A method of repairing a photovoltaic module

Abstract

This invention discloses a method for repairing photovoltaic modules, comprising the following steps: Positioning the junction box using a first positioning mechanism; then, drilling the junction box with a drill bit through a positioning hole to a predetermined position to break the solder joints, separating the busbar from the copper base plate; positioning the junction box using a second positioning mechanism; cutting the adhesive layer between the junction box and the photovoltaic module using a tool on the second positioning mechanism; and then removing the junction box from the photovoltaic module. Specifically, when cutting the adhesive layer between the junction box and the photovoltaic module, the tool avoids the busbar. Compared with existing technologies, this invention separates the busbar from the copper base plate inside the junction box by drilling away the solder joints. Furthermore, when cutting the adhesive layer between the junction box and the photovoltaic module, the tool avoids the busbar before removing the junction box. The entire process is simple, highly efficient, and the busbar is broken at the solder joint, retaining sufficient length and preventing deformation.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic module repair technology, and in particular to a method for repairing photovoltaic modules. Background Technology

[0002] During the production of photovoltaic modules, the busbars of the cell strings need to be connected to the conductive terminals in the module junction box on the back of the module. Then, the electrical energy generated by the photovoltaic module is led out and connected to the external load through the cable of the junction box. Currently, a new junction box welding method has emerged, namely laser welding. Laser welding can save consumables and energy consumption. However, if the welding is not up to standard, the only solution is to tear the busbar to separate it from the copper base plate of the junction box. Patent application CN202310366522 discloses a busbar splicing device and a method for reworking the junction box after welding, including the following steps: S100, removing the junction box from the cell string assembly, cutting off the busbar segment that was welded to the junction box on the cell string assembly, and the remaining busbar on the cell string assembly after cutting is the first busbar. S200: After overlapping and welding the first busbar with the new second busbar using the busbar splicing device, S200: Install the new junction box on the battery string assembly and weld the spliced ​​busbar to the new junction box. Step S100 includes the following sub-steps: S101: Remove the junction box cover and clean the adhesive inside the junction box. S102: Cut the adhesive between the junction box and the battery string assembly. S103: If the busbar and junction box are laser-welded, the busbar can be pulled apart by force. However, while this method of separating the busbar from the copper base plate of the junction box is simple, the pulled busbar may bend and deform, even forming barbs. Re-welding will result in unreliable welding quality and hinder the extension of the busbar overlap, increasing the difficulty of subsequent photovoltaic module maintenance. Furthermore, since the busbar is fixed inside the junction box by welding, pulling it apart inside the box is difficult and laborious. Summary of the Invention

[0003] This invention provides a method for repairing photovoltaic modules, which solves the problems of excessive force and easy deformation of busbars when repairing photovoltaic modules by forcefully pulling them.

[0004] This invention provides a method for repairing photovoltaic modules, comprising the following steps:

[0005] S1: The junction box is positioned by the first positioning mechanism, and then the drill bit of the electric drill passes through the positioning hole on the first positioning mechanism and drills to the predetermined position to break the solder joint inside the junction box, so that the bus bar is separated from the copper base plate.

[0006] S2: Remove the first positioning mechanism, and then position the junction box using the second positioning mechanism. The cutter on the second positioning mechanism cuts the adhesive layer between the junction box and the photovoltaic module, and then removes the junction box from the photovoltaic module. When cutting the adhesive layer between the junction box and the photovoltaic module, the cutter avoids the busbar.

[0007] S3: Overlap the new busbar with the busbar on the photovoltaic module, and then weld the new busbar to the busbar on the photovoltaic module using a welding device;

[0008] S4: Install the new junction box on the photovoltaic module and weld the continued busbar to the new junction box.

[0009] Preferably, in step S1, the limiter is fixed on the drill rod of the electric drill, and the limiter cooperates with the fourth positioning plate of the first positioning mechanism to determine the drilling depth of the drill bit, and the positioning hole is set on the fourth positioning plate.

[0010] Preferably, in step S1, the first positioning mechanism defines the three sides of the junction box by means of the first positioning plate, the second positioning plate and the third positioning plate, thereby completing the positioning of the junction box.

[0011] Preferably, in step S1, the fourth positioning plate is moved to align the positioning hole with the weld point below, and then the position of the fourth positioning plate is fixed by bolts.

[0012] Preferably, in step S1, the first positioning plate, the second positioning plate, and the third positioning plate are first slid to the three sides of the junction box, and then the positions of the first positioning plate, the second positioning plate, and the third positioning plate are fixed by bolts.

[0013] Preferably, in step S2, the cutting tool includes a first shovel and a second shovel, the distance between the two second shovels is greater than the distance between the first shovels, and when the two first shovels are inserted between the junction box and the photovoltaic module from both sides of the junction box, the two second shovels cut the adhesive layer on both sides of the busbar.

[0014] Preferably, in step S2, the tool includes two slidable tool holders, with the first and second shovels both mounted on the tool holders, and the drive assembly on the second positioning mechanism drives the tool holders to move towards each other and away from each other.

[0015] Preferably, in step S2, the driving assembly includes: a motor, a gear, and two racks. The two racks are respectively fixed to two tool holders. The gear is located between the two racks and meshes with the racks. The motor drives the gear to rotate, causing the two tool holders to move towards each other and away from each other.

[0016] Preferably, in step S2, the second positioning mechanism defines the three sides of the junction box by three fifth positioning plates, thereby completing the positioning of the junction box.

[0017] Preferably, in step S2, the three fifth positioning plates are first slid to the three sides of the junction box, and then the positions of the three fifth positioning plates are fixed by bolts.

[0018] Compared to existing technologies, this invention separates the busbar from the copper base plate inside the junction box by drilling away the solder joints. Then, when cutting the adhesive layer between the junction box and the photovoltaic module, the busbar is avoided, and the junction box is removed. The entire process is simple, highly efficient, and the busbar is cut off at the solder joint, preserving sufficient length and preventing deformation. This makes subsequent busbar reconnection easier, faster, and ensures high-quality reconnection, thus significantly improving overall repair quality. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the structure of the first clamp of the present invention;

[0021] Figure 2 This is a bottom view of the first clamp of the present invention;

[0022] Figure 3 This is a schematic diagram of the structure of the second clamp of the present invention;

[0023] Figure 4 This is a front view of the second clamp of the present invention;

[0024] Figure 5 This is a partial structural diagram of the second clamp of the present invention;

[0025] Figure 6 This is a schematic diagram of the tool used in this invention cutting the adhesive layer;

[0026] Figure 7 This is a schematic diagram of the workflow of the present invention.

[0027] Figure label:

[0028] 1. First clamp, 11. First positioning mechanism, 12. Fourth positioning plate, 13. Fixed seat, 121. Positioning hole, 111. First positioning plate, 112. Second positioning plate, 113. Third positioning plate, 2. Second clamp, 21. Second positioning mechanism, 22. Cutting tool, 23. Drive assembly, 24. Positioning seat, 211. Fifth positioning plate, 221. Tool holder, 222. First shovel, 223. Second shovel, 231. Drive shaft, 232. Gear, 233. Rack, 3. Junction box, 4. Drill rod, 5. Limiter, 6. Adhesive layer. Detailed Implementation

[0029] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0030] See attached document Figure 7 This embodiment provides a method for repairing photovoltaic modules, including the following steps:

[0031] Step S1: Refer to Appendix Figure 1 The junction box 3 is positioned by the first positioning mechanism 11. Then, the drill bit passes through the positioning hole 121 on the first positioning mechanism 11 and drills to the predetermined position to break the solder joint inside the junction box 3, separating the busbar from the copper base plate. The solder joint is the welding position between the busbar and the copper base plate inside the junction box 3. The positioning mechanism 11 prevents the positioning hole 121 from moving when drilling the solder joint. The positioning hole 121 also constrains the drill rod 4 of the motor, preventing the drill bit from shifting when drilling through the solder joint. Separating the busbar from the copper base plate by drilling through the solder joint saves the process of scraping glue and eliminates the need to forcibly pull the busbar in such a small space inside the box, effectively improving maintenance efficiency. Secondly, the busbar does not deform. Since the busbar is broken at the solder joint position, it retains sufficient length for subsequent splicing and extension.

[0032] Step S2: Remove the first positioning mechanism 11, as shown in the attached document. Figure 3 and attached Figure 6Then, the junction box 3 is positioned by the second positioning mechanism 21. The cutter 22 on the second positioning mechanism 21 cuts the adhesive layer 6 between the junction box 3 and the photovoltaic module, and then removes the junction box 3 from the photovoltaic module. When cutting the adhesive layer 6 between the junction box 3 and the photovoltaic module, the cutter 22 avoids the busbar. The positioning of the junction box 3 by the second positioning mechanism 21 prevents displacement between the cutter 22 and the junction box 3 when the cutter 22 cuts the adhesive layer 6, ensuring that the busbar is not cut by the cutter 22 and retains sufficient length. The junction box 3 is bonded to the photovoltaic module by the adhesive layer 6; after cutting the adhesive layer 6, the junction box 3 can be easily removed from the photovoltaic module.

[0033] Step S3: Overlap the new busbar with the existing busbar on the photovoltaic module, and then weld the new busbar to the existing busbar on the photovoltaic module using a welding device. After steps S1 and S2, junction box 3 is removed, and the busbar retains sufficient length without deformation. Therefore, in this step, the new busbar can be normally overlapped and welded to the photovoltaic module without the need for special tools. For example, it is not necessary to use tools to insert into the gap between the busbar and the photovoltaic module to support the busbar on the tool surface. This further reduces the difficulty of maintenance and speeds up the maintenance process.

[0034] Step S4: Install the new junction box 3 on the photovoltaic module and weld the continued busbar to the new junction box 3.

[0035] In step S1, the method for the drill bit to reach the predetermined position inside the junction box 3 is as follows: a limiter 5 is fixed to the drill rod 4 of the electric drill. Specifically, the limiter 5 is a circular plate, and multiple screws pass through the circular plate and abut against the groove of the drill rod 4 to fix the circular plate to the drill rod 4. The limiter 5 cooperates with the fourth positioning plate 12 of the first positioning mechanism 11 to determine the drilling depth of the drill bit. Specifically, after the drill bit passes through the copper base plate, the limiter 5 is blocked by the fourth positioning plate 12 to prevent the drill bit from moving further down. The positioning hole 121 is provided on the fourth positioning plate 12.

[0036] In step S1, refer to the appendix Figure 2 The specific steps for the first positioning mechanism 11 to position the junction box 3 are as follows: the first positioning mechanism 11 defines the three sides of the junction box 3 by means of the first positioning plate 111, the second positioning plate 112 and the third positioning plate 113 respectively, thereby completing the positioning of the junction box 3.

[0037] In step S1, the fourth positioning plate 12 is moved to align the positioning hole 121 with the solder joint below, and then the position of the fourth positioning plate 12 is fixed by bolts. The position of the solder joint inside the junction box 3 may be different. The fourth positioning plate 12 is slid on the fixed base 13 so that the positioning hole 121 is directly above the solder joint, and then the fourth positioning plate 12 is fixed on the fixed base 13 by bolts. This design allows the drill bit to drill solder joints inside different types of junction boxes 3. The first positioning mechanism 11, the fourth positioning plate 12, and the fixed base 13 constitute the first clamp 1. Specifically, the fourth positioning plate 12 is located at the upper end of the fixed base 13, and the first positioning mechanism 11 is located in the portal groove at the lower end of the fixed base 13. The first positioning plate 111, the second positioning plate 112, and the third positioning plate 113 of the first positioning mechanism 11 are all slidably connected to the fixed base 13. Specifically, the fourth positioning plate 12 is provided with a waist-shaped stepped hole, and the fixing seat 13 is provided with a screw hole. The bolt passes through the stepped hole and is fixed with the screw hole. When the fourth positioning plate 12 slides, the moving stepped hole and the screw hole remain in communication.

[0038] In step S1, the first positioning plate 111, the second positioning plate 112, and the third positioning plate 113 are first slid to the three sides of the junction box 3. After the first positioning plate 111, the second positioning plate 112, and the third positioning plate 113 are in contact with the junction box 3, they are then fixed to the fixing base 13 with bolts. This design allows the first positioning mechanism 11 to position junction boxes 3 of different specifications. The fixing method of the first positioning plate 111, the second positioning plate 112, and the third positioning plate 113 on the fixing base 13 is the same as the fixing method of the fourth positioning plate 12 on the fixing base 13.

[0039] In step S2, the step of the cutter 22 cutting the adhesive layer 6 to avoid the busbar is as follows: the cutter 22 includes a first scraper 222 and a second scraper 223. The distance between the two second scrapers 223 is greater than the distance between the first scrapers 222. When the two first scrapers 222 are inserted between the junction box 3 and the photovoltaic module from both sides of the junction box 3, the two second scrapers 223 cut the adhesive layer 6 on both sides of the busbar. Specifically, the two first scrapers 222 are inserted between the junction box 3 and the photovoltaic module as they approach each other. (Refer to the attached document.) Figure 6 When the distance between the two first scrapers 222 is very close, the two second scrapers 223 cut off the adhesive layers 6 on both sides of the manifold, while the two first scrapers 222 will cut off the other adhesive layers 6. The manifold is located between the two second scrapers 223 and does not contact the second scrapers 223.

[0040] In step S2, refer to the appendix. Figure 4The cutting tool 22 includes two sliding blade holders 221 located on both sides of the junction box 3. A first scraper 222 and a second scraper 223 are both mounted on the blade holders 221. The drive assembly 23 on the second positioning mechanism 21 drives the blade holders 221 to move towards each other and away from each other. When the blade holders 221 move towards each other, the first scraper 222 and the second scraper 223 cut the adhesive layer 6 between the junction box 3 and the photovoltaic module.

[0041] In step S2, the drive assembly 23 includes a motor, a gear 232, and two racks 233. A transmission shaft 231 is fixed on the gear 232. The two racks 233 are respectively fixed to two tool holders 221. The gear 232 is located between the two racks 233 and meshes with the racks 233. The main shaft of the motor is connected to the transmission shaft 231. The motor drives the gear 232 to rotate, causing the two tool holders 221 to move towards each other and away from each other.

[0042] In step S2, refer to the appendix. Figure 5 The specific steps for the second positioning mechanism 21 to position the junction box 3 are as follows: the second positioning mechanism 21 uses three fifth positioning plates 211 to define the three sides of the junction box 3 respectively, thereby completing the positioning of the junction box 3.

[0043] In step S2, the three fifth positioning plates 211 are first slid to the three sides of the junction box 3. After the three fifth positioning plates 211 are in contact with the junction box 3, they are fixed to the positioning seat 24 with bolts. This design enables the second positioning mechanism 21 to position junction boxes 3 of different specifications. The second positioning mechanism 21, the positioning seat 24, the cutter 22, and the drive assembly 23 constitute the second clamp 2. Specifically, the cutter 22 is connected to the positioning seat 24 via a guide rail and a slider. The cutter 22 is located at the lower end of the positioning seat 24. The second positioning mechanism 21 is located between the two cutter holders 221 of the cutter 22, and the first scraper 222 and the second scraper 223 are both located below the second positioning mechanism 21. The drive assembly 23 is located at the upper end of the positioning seat 24, and the fifth positioning plates 211 are slidably connected to the positioning seat 24. The fixing method of the fifth positioning plates 211 on the positioning seat 24 is the same as the fixing method of the fourth positioning plate 12 on the fixing seat 13.

[0044] After removing junction box 3, the busbar is separated from the copper base plate by drilling away the solder joints. A groove that matches the drill bit will appear on the busbar. Therefore, the busbar at the groove can be cut off first to make the end of the busbar flat. The effect will be better when it is extended by overlapping with a new busbar later.

[0045] In this invention, the busbar is separated from the copper base plate inside the junction box 3 by drilling away the solder joints. Then, the adhesive layer 6 between the junction box 3 and the photovoltaic module is cut using a cutting tool 22, avoiding the busbar. Finally, the junction box 3 is removed. The entire process is simple and efficient. The busbar is cut from the solder joint, preserving sufficient length and preventing deformation. Subsequent busbar reconnection is easy and fast, effectively ensuring the quality of the reconnection and thus significantly improving overall repair quality.

[0046] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for repairing photovoltaic modules, characterized in that, Includes the following steps: S1: The junction box is positioned by the first positioning mechanism, and then the drill bit of the electric drill passes through the positioning hole on the first positioning mechanism and drills to the predetermined position to break the solder joint inside the junction box, so that the bus bar is separated from the copper base plate. S2: Remove the first positioning mechanism, and then position the junction box using the second positioning mechanism. The cutter on the second positioning mechanism cuts the adhesive layer between the junction box and the photovoltaic module, and then removes the junction box from the photovoltaic module. When cutting the adhesive layer between the junction box and the photovoltaic module, the cutter avoids the busbar. S3: Overlap the new busbar with the busbar on the photovoltaic module, and then weld the new busbar to the busbar on the photovoltaic module using a welding device; S4: Install the new junction box onto the photovoltaic module and weld the continued busbar to the new junction box; In step S2, the cutting tool includes a first shovel and a second shovel. The distance between the two second shovels is greater than the distance between the first shovels. When the two first shovels are inserted between the junction box and the photovoltaic module from both sides of the junction box, the two second shovels cut the adhesive layer on both sides of the busbar.

2. The method for repairing photovoltaic modules according to claim 1, characterized in that, In step S1, the limiter is fixed on the drill rod of the electric drill. The limiter cooperates with the fourth positioning plate of the first positioning mechanism to determine the drilling depth of the drill bit. The positioning hole is set on the fourth positioning plate.

3. The method for repairing photovoltaic modules according to claim 2, characterized in that, In step S1, the first positioning mechanism defines the three sides of the junction box by means of the first positioning plate, the second positioning plate and the third positioning plate, thereby completing the positioning of the junction box.

4. The method for repairing photovoltaic modules according to claim 3, characterized in that, In step S1, the fourth positioning plate is moved to align the positioning hole with the weld point below, and then the position of the fourth positioning plate is fixed by bolts.

5. The method for repairing photovoltaic modules according to claim 4, characterized in that, In step S1, the first positioning plate, the second positioning plate, and the third positioning plate are first slid to the three sides of the junction box, and then the positions of the first positioning plate, the second positioning plate, and the third positioning plate are fixed by bolts.

6. The method for repairing photovoltaic modules according to claim 5, characterized in that, In step S2, the cutting tool includes two sliding blade holders. The first blade and the second blade are both mounted on the blade holders. The driving component on the second positioning mechanism drives the blade holders to move towards each other and away from each other.

7. The method for repairing photovoltaic modules according to claim 6, characterized in that, In step S2, the drive assembly includes a motor, a gear, and two racks. The two racks are fixed to two tool holders respectively. The gear is located between the two racks and meshes with the racks. The motor drives the gear to rotate, causing the two tool holders to move towards each other and away from each other.

8. The method for repairing photovoltaic modules according to claim 7, characterized in that, In step S2, the second positioning mechanism defines the three sides of the junction box by using three fifth positioning plates, thereby completing the positioning of the junction box.

9. The method for repairing photovoltaic modules according to claim 8, characterized in that, In step S2, the three fifth positioning plates are first slid to the three sides of the junction box, and then the positions of the three fifth positioning plates are fixed by bolts.

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