so the applicant specially developed and designed the tooling fixtures.

[0053] like Figure 3 and Figure 4 As shown, the tooling fixture includes a support body 1, a tilting arm 2 that can be flipped and mounted on the box body, a clamping mechanism mounted on the tilting arm 2 for clamping photovoltaic panel substrates, a horizontal platform 3 fixedly mounted on the support body 1, and a pitch drive structure mounted on the support body 1 for driving the tilting arm 2 to flip.

[0054] The conventional way to implement the clamping mechanism is to use a robotic arm to clamp the plate-shaped photovoltaic panel substrate, or to use a specific design, such as forming a specific shape on the photovoltaic panel substrate and then using a corresponding clamp of a specific shape to clamp the photovoltaic panel substrate. The forms of implementation are diverse and can be easily implemented using existing conventional clamps on the market. However, since the clamping mechanism is not the research direction and protection element of this invention, this invention will not discuss it further.

[0055] The pitch drive structure can sequentially complete the following actions in one cycle: drive the supine arm 2 to pitch up and flip, drive the supine arm 2 to lie down and flip, and stop driving the supine arm 2. When the driving action of the supine arm 2 pitching up and flipping ends, the supine arm 2 is in a fully pitched state. When the driving action of the supine arm 2 lying down and flipping ends, the supine arm 2 is in a fully lying state. The supine arm 2 has a positioning plane. When the supine arm 2 is in a fully lying state, the positioning plane is attached to the horizontal platform 3 so that the photovoltaic panel substrate held on the supine arm 2 is in a completely horizontal state.

[0056] The periodic lifting and lowering of the supine arm 2 is for repositioning. However, the photovoltaic panel substrate is different from other processing methods. It needs to be placed horizontally and processed on its flat surface. Therefore, in many processes, the photovoltaic panel substrate needs to be placed on a flat platform. If it is directly pulled back to reposition, the surface of the photovoltaic panel may scrape against the flat platform and cause some damage. Therefore, this invention sets it to a flipping form. This design is more suitable for the interlaced flipping process. If the flipping process is completed by a separate flipping device, the best placement of the flipping device from the perspective of the overall spatial layout of the mechanical equipment is directly above the supine arm 2.

[0057] During a cycle, after the supine arm 2 completes the lifting and lowering functions, it needs to remain in a lying position for a certain period of time. This continuous lying position is to allow each processing device to complete its required processing within this time. With the maturity of modern industrial technology, machines can complete each process very quickly. For example, in the process of checking flatness, a large area of ​​photovoltaic panel substrate surface can be checked in a very short time using a vision sensor. Therefore, in the actual design process, the reserved time for continuous lying position does not need to be very long.

[0058] Since the above functions need to be completed automatically, the pitch drive structure requires special development and design.

[0059] like Figures 5-10 As shown, the pitch drive structure includes a rotary drive element 4 (generally a motor and a gearbox) fixedly mounted on the support body 1, a first shaft 5 connected to the output shaft of the rotary drive element 4, and a second shaft 6, a third shaft 7, a fourth shaft 8, and a fifth shaft 9 respectively rotatably mounted on the support body 1. The fifth shaft 9 is horizontally and fixedly connected to the bottom of the supine arm 2.

[0060] The first shaft 5 is fixedly fitted with a first small gear 10 and a tilting drive wheel 17; the second shaft 6 is fixedly fitted with a second small gear 11; the third shaft 7 is fixedly fitted with a third small gear 12 and a first large gear 13; the fourth shaft 8 is fixedly fitted with a horizontal drive wheel 18 and a second large gear 14; and the two ends of the fifth shaft 9 are respectively fixedly fitted with a tilting gear 15 and a horizontal gear 16.

[0061] The first pinion 10, the second pinion 11, the third pinion 12, the rising gear 15, and the falling gear 16 are all the same type of pinion with the same parameters. The first large gear 13 and the second large gear 14 are all the same type of large gear with the same parameters. The pitch circle diameter of the rising drive wheel 17 and the falling drive wheel 18 is the same as that of the pinion. The number of teeth of the large gear is twice the number of teeth of the pinion, and the remaining parameters of the large gear and the pinion are the same. The outer ring of the rising drive wheel 17 and the falling drive wheel 18 only has a partially continuous outer ring tooth 19, and the outer ring tooth 19 is the same as the tooth of the pinion and the large gear.

[0062] The first pinion 10 meshes with the second pinion 11, the second pinion 11 meshes with the third pinion 12, and the first large gear 13 meshes with the second large gear 14;

[0063] When the outer rings of the lifting drive wheel 17 and the lifting gear 15 are attached together and the outer ring teeth 19 of the lifting drive wheel 17 mesh with the lifting gear 15, the lifting drive function is realized. When the outer rings of the lying drive wheel 18 and the lying gear 16 are attached together and the outer ring teeth 19 of the lying drive wheel 18 mesh with the lying gear 16, the lying drive function is realized.

[0064] After the lifting drive function ends, the lying drive function begins. The total number of teeth on the lifting drive wheel 17 and the lying drive wheel 18 is less than the number of teeth on the pinion. This means that after the lying drive function ends, the lifting drive wheel 17 and the lying drive wheel 18 will continue to rotate for a period of time without driving the operation of the supine arm 2.

[0065] from Figures 5 to 10 This refers to the motion process of the pitch drive structure within one cycle. During this process, the rotation output direction of the rotary drive element 4 is clockwise, and the first shaft 5 rotates clockwise. Then, the first pinion 10 and the pitch drive wheel 17 will rotate clockwise along with the first shaft 5. The pitch drive wheel 17 is directly connected to the pitch gear 15. The purpose of the pitch drive wheel 17 is to drive the pitch gear 15 to rotate clockwise to drive the pitch function of the supine arm 2. Since the pitch gear 15 needs to be driven clockwise to achieve the pitch of the supine arm 2, it can be known by reverse reasoning that the lying process of the supine arm 2 requires the lying gear 16 to be driven counterclockwise. Therefore, this invention uses multiple gears to achieve this purpose.

[0066] As shown in the diagram, when the first pinion 10 rotates clockwise, the second pinion 11 meshing with the first pinion 10 will rotate counterclockwise, and the third pinion 12 meshing with the second pinion 11 will rotate clockwise. The first large gear 13, which is located on the third shaft 7 and is the same as the third pinion 12, will rotate clockwise accordingly. The second large gear 14 meshing with the first large gear 13 will rotate counterclockwise, ultimately causing the horizontal drive wheel 18, which is located on the fourth shaft 8 and is the same as the second large gear 14, to rotate counterclockwise. This achieves the design objective of the upward drive wheel 17 rotating clockwise and the horizontal drive wheel 18 rotating counterclockwise.

[0067] Then, using mechanical calculation formulas, we know that the pitch circle diameter of a gear is the product of the module and the number of teeth. Since the large gear has the same parameters as the small gear except that its number of teeth is twice that of the small gear, the pitch circle diameter of the large gear will be twice that of the small gear. Therefore, assuming the radius of the small gear is r, the radius of the large gear is 2r. Because the first small gear 10, the second small gear 11, and the third small gear 12 are the same type of small gear, the rotational speed of the third shaft 7 is actually the rotational speed output by the rotary drive element 4. Assuming the rotational speed output by the rotary drive element 4 is w, which is the rotational speed of the third small gear 12, then the rotational speed of the first large gear 13, which is coaxial with the third small gear 12, is w. According to the calculation formulas for angular velocity and linear velocity, we can obtain... Given that the linear velocity of the first large gear 13 is v(first) = 2wr, and the linear velocity of the second large gear 14 directly connected to the first large gear 13 is v(second) = 2wr, and the rotational speed of the second large gear 14 is w(second) = v(second) / 2r = w, then the rotational speed of the horizontal drive wheel 18, which is coaxial with the second large gear 14, is also w. The rotational speed of the first shaft 5 is itself w, which means the rotational speed of the vertical drive wheel 17 is w. Based on this design premise, it can be known that the horizontal drive wheel 18 and the vertical drive wheel 17 have the same rotational speed except that they turn in opposite directions. This perfectly controls the consistency of the total duration of the vertical and horizontal processes, making the specifications of the parts used in the pitch drive structure as similar as possible, saving design costs, reducing assembly difficulty, and improving uniformity.

[0068] After realizing the function of the lying down drive wheel 18 and the lifting drive wheel 17 rotating in opposite directions at the same speed, the lifting and lying down processes of the supine arm 2 can be realized.

[0069] In the diagram, the lying-down drive wheel 18 on the left rotates counterclockwise, while the lifting drive wheel 17 on the right rotates clockwise. Figure 5 The outer ring tooth 19 of the lower lifting drive wheel 17 is about to mesh with the lifting gear 15, and after meshing, it will enter the... Figure 6 In this state, the outer ring tooth 19 of the lifting drive wheel 17 drives the lifting gear 15 to rotate counterclockwise, gradually rotating and lifting the supine arm 2 until... Figure 7When the supine arm 2 is in a fully extended position, the outer ring tooth 19 of the extension drive wheel 17 has disengaged from the extension gear 15, while the outer ring tooth 19 of the folding drive wheel 18 is about to engage with the folding gear 16, and then proceeds into... Figure 8 In this state, the outer ring tooth 19 of the lying-down drive wheel 18 drives the lying-down gear 16 to rotate clockwise, gradually rotating the supine arm 2 to lie down, until... Figure 9 When the supine arm 2 is in a fully reclined position, the outer ring tooth 19 of the reclining drive wheel 18 has disengaged from the reclining gear 16, and the reclining drive wheel 18 is in an idling state. However, because the lifting drive wheel 17 has not rotated back one revolution, it is also in an idling state. This situation, where both the reclining drive wheel 18 and the lifting drive wheel 17 are in an idling state, will continue for a period of time. Figure 10 The image shows this period of time. During this process, the supine arm 2 remains in a completely horizontal position, awaiting processing of the photovoltaic panel substrate on the supine arm 2, until the idling drive wheel 17 finishes spinning and returns to its original position. Figure 5 This state completes one exercise cycle.

[0070] Each motion cycle corresponds to the working time and matching station time of one processing equipment. Photovoltaic panel substrates require multiple processing steps by multiple processing equipment, which means multiple operation cycles are required.

[0071] For ease of implementation, the first axis 5, the second axis 6, the third axis 7, the fourth axis 8, and the fifth axis 9 are all in the same plane, and they are preferably all set in a vertical plane.

[0072] The ideal state is a fully tilted-up position, which is a vertical position, meaning that each rotation is 90 degrees. This is more favorable for the design requirements of each gear and the flipping device, and makes it easier to calculate and plan.

[0073] The support body 1 is a box with an inner cavity. The pitch drive structure is set inside the box. A notch 20 is opened on the box. The flipping movement of the supine arm 2 is located at the notch 20. The horizontal platform 3 is fixedly set outside the notch 20. Since the important components of the pitch drive structure are gears, using a box to house the entire pitch drive structure can avoid the gears being exposed. Only the supine arm 2 needs to be exposed through the notch 20.

[0074] The clamping mechanism is rotatable relative to the supine arm 2 to complete the flipping process of the photovoltaic panel substrate.

[0075] It should be understood that in the claims and description of this invention, all instances of "comprising..." should be understood as having an open meaning, that is, their meaning is equivalent to "containing at least...", and should not be understood as having a closed meaning, that is, their meaning should not be understood as "containing only...".

[0076] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

Claims

1. A manufacturing process for a high-conversion-capacity photovoltaic panel, characterized in that, Includes the following steps: Step 1: Select a square metal backplate, an insulating plate, and a photovoltaic panel. Attach the insulating plate to the metal backplate and the photovoltaic panel to the insulating plate. Press them together to form the photovoltaic panel substrate. The thickness of the metal backing plate is 0.5–1 mm, and the thickness of the insulating plate is 0.02–0.08 mm. Step 2: Install the photovoltaic panel substrate on the tooling fixture, and apply the following layers to the surface of the photovoltaic panel substrate in sequence: polyvinyl butyral coating equipment, polyolefin coating equipment, polystyrene and polycarbonate polymer coating equipment, and oxide coating equipment. The oxides in the oxide layer are zirconium dioxide, zinc oxide, and titanium dioxide. Step 3: Transfer the photovoltaic panel substrate into the heating equipment, and after curing, obtain the finished photovoltaic panel; Step 4: The photovoltaic panel products are sequentially tested for flatness, thickness, and impact strength using flatness testing equipment, thickness testing equipment, impact strength testing equipment, code printing equipment, and packaging equipment. This process yields qualified photovoltaic panels that have passed inspection and are fully packaged. Both the flatness detection equipment and the thickness detection equipment use laser displacement sensors.

2. The manufacturing process of a high-conversion-capacity photovoltaic panel according to claim 1, characterized in that: The metal back plate is an aluminum plate or a titanium-zinc plate.

3. The manufacturing process of a high-conversion-capacity photovoltaic panel according to claim 1, characterized in that: The insulating board is made of rigid polyvinyl chloride or polyethylene terephthalate.

4. The manufacturing process of a high-conversion-capacity photovoltaic panel according to claim 1, characterized in that: The equipment for coating polyvinyl butyral, coating polyolefin, coating polystyrene and polycarbonate polymers, coating oxide, heating equipment, flatness testing equipment, thickness testing equipment, impact strength testing equipment, coding equipment, and packaging equipment are arranged in a circular pattern on a turntable (21). Multiple equipment mounting positions (27) are evenly distributed around the circumference of the turntable (21). One side of the turntable (21) is a reference station, where tooling fixtures are installed. A main shaft (22) is located at the center of the turntable (21), and a shifting drive element (23) is fixedly installed beside the main shaft (22). 2) A shaft gear (24) is fixedly sleeved on the upper part, and a shift wheel (25) is fixedly sleeved on the output shaft of the shift drive element (23). The shift wheel (25) is connected to the shaft gear (24). The outer ring of the shift wheel (25) only has a portion of continuous shift teeth (26). The shift teeth (26) are the same as the teeth of the shaft gear (24). The shift wheel (25) will only drive the shaft gear (24) to rotate when the shift teeth (26) mesh with the shaft gear (24) for each rotation. The main shaft (22) rotates with the shaft gear (24) for each rotation of the shift wheel (25) at an angle measured by the unit.

5. The manufacturing process of a high-conversion-capacity photovoltaic panel according to any one of claims 1 to 4, characterized in that: The fixture includes a support body (1), a tilting arm (2) that can be flipped on the box, a clamping mechanism on the tilting arm (2) for clamping the photovoltaic substrate, a horizontal platform (3) fixed on the support body (1), and a pitch drive structure on the support body (1) for driving the tilting arm (2) to flip. The pitch drive structure can sequentially complete the connecting movements of driving the tilting arm (2) to tilt up and flip, driving the tilting arm (2) to tilt down and flip, and stopping the driving of the tilting arm (2) in one cycle. When the driving movement of the tilting arm (2) tilting up and flipping ends, the tilting arm (2) is in a fully tilted state. When the driving movement of the tilting arm (2) tilting down and flipping ends, the tilting arm (2) is in a fully tilted state. The tilting arm (2) has a positioning plane. When the tilting arm (2) is in a fully tilted state, the positioning plane is attached to the horizontal platform (3) so that the photovoltaic substrate clamped on the tilting arm (2) is in a completely horizontal state.

6. The manufacturing process of a high-conversion-capacity photovoltaic panel according to claim 5, characterized in that: The pitch drive structure includes a rotary drive element (4) fixedly mounted on the support, a first shaft (5) connected to the output shaft of the rotary drive element (4), and a second shaft (6), a third shaft (7), a fourth shaft (8), and a fifth shaft (9) respectively rotatably mounted on the support (1). The fifth shaft (9) is horizontally and fixedly connected to the bottom of the supine arm (2). A first pinion (10) and a pitch drive wheel (17) are fixedly mounted on the first shaft (5). A second pinion (11) is fixedly mounted on the second shaft (6). A third pinion (12) and a first large gear (13) are fixedly mounted on the third shaft (7). A reclining drive wheel (18) and a second large gear (14) are fixedly mounted on the fourth shaft (8). Pitch gear (15) and reclining gear (16) are fixedly mounted at both ends of the fifth shaft (9). The outer rings of the pitch drive wheel (17) and the reclining drive wheel (18) only have partially continuous outer ring teeth. (19), the outer ring teeth (19) are the same as the teeth of the pinion and the gear. The first pinion (10) meshes with the second pinion (11), the second pinion (11) meshes with the third pinion (12), the first gear (13) meshes with the second gear (14), the outer rings of the lifting drive wheel (17) and the lifting gear (15) are attached and combined. When the outer ring teeth (19) of the lifting drive wheel (17) mesh with the lifting gear (15), the lifting drive function is realized. The horizontal drive wheel ( 18) When the outer ring of the retractable gear (16) is in contact with the outer ring tooth (19) of the retractable drive wheel (18) and meshes with the retractable gear (16), the retractable drive function is realized. After the lifting drive function ends, the retractable drive function is entered. The total number of teeth of the lifting drive wheel (17) and the retractable drive wheel (18) is less than the number of teeth of the pinion, so that after the retractable drive function ends, the lifting drive wheel (17) and the retractable drive wheel (18) continue to rotate for a period of time without driving the operation of the retractable arm (2).

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