A visual inspection method for solar module stacking

Abstract

This invention relates to the field of solar module inspection technology, specifically to a visual inspection method for solar modules after shingled welding, comprising the following steps: S1, acquiring the entire image; S2, cropping the weld point image; S3, stitching together to form an inspection image; A1, identifying the grid lines; A2, performing position correction and template matching coordinates on the image based on the grid lines, and cropping smaller images; A3, identifying edge positions; A4, performing position correction based on the edge positions of the solar cells, and cropping the grid line portion of the image; A5, performing position correction. This invention stitches together the images after finding the position of each grid line in the image, because the grid line position corresponds to the weld point position. Furthermore, it first finds the busbars by using the relative positions of the solar cell edges, thereby finding the specific location of the weld point. By processing the HSL three channels of the weld point area image, the weld scars are separated for further analysis to obtain the welding effect result, effectively preventing false detections and missed detections.

Description

Technical Field

[0001] This invention relates to the field of solar module inspection technology, and specifically to a visual inspection method for solar modules after stacking. Background Technology

[0002] In the post-stacking process of photovoltaic module production, where equipment welds the solder strips and busbars between cell strings, numerous welding problems such as open welds, incomplete welds, shrinkage, and misaligned welds are prone to occur. Additionally, defects such as creepage defects, excessively long or short solder strips, and missing busbars can arise due to equipment malfunction. Currently, most of these defects are detected manually by visual inspection, which leads to a large number of missed and false positives. Furthermore, because a single module has many welding points, and the weld joints are small, the welding characteristics vary depending on factors such as materials, welding temperature, and welding time, resulting in a variety of different welding defects. This leads to numerous false positives and missed positives when using conventional visual inspection equipment. Summary of the Invention

[0003] The purpose of this invention is to address the aforementioned shortcomings in the prior art by providing a visual inspection method for solar module stacking.

[0004] The objective of this invention is achieved through the following technical solution: a visual inspection method for solar module stacking after lamination, comprising the following steps:

[0005] S1. Acquire a complete image of the solar cell;

[0006] S2. Cut out the solder joint images of the solar cell's solder strips and busbars;

[0007] S3. Combine all the solder joint images into a single inspection image;

[0008] It also includes the following steps:

[0009] A1. Identify the grid lines of the solar cell based on the detected image;

[0010] A2. Correct the position of the image and match the template coordinates according to the grid lines. Crop the image into smaller images according to the grid lines and solder joints at the coordinates of the detected image.

[0011] A3. Identify the edge location of the solar cell;

[0012] A4. Based on the edge position of the solar cell, perform position correction, perform spot analysis to find the position of the busbar and its upper and lower edge coordinates, and crop the grid line part of the image;

[0013] A5. After locating the grid lines and the edges of the solar cells in the image obtained in step A4, position correction is performed.

[0014] The present invention is further configured to include the following steps:

[0015] A6. Perform feature segmentation on the image obtained in step A5 to separate the weld scar image;

[0016] A7. Perform spot analysis and multi-template matching based on weld scar images;

[0017] A8. Solder joint positioning is obtained by measuring the position of the busbar and the position of the grid line;

[0018] A9. Inspect the solder joints;

[0019] A10. Determine the length of the busbar by analyzing the portion that exceeds the busbar length.

[0020] The present invention is further configured such that, in step S1, a full image of the solar cell is acquired by a visual inspection device after the solar module is stacked;

[0021] The visual inspection device for solar module stacking includes a gantry frame, a triggering mechanism, and an encoding mechanism; the gantry frame is provided with a first crossbeam and a second crossbeam; the second crossbeam is located at the bottom of the first crossbeam; the first crossbeam is provided with an inspection camera and an inspection light source; the second crossbeam is provided with a backlight structure at the bottom of the inspection camera and the inspection light source;

[0022] The triggering mechanism includes a trigger seat and a trigger sensor disposed on the trigger seat;

[0023] The encoding mechanism includes an encoder base, a rubber-coated wheel rotatably mounted on the encoder base, and an encoder that is coaxially driven with the rubber-coated wheel.

[0024] The present invention is further configured such that: the first crossbeam is provided with a slide rail along its length; a slider is slidably mounted on the slide rail; the slider is provided with a fixed seat; and the detection camera and the detection light source are respectively mounted on the fixed seat.

[0025] The slider is provided with a plurality of first adjustment holes along the width direction of the first crossbeam; the fixed base is provided with a first adjustment groove that cooperates with the first adjustment holes; the first adjustment groove is provided along the width direction of the first crossbeam.

[0026] The present invention is further configured such that the visual inspection device for solar module stacking after lamination also includes a camera mount and a light source mount; the inspection camera is mounted on the camera mount; and the inspection light source is mounted on the light source mount.

[0027] The camera mount is provided with a second adjustment groove along the height direction; the fixed base is provided with a second adjustment hole along the height direction that cooperates with the second adjustment groove.

[0028] The camera mount is provided with a third adjustment hole along the height direction; the light source mount is provided with a third adjustment groove along the height direction that cooperates with the third adjustment hole.

[0029] The present invention is further configured such that the detection light source is an AOI light source; a through hole is provided in the middle of the detection light source; the detection camera is located at the top of the detection light source; and the detection light source and the through hole are positioned directly opposite each other.

[0030] The present invention is further configured such that the backlight structure includes a backlight base disposed on the second crossbeam and a backlight source disposed on the backlight base; the backlight source is disposed at the bottom of the detection light source;

[0031] The trigger sensor is a limit switch.

[0032] The present invention is further configured such that the encoder base includes a tension adjusting base disposed on the encoder base, a fixed shaft disposed on the tension adjusting base, and a tension adjusting arm rotatably disposed on the fixed shaft; the rubber-coated wheel and the encoder are both disposed on the tension adjusting arm; a tension spring is provided between the tension adjusting arm and the fixed shaft.

[0033] The present invention is further configured such that the visual inspection device for the solar module after stacking includes a transmission mechanism; the transmission mechanism is provided with a drive shaft; and the rubber-coated wheel abuts against the top of the drive shaft.

[0034] The present invention is further configured such that the visual inspection device for the solar module stacking after welding also includes a display and an alarm light mounted on the gantry.

[0035] The beneficial effects of this invention are as follows: This invention stitches together the images after finding the position of each grid line in the image. Since the grid line position corresponds to the solder joint position, the busbar is first found by the relative position of the edge of the battery cell, thereby finding the specific position of the solder joint. By processing the HSL three channels of the solder joint area image, the solder scar is separated for further analysis, and the welding effect result is obtained, which can effectively prevent false detection and missed detection. Attached Figure Description

[0036] The invention will be further illustrated with reference to the accompanying drawings, but the embodiments in the drawings do not constitute any limitation on the invention. For those skilled in the art, other drawings can be obtained based on the following drawings without any creative effort.

[0037] Figure 1 This is a flowchart illustrating the principle of the present invention;

[0038] Figure 2 This is a schematic diagram of the structure of the solar cell of the present invention;

[0039] Figure 3 This is a schematic diagram of the structure of the visual inspection device for solar module stacking after the present invention;

[0040] Figure 4 yes Figure 3 A magnified view of part A in the middle;

[0041] Figure 5 This is a schematic diagram of the structure of the visual inspection device for solar module stacking after the present invention, after concealing the coding mechanism and the transmission mechanism;

[0042] Figure 6 This is a schematic diagram of the structure of the detection camera and detection light source of the present invention;

[0043] Figure 7 This is a schematic diagram of the structure of the detection camera and detection light source of the present invention from another perspective;

[0044] Figure 8 This is a schematic diagram of the encoding mechanism of the present invention;

[0045] The components are as follows: 1. Gantry frame; 11. First crossbeam; 12. Second crossbeam; 13. Transmission mechanism; 14. Drive shaft; 15. Display; 16. Alarm light; 21. Detection camera; 22. Detection light source; 23. Perforation; 3. Trigger seat; 31. Trigger sensor; 4. Encoder seat; 41. Rubber-coated wheel; 42. Encoder; 43. Tension adjustment seat; 44. Fixed shaft; 45. Tension adjustment arm; 46. Tension spring; 51. Slide rail; 52. Slider; 53. First adjustment hole; 6. Fixed seat; 61. First adjustment groove; 62. Second adjustment hole; 7. Camera seat; 71. Second adjustment groove; 72. Third adjustment hole; 8. Light source seat; 81. Third adjustment groove; 91. Backlight seat; 92. Backlight source; 100. Solar cell; 101. Welding strip; 102. Busbar; 103. Grid line; 104. Welding point. Detailed Implementation

[0046] The present invention will be further described in conjunction with the following embodiments.

[0047] Depend on Figures 1 to 8 As can be seen, the visual inspection method for solar module stacking after welding described in this embodiment includes the following steps:

[0048] S1. Acquire a complete image of solar cell 100;

[0049] S2. Cut out the image of the solder joint 104 of the solder strip 101 of the solar cell 100 and the busbar 102;

[0050] S3. Stitch together all the solder joint 104 images into one inspection image;

[0051] It also includes the following steps:

[0052] A1. Identify the grid lines 103 of the solar cell 100 based on the detected image;

[0053] A2. Based on the grid line 103, perform position correction and template matching coordinates on the image, and perform small image cropping on the coordinates of the detected image based on the grid line 103 and solder point 104.

[0054] A3. Identify the edge position of solar cell 100;

[0055] A4. Based on the edge position of the solar cell 100, perform position correction, perform spot analysis to find the position of the busbar 102 and its upper and lower edge coordinates, and crop part of the image of the grid line 103;

[0056] A5. After locating the grid line 103 and the edge of the solar cell 100 in the image obtained in step A4, position correction is performed.

[0057] The visual inspection method for solar module stacking after welding described in this embodiment further includes the following steps:

[0058] A6. Perform feature segmentation on the image obtained in step A5 to separate the weld scar image;

[0059] A7. Perform spot analysis and multi-template matching based on weld scar images;

[0060] A8. The solder joint 104 is positioned by the position of the busbar 102 and the position of the grid line 103;

[0061] A9. Inspect solder joint 104;

[0062] A10. Determine the length of the busbar by analyzing the portion that exceeds busbar 102.

[0063] Specifically, through the above-described configuration, this embodiment can match the grid lines 103 in the images acquired by the three area array cameras, find the position of each grid line 103 in the image, and then stitch them together. Since the position of the grid line 103 corresponds to the position of the solder joint 104, the busbar 102 is first found through the relative position of the edge of the battery cell, thereby finding the specific position of the solder joint 104. By processing the three HSL channels of the image of the solder joint 104 area, the weld scar is separated for further analysis, and the welding effect result is obtained, which can effectively prevent false detection and missed detection.

[0064] The method for visual inspection of solar modules after stacking and welding described in this embodiment includes step S1, in which a full image of the solar cell 100 is acquired by a visual inspection device for solar modules after stacking and welding.

[0065] The visual inspection device for solar module stacking includes a gantry frame 1, a triggering mechanism, and an encoding mechanism; the gantry frame 1 is provided with a first crossbeam 11 and a second crossbeam 12; the second crossbeam 12 is located at the bottom of the first crossbeam 11; the first crossbeam 11 is provided with an inspection camera 21 and an inspection light source 22; the second crossbeam 12 is provided with a backlight structure at the bottom of the inspection camera 21 and the inspection light source 22.

[0066] The triggering mechanism includes a trigger seat 3 and a trigger sensor 31 disposed on the trigger seat 3;

[0067] The encoding mechanism includes an encoder base 4, a rubber-coated wheel 41 rotatably mounted on the encoder base 4, and an encoder 42 that is coaxially driven with the rubber-coated wheel 41.

[0068] Specifically, in the visual inspection device for solar module stacking described in this embodiment, when the solar module flows through the production line to the trigger sensor 31 of the trigger seat 3, the detection light source 22 and the detection camera 21 simultaneously perform preparatory work for taking pictures. When the production line moves, it drives the rubber-coated wheel 41 and the encoder 42 to rotate, causing the encoder 42 to output pulses to the detection camera 21 for picture processing. Therefore, in this embodiment, through the cooperation of the encoder 42 and the trigger sensor 31, the position data of the solar module is read in the encoder 42 when it passes through the trigger sensor 31, recording the position of each product on the production line and realizing the positioning function. The gantry frame 1 in this embodiment has a small and flexible installation space and can be used in various occasions and small spaces. Therefore, it can be installed in any occasion to realize different inspection needs, thereby greatly reducing the time added by production steps and improving production quality.

[0069] This embodiment describes a visual inspection method for solar module stacking after lamination. The first crossbeam 11 is provided with a slide rail 51 along its length. A slider 52 is slidably mounted on the slide rail 51. The slider 52 is provided with a fixing seat 6. The inspection camera 21 and the inspection light source 22 are respectively mounted on the fixing seat 6. Specifically, the positions of the inspection camera 21 and the inspection light source 22 can be adjusted through the above settings. The slide rail 51 and the slider 52 are model SGR15N-SGB15N-4. The slider 52 of this model has an internal locking function. When adjusted to an appropriate position, the locking function can be used to fix the structure in a certain position. This structure can effectively prevent inaccurate inspection caused by accidental human contact.

[0070] The slider 52 is provided with a plurality of first adjustment holes 53 along the width direction of the first crossbeam 11; the fixed base 6 is provided with a first adjustment groove 61 that mates with the first adjustment holes 53; the first adjustment groove 61 is provided along the width direction of the first crossbeam 11. The above arrangement allows for adjustment of the front and rear positions of the detection camera 21 and the detection light source 22.

[0071] The present embodiment describes a visual inspection method for solar module stacking after welding. The visual inspection device for solar module stacking after welding further includes a camera mount 7 and a light source mount 8; the inspection camera 21 is mounted on the camera mount 7; and the inspection light source 22 is mounted on the light source mount 8.

[0072] The camera mount 7 is provided with a second adjustment groove 71 along the height direction; the fixed base 6 is provided with a second adjustment hole 62 along the height direction that cooperates with the second adjustment groove 71.

[0073] The camera mount 7 is provided with a third adjustment hole 72 along the height direction; the light source mount 8 is provided with a third adjustment groove 81 along the height direction that cooperates with the third adjustment hole 72. The height of the detection light source 22 can be adjusted by the above configuration.

[0074] This embodiment describes a visual inspection method for solar module stacking after lamination. The inspection light source 22 is an AOI (Automated Optical Inspection) light source. A through-hole 23 is provided through the center of the inspection light source 22. The inspection camera 21 is located at the top of the inspection light source 22. The inspection light source 22 and the through-hole 23 are directly opposite each other. Specifically, the AOI light source contains two colors: blue and green. The brightness of each color can be independently adjusted at the light source controller. The arrangement of the LEDs inside the AOI light source varies in angle across each row, resulting in different illumination surfaces and reflections, thus creating an effective lighting effect.

[0075] The present embodiment describes a visual inspection method for solar module stacking after lamination. The backlight structure includes a backlight base 91 disposed on the second crossbeam 12 and a backlight source 92 disposed on the backlight base 91. The backlight source 92 is disposed at the bottom of the detection light source 22. Specifically, through the above arrangement, supplementary lighting can be provided to the product, effectively increasing the prominence of features within the visible range of the detection camera 21, reducing false and missed detections, thereby improving detection accuracy.

[0076] The trigger sensor 31 is a limit switch.

[0077] This embodiment describes a visual inspection method for solar module stacking after welding. The encoder base 4 includes a tension adjusting base 43, a fixed shaft 44, and a tension adjusting arm 45 rotatably mounted on the fixed shaft 44. The rubber-coated wheel 41 and encoder 42 are both mounted on the tension adjusting arm 45. A tension spring 46 is provided between the tension adjusting arm 45 and the fixed shaft 44. This embodiment also describes a visual inspection method for solar module stacking after welding. The visual inspection device further includes a transmission mechanism 13; the transmission mechanism 13 has a drive shaft 14; the rubber-coated wheel 41 abuts against the top of the drive shaft 14.

[0078] Specifically, through the above-mentioned arrangement, the rubber-coated wheel 41 and the drive shaft 14 can be closely abutted under the action of the tension spring 46. When vibrating, the position of the rubber-coated wheel 41 will change, and the tension of the tension spring 46 can adapt to the amplitude, thereby reducing the instability caused by vibration.

[0079] This embodiment describes a visual inspection method for solar module stacking after welding. The visual inspection device for solar module stacking after welding also includes a display 15 and an alarm light 16 mounted on the gantry 1. This setup facilitates user observation. The inspection results are displayed on the display 15, and the alarm light 16 can sound an alarm when defective products are detected.

[0080] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit the scope of protection of the present invention. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the essence and scope of the technical solutions of the present invention.

Claims

1. A visual inspection method for solar module stacking after lamination, characterized in that: Includes the following steps: S1. Acquire a complete image of the solar cell (100); S2. Cut out the image of the solder joint (104) of the solder strip (101) of the solar cell (100) and the busbar (102); S3. Stitch together all the solder joint (104) images into one inspection image; It also includes the following steps: A1. Identify the grid lines (103) of the solar cell (100) based on the detected image. A2. The image is corrected and the template is matched according to the grid line (103). The small image is cropped according to the grid line (103) and the solder point (104) on the coordinates of the detected image. A3. Identify the edge position of the solar cell (100); A4. Based on the edge position of the solar cell (100), position correction is performed, spot analysis is performed to find the position of the busbar (102) and its upper and lower edge coordinates, and the image of the grid line (103) is cropped. A5. After locating the grid lines (103) and the edges of the solar cells (100) in the image obtained in step A4, position correction is performed. It also includes the following steps: A6. Perform feature segmentation on the image obtained in step A5 to separate the weld scar image; A7. Perform spot analysis and multi-template matching based on weld scar images; A8. The solder joint (104) is positioned by the position of the busbar (102) and the position of the grid line (103); A9. Inspect the solder joint (104); A10. Determine the length of the busbar by analyzing the portion that exceeds the busbar (102); In step S1, a full image of the solar cell (100) is acquired by a visual inspection device after the solar module is stacked. The visual inspection device for solar module stacking includes a gantry (1), a triggering mechanism, and an encoding mechanism; the gantry (1) is provided with a first crossbeam (11) and a second crossbeam (12); the second crossbeam (12) is located at the bottom of the first crossbeam (11); the first crossbeam (11) is provided with an inspection camera (21) and an inspection light source (22); the second crossbeam (12) is provided with a backlight structure at the bottom of the inspection camera (21) and the inspection light source (22); The triggering mechanism includes a trigger seat (3) and a trigger sensor (31) disposed on the trigger seat (3); The encoding mechanism includes an encoding base (4), a rubber-coated wheel (41) rotatably mounted on the encoding base (4), and an encoder (42) that is coaxially driven with the rubber-coated wheel (41). In this process, the grid lines (103) of the images acquired by the three area array cameras are matched to find the position of each grid line (103) in the image and then stitched together. Since the position of the grid line (103) corresponds to the position of the solder joint (104), the busbar (102) is found first by the relative position of the edge of the battery cell, and then the specific position of the solder joint (104) is found. The solder scar is separated for further analysis by processing the three HSL channels of the image of the solder joint (104) area.

2. The visual inspection method for solar module stacking after lamination according to claim 1, characterized in that: The first crossbeam (11) is provided with a slide rail (51) along its length; a slider (52) is slidably provided on the slide rail (51); the slider (52) is provided with a fixed seat (6); the detection camera (21) and the detection light source (22) are respectively provided on the fixed seat (6); The slider (52) is provided with a plurality of first adjustment holes (53) along the width direction of the first crossbeam (11); the fixed seat (6) is provided with a first adjustment groove (61) that cooperates with the first adjustment holes (53); the first adjustment groove (61) is provided along the width direction of the first crossbeam (11).

3. The visual inspection method for solar module stacking after lamination according to claim 2, characterized in that: The visual inspection device for solar module stacking also includes a camera mount (7) and a light source mount (8); the inspection camera (21) is mounted on the camera mount (7); the inspection light source (22) is mounted on the light source mount (8). The camera mount (7) is provided with a second adjustment groove (71) along the height direction; the fixed base (6) is provided with a second adjustment hole (62) along the height direction that cooperates with the second adjustment groove (71); The camera mount (7) is provided with a third adjustment hole (72) along the height direction; the light source mount (8) is provided with a third adjustment groove (81) along the height direction that cooperates with the third adjustment hole (72).

4. The visual inspection method for solar module stacking after lamination according to claim 1, characterized in that: The detection light source (22) is an AOI light source; a through hole (23) is provided in the middle of the detection light source (22); the detection camera (21) is located on the top of the detection light source (22); the detection light source (22) and the through hole (23) are positioned opposite each other.

5. The visual inspection method for solar module stacking after lamination according to claim 1, characterized in that: The backlight structure includes a backlight base (91) disposed on the second crossbeam (12) and a backlight source (92) disposed on the backlight base (91); the backlight source (92) is disposed at the bottom of the detection light source (22); The trigger sensor (31) is a limit switch.

6. The method for visual inspection of solar module stacking after lamination according to claim 1, characterized in that: The encoder base (4) includes a tension adjustment base (43) disposed on the encoder base (4), a fixed shaft (44) disposed on the tension adjustment base (43), and a tension adjustment arm (45) rotatably disposed on the fixed shaft (44); the rubber-coated wheel (41) and the encoder (42) are both disposed on the tension adjustment arm (45); a tension spring (46) is provided between the tension adjustment arm (45) and the fixed shaft (44).

7. The visual inspection method for solar module stacking after lamination according to claim 1, characterized in that: The visual inspection device for solar module stacking also includes a transmission mechanism (13); the transmission mechanism (13) is provided with a drive shaft (14); the rubber-coated wheel (41) abuts against the top of the drive shaft (14).

8. The method for visual inspection of solar modules after shingling according to claim 1, characterized in that: The visual inspection device for solar module stacking also includes a display (15) mounted on the gantry (1) and an alarm light (16) mounted on the gantry (1).

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